Komatsu WA430-5 Wheel Loader Shop Manual SEBM025407 PDF DOWNLOAD

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Komatsu WA430-5 Wheel Loader Shop Manual SEBM025407  – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA430-5 Wheel Loader Shop Manual SEBM025407  – PDF DOWNLOAD

Language : English
Pages : 1232
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA430-5 Wheel Loader Shop Manual SEBM025407  – PDF DOWNLOAD

Machine model Serial number

• WA430-5 60001 and up

COVER . 1
CONTENTS 2
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 35
LIST OF LUBRICANT AND COOLANT . 37
10 STRUCTURE AND FUNCTION,MAINTENANCE STANDARD 39
COOLING SYSTEM 40
ENGINE MOUNT, TRANSMISSION MOUNT 41
POWER TRAIN . 42
POWER TRAIN SYSTEM DIAGRAM 43
DRIVE SHAFT (PROPELLER SHAFT) . 46
TORQUE CONVERTER,TRANSMISSION PIPING 47
TORQUE CONVERTER 48
TRANSMISSION 56
TRANSMISSION CONTROL VALVE 72
AXLE 90
DIFFERENTIAL 92
FINAL DRIVE . 104
AXLE MOUNTING,CENTER HINGE PIN 110
STEERING PIPING . 114
STEERING COLUMN,ORBIT-ROLL 115
STEERING VALVE 116
ORBIT-ROLL VALVE 131
STOP VALVE 135
STEERING PUMP, SWITCH PUMP 136
EMERGENCY STEERING PUMP(OP) . 138
EMERGENCY STEERING MOTOR(OP) 139
STEERING CYLINDER . 140
JOYSTICK STEERING LEVER (OP) 142
STEERING LEVER (OP) . 143
STEERING SWITCH VALVE (OP) 145
BRAKE PIPING 146
BRAKE VALVE . 148
CHARGE VALVE 155
ACCUMULATOR (FOR BRAKE) . 159
BRAKE . 162
PARKING BRAKE CONTROL . 167
PARKING BRAKE . 168
PARKING BRAKE SOLENOID VALVE 170
PARKING BRAKE EMERGENCY RELEASE VALVE . 172
HYDRAULIC PIPING 174
WORK EQUIPMENT CONTROL LEVER 178
HYDRAULIC TANK 180
TORQUE CONVERTER CHARGING,WORK EQUIPMENT,AND PILOT CONTROL PUMPS 182
PPC RELIEF VALVE 184
E.S.S.S .VALVE (OP) . 186
WORK EQUIPMENT CONTROL VALVE 188
WORK EQUIPMENT PPC VALVE 206
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) . 212
OPERATION . 214
EPC SOLENOID VALVE(OP) 218
SHUT OFF VALVE (OP) . 221
ATTACHMENT PPC VALVE(OP) 222
COOLING FAN MOTOR . 226
COOLING FAN MOTOR DRIVE PUMP 232
WORK EQUIPMENT LINKAGE 240
BUCKET 242
BUCKET POSITIONER,LIFT ARM KICK-OUT . 244
WORK EQUIPMENT CYLINDER . 250
CAB . 251
AIR CONDITIONER (OP) 252
MACHINE MONITORING SYSTEM . 253
MACHINE MONITOR . 260
TRANSMISSION CONTROL SYSTEM . 327
TRANSMISSION CONTROLLER . 356
WORK EQUIPMENT CONTROL SYSTEM (OP) 358
WORK EQUIPMENT CONTROLLER . 374
ELECTRIC TRANSMISSION CONTROL . 376
KICK DOWN,HOLD SWITCH . 380
ENGINE STARTING CIRCUIT . 381
ENGINE STOP CIRCUIT . 383
PREHEATING CIRCUIT 384
ENGINE POWER MODE SELECTOR CIRCUIT . 385
PARKING BRAKE CIRCUIT . 386
SENSORS . 390
20 TESTING AND ADJUSTING 401
TESTING AND ADJUSTING DATA 402
STANDARD VALUE TABLE FOR CHASSIS 403
TESTING AND ADJUSTING . 411
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING . 412
MEASURING ENGINE SPEED 413
MEASURING EXHAUST COLOR . 415
MEASURING EXHAUST TEMPERATURE . 416
ADJUSTING VALVE CLEARANCE . 418
MEASURING COMPRESSION PRESSURE 419
MEASURING BLOW-BY PRESSURE 420
MEASURING ENGINE OIL PRESSURE . 421
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 422
TESTING AND ADJUSTING FUEL INJECTION TIMING . 423
ADJUSTING ENGINE SPEED SENSOR . 425
BLEEDING AIR FROM FUEL CIRCUIT 426
ADJUSTING ENGINE STOP MOTOR LEVER . 427
ADJUSTING ACCELERATOR PEDAL 429
ADJUSTING TRANSMISSION SPEED SENSOR . 431
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE 432
DRAWING OF SPECIAL TOOL . 436
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT 437
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 438
TESTING AND ADJUSTING STEERING CONTROL 440
TESTING AND ADJUSTING STEERING OIL PRESSURE . 441
TESTING HYDRAULIC FAN . 443
MEASURING BRAKE OIL PRESSURE 444
TESTING WEAR OF WHEEL BRAKE DISC 446
BLEEDING AIR FROM BRAKE CIRCUIT . 447
TESTING WEAR OF PARKING BRAKE DISC 448
MANUAL RELEASE METHOD FOR PARKING BRAKE . 449
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE . 450
TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE 452
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE . 454
TESTING AND ADJUSTING BUCKET POSITIONER . 456
TESTING AND ADJUSTING LIFT ARM KICK-OUT . 457
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP 458
ADJUSTING MACHINE MONITOR . 459
TESTING AND ADJUSTING LOAD METER 462
BLEEDING AIR 466
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT . 467
RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT . 467
PM CLINIC INSPECTION CHART 469
TROUBLESHOOTING . 471
POINTS TO REMEMBER WHEN TROUBLESHOOTING . 472
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 473
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . 474
CHECKS BEFORE TROUBLESHOOTING . 482
SPECIAL FUNCTIONS OF MACHINE MONITOR 484
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS . 519
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 528
T-ADAPTER TABLE . 551
CONNECTOR TYPES AND MOUNTING LOCATIONS 554
CONNECTOR LAYOUT DRAWING 562
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM(TM MODE) . 571
TRANSMISSION CONTROL SYSTEM DIAGRAM . 574
ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED . 577
ERROR CODE [15SAL1] (F_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 578
ERROR CODE [15SALH] (F_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 579
ERROR CODE [15SBL1] (R_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 580
ERROR CODE [15SBLH] (R_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 581
ERROR CODE [15SEL1] (1ST_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 582
ERROR CODE [15SELH] (1ST_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 583
ERROR CODE [15SFL1] (2ND_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 584
ERROR CODE [15SFLH] (2ND_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 585
ERROR CODE [15SGL1] (3RD_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 586
ERROR CODE [15SGLH] (3RD_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 587
ERROR CODE [15SHL1] (4TH_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 588
ERROR CODE [15SHLH] (4TH_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 589
ERROR CODE [15SJL1] (LOCKUP_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 590
ERROR CODE [15SJLH] (LOCKUP_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED . 591
ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED 592
ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED 593
ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 594
ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 595
ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED . 596
ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED . 597
ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 598
ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 600
ERROR CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED . 602
ERROR CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED . 603
ERROR CODE [D198KB] (GROUND FAULT IN LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED [*] 604
ERROR CODE [D198KY] (HOT-SHORT IN LOW-TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED . 605
ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED 606
ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED . 607
ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED 608
ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED 610
ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED . 612
ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED 614
ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED . 616
ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED . 618
ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED . 620
ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED 622
ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED 624
ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED 625
ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED 626
ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED 628
ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED . 630
ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED . 632
ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED 634
ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED . 636
ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED . 638
ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED . 639
ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED . 640
ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED . 641
ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED 642
ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED . 643
ERROR CODE [DLT3KA] (SPEED SENSOR TRANSMISSION OUTPUT SHAFT REVOLUTION SYSTEM DISCONTINUITY) IS DISPLAYED . 644
ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED 645
ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED . 646
ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 647
ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED 648
ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED . 649
ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED . 650
ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 651
ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED . 652
ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 653
ERROR CODE [DXH4KA] (1ST_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 654
ERROR CODE [DXH4KB] (1ST_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 655
ERROR CODE [DXH5KA] (2ND_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 656
ERROR CODE [DXH5KB] (2ND_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 657
ERROR CODE [DXH6KA] (3RD_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 658
ERROR CODE [DXH6KB] (3RD_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 659
ERROR CODE [DXH7KA] (R_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 660
ERROR CODE [DXH7KB] (R_ECMV (E-POCV) SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 661
ERROR CODE [DXH8KA] (F_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 662
ERROR CODE [DXH8KB] (F_ECMV (E-POCV) SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 663
ERROR CODE [DXHHKA] (4TH_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 664
ERROR CODE [DXHHKB] (4TH_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 665
ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) . 666
ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) . 668
TROUBLESHOOTING CODE[TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM 670
TROUBLESHOOTING CODE[TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING . 672
TROUBLESHOOTING CODE[TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE . 674
TROUBLESHOOTING CODE[TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE 676
TROUBLESHOOTING CODE[TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE . 678
TROUBLESHOOTING CODE[TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT . 680
TROUBLESHOOTING CODE[TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING . 681
TROUBLESHOOTING CODE[TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING . 682
TROUBLESHOOTING CODE[TM-9a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT) 683
TROUBLESHOOTING CODE[TM-9b] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE . 684
TROUBLESHOOTING CODE[TM-10] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE . 686
TROUBLESHOOTING CODE[TM-11] “STARTING SWITCH””C””(IGN_C) SIGNAL SYSTEM FAILURE 688
TROUBLESHOOTING CODE[TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT 690
TROUBLESHOOTING CODE[TM-13] THE ENGINE POWER MODE CANNOT BE SELECTED 692
TROUBLESHOOTING CODE[TM-14] TRAVEL DAMPER NO/OFF SWITCH DISCONTINUITY OR GROUND FAULT [*] . 694
TROUBLESHOOTING CODE[TM-15] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY 695
TROUBLESHOOTING CODE[TM-16] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 696
TROUBLESHOOTING CODE[TM-17] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING [*] 697
TROUBLESHOOTING CODE[TM-18] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 698
TROUBLESHOOTING CODE[TM-19] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 699
TROUBLESHOOTING CODE[TM-20] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING 700
TROUBLESHOOTING CODE[TM-21] FECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING . 701
TROUBLESHOOTING CODE[TM-22] RECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING . 702
TROUBLESHOOTING CODE[TM-23] 1ST ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING 703
TROUBLESHOOTING CODE[TM-24] 2ND ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING 704
TROUBLESHOOTING CODE[TM-25] 3RD ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING 705
TROUBLESHOOTING CODE[TM-26] 4TH ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING 706
TROUBLESHOOTING CODE[TM-27] LOCK-UP ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING 707
TROUBLESHOOTING CODE[TM-28] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING . 708
TROUBLESHOOTING CODE[TM-29] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING 709
TROUBLESHOOTING CODE[TM-30] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE 710
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM(WRK MODE) 711
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM . 714
ERROR CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED 717
ERROR CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED . 718
ERROR CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED 719
ERROR CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 720
ERROR CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 722
ERROR CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED . 724
ERROR CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED . 725
ERROR CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED 726
ERROR CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED . 727
ERROR CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED . 728
ERROR CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED . 729
ERROR CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED . 730
ERROR CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 731
ERROR CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED . 732
ERROR CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED . 733
ERROR CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 734
ERROR CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 735
ERROR CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 736
ERROR CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 737
ERROR CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 738
ERROR CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED . 739
ERROR CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED . 740
ERROR CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED . 741
ERROR CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 742
ERROR CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED 743
ERROR CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED . 744
ERROR CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED . 745
ERROR CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED 746
ERROR CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED . 747
ERROR CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED . 748
ERROR CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED . 749
ERROR CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED . 750
ERROR CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED 751
ERROR CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED . 752
ERROR CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED . 753
ERROR CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED 754
ERROR CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 755
ERROR CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED 756
ERROR CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 757
ERROR CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED . 758
ERROR CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 759
ERROR CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 760
ERROR CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 761
ERROR CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 762
ERROR CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 763
ERROR CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 764
ERROR CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED . 765
ERROR CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED . 766
ERROR CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 767
ERROR CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED . 768
ERROR CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED 769
ERROR CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 770
ERROR CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 771
ERROR CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 772
ERROR CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 773
ERROR CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 774
ERROR CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 775
ERROR CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 776
ERROR CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 777
TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM 778
TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM 779
TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM 780
TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM 782
TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SETTING SWITCH SYSTEM . 784
TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM 786
TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM 788
TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM 789
TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM 790
TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM . 792
TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM . 794
TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM . 795
TROUBLESHOOTING CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM 796
TROUBLESHOOTING CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM . 797
TROUBLESHOOTING CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM . 798
TROUBLESHOOTING CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM 799
TROUBLESHOOTING CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM 800
TROUBLESHOOTING CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM 801
TROUBLESHOOTING CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM . 802
TROUBLESHOOTING CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM . 803
TROUBLESHOOTING CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM 804
TROUBLESHOOTING CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM . 805
TROUBLESHOOTING CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM . 806
TROUBLESHOOTING CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM 807
TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER,LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION . 808
TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION . 810
TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION 812
TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION 814
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) 817
MONITOR SYSTEM DIAGRAM 820
ERROR CODE [2F00MA] DRAGGING OF PARKING BRAKE . 824
ERROR CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW 826
ERROR CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW . 827
ERROR CODE [AA1ANX] AIR CLEANER 1 CLOGGED . 828
ERROR CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED . 830
ERROR CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED,DETECTION FAILURE) . 831
ERROR CODE [B@BAZG] ENGINE OIL PRESSURE LOW . 832
ERROR CODE [B@BAZK] ENGINE OIL LEVEL LOW 833
ERROR CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING 834
ERROR CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL 835
ERROR CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING . 836
ERROR CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING 837
ERROR CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED . 838
ERROR CODE [D5ZHL6] STARTING SWITCH C (IGN””C””) INPUT FAILURE 840
ERROR CODE [DA80L4] AUTO GREASE INPUT FAILURE . 841
ERROR CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) IS OFF . 842
ERROR CODE [DAF5KP] 5V POWER SUPPLY OUTPUT FAILURE 844
ERROR CODE [DAF6KP] 24V POWER SUPPLY OUTPUT FAILURE . 846
ERROR CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION 848
ERROR CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION 849
ERROR CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) 850
ERROR CODE [DbQsKr] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 851
ERROR CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 852
ERROR CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SW1) INPUT ERROR 853
ERROR CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SW2) INPUT ERROR 854
ERROR CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE 855
ERROR CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR 856
ERROR CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE [*] 858
ERROR CODE [DDS5L6] DECREASED STEERING OIL PRESSURE . 860
ERROR CODE [DDY0LD] CANCEL SWITCH FAILURE [*] . 862
ERROR CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE 864
ERROR CODE [dge3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM . 865
ERROR CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE . 866
ERROR CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE 867
ERROR CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE . 868
ERROR CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE [*] 870
ERROR CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE [*] 872
ERROR CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE [*] . 874
ERROR CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM 875
ERROR CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE 876
TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT) 878
TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT) 880
TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT) . 881
TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 882
TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 884
TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON 885
TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 886
TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON . 887
TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON . 888
TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON . 889
TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON . 890
TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1) 891
TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◇] (PANEL SW2) 892
TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3) 893
TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4) 894
TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH . 895
TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH . 896
TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT) 897
TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR . 898
TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM) 899
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE) . 901
H-1 THE MACHINE DOES NOT START 902
H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS)(WHEN THE LOCK-UP CLUTCH IS PROVIDED) 904
H-3a THE TRAVED SPEED IS SLOW,THE THRUSTING FORCE IS WEAK,THE UPHILL TRAVELING POWER IS WEAK,AND THE GEAR IS NOT SHIFTED 905
H-3b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LOT IN(IF THE LOCK-UP CLUTCH IS EQUIPPED) . 907
H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR . 908
H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 910
H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH 912
H-7 THE STEERING WHEEL DOES NOT TURN 913
H-8 THE STEERING WHEEL IS HEAVY . 914
H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED 915
H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING 915
H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT . 915
H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL 916
H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED 917
H-14 THE BRAKE IS NOT RELEASED OR DRAGGED . 918
H-15 THE LIFT ARM DOES NOT RISE . 919
H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT . 920
H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT . 921
H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKER RISES IN THE AIR) . 921
H-19 HYDRAULIC DRIFTS OF THE LIFE ARM OCCUR OFTEN . 921
H-20 THE LIFT ARM WOBBLES DURING OPERATION 921
H-21 WHEN THE CONTROL LOVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY 922
H-22 THE BUCKET DOES NOT TILT BACK 923
H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT 924
H-24 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK 925
H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 925
H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN . 925
H-27 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 926
H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY . 926
H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY . 927
H-30 ECSS DOES NOT WORK,AND THERE IS PITCHING AND BOUNCING 928
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) . 929
ELECTRICAL SYSTEM DIAGRAM . 930
TROUBLESHOOTING CODE:[E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM)) . 932
TROUBLESHOOTING CODE:[E-1-b] (THE ENGINE DOES NOT START) 936
TROUBLESHOOTING CODE:[E-2] (THE ENGINE DOES NOT STOP) . 938
TROUBLESHOOTING CODE:[E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT) . 940
TROUBLESHOOTING CODE:[E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED) 942
TROUBLESHOOTING CODE:[E-5] (THE FRONT WIPER DOES NOT FUNCTION) 944
TROUBLESHOOTING CODE:[E-6] (THE REAR WIPER DOES NOT FUNCTION) . 948
TROUBLESHOOTING CODE:[E-7] (THE SIDE WIPER DOES NOT FUNCTION (IF EQUIPPED)) . 950
TROUBLESHOOTING CODE:[E-8] (THE WIND WASHER DOES NOT FUNCTION) 951
TROUBLESHOOTING CODE:[E-9] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON) . 954
TROUBLESHOOTING CODE:[E-10] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION) 957
TROUBLESHOOTING CODE:[E-11] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP)) . 959
TROUBLESHOOTING CODE:[E-12] (THE TURN SIGNAL DOES NOT BLINK) 960
TROUBLESHOOTING CODE:[E-13] (THE BORN DOES NOT SOUND) . 962
TROUBLESHOOTING CODE:[E-14] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP) 964
TROUBLESHOOTING OF ENGINE (S MODE) 967
METHOD OF USING TROUBLESHOOTING CHARTS 968
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) . 972
S-2 ENGINE DOES NOT START . 973
(1) ENGINE DOES NOT TURN 973
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 974
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 975
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 976
S-4 ENGINE STOPS DURING OPERATIONS 977
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) . 978
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 979
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 980
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) . 981
S-9 OIL BECOMES CONTAMINATED QUICKLY 982
S-10 FUEL CONSUMPTION IS EXCESSIVE 983
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN 984
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) . 985
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL) 986
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) . 987
S-15 ABNORMAL NOISE IS MADE . 988
S-16 VIBRATION IS EXCESSIVE . 989
30 DISASSEMBLY AND ASSEMBLY . 991
HOW TO READ THIS MANUAL . 993
PRECAUTIONS WHEN PERFORMING OPERATION . 995
SPECIAL TOOL LIST . 997
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 1013
REMOVAL .1013
INSTALLATION 1014
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY 1015
REMOVAL .1015
INSTALLATION 1015
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 1016
SPECIAL TOOL 1016
REMOVAL .1016
INSTALLATION 1021
REMOVAL AND INSTALLATION OF ENGINE ADDEMBLY .1024
SPECIAL TOOL 1024
REMOVAL .1024
INSTALLATION 1030
REMOVAL AND INSTALLATION OF AFTER COOLER ASSEMBLY .1031
REMOVAL .1031
INSTALLATION 1031
REMOVAL AND INSTALLATION OF RADIATOR, FAN MOTOR AND AFTER COOLER ASSEMBLY .1033
REMOVAL .1033
INSTALLATION 1035
REMOVAL AND INSTALLATION FUEL TANK ASSEMBLY .1036
REMOVAL 1036
INSTALLATION 1037
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC AND PLATE 1038
SPECIAL TOOL 1038
REMOVAL .1038
INSTALLATION 1040
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 1041
REMOVAL .1041
INSTALLATION 1045
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY .1047
SPECIAL TOOL 1047
DISASSEMBLY .1047
ASSEMBLY 1054
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY 1062
SPECIAL TOOLS .1062
DISASSEMBLY .1062
ASSEMBLY 1068
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY 1078
SPECIAL TOOLS .1078
DISASSEMBLY .1078
ASSEMBLY 1080
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION) 1086
SPECIAL TOOLS .1086
DISASSEMBLY .1086
ASSEMBLY 1088
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY(LOCK-UP SPECIFICATION) 1090
SPECIAL TOOLS .1090
DISASSEMBLY .1090
ASSEMBLY 1092
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY .1096
REMOVAL .1096
INSTALLATION 1096
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY 1097
REMOVAL 1097
INSTALLATION 1099
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY .1100
SPECIAL TOOLS .1100
DISASSEMBLY .1100
ASSEMBLY 1103
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY .1109
SPECIAL TOOLS .1109
DISASSEMBLY .1109
ASSEMBLY 1115
REMOVAL AND INSTALLATION OF CENTER HING PIN .1130
SPECIAL TOOL 1130
REMOVAL .1130
INSTALLATION 1134
REMOVAL AND INSTALLATION OF CAB ASSEMBLY 1138
REMOVAL 1138
INSTALLATION 1140
REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY 1141
SPECIAL TOOL 1141
REMOVAL .1141
INSTALLATION 1144
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS(STUCK GLASS) .1145
SPECIAL TOOL 1145
REMOVAL .1145
INSTALLATION 1146
COATING MATERIALS .1152
REMOVAL AND INSTALLATION OF TORQUE CONVERTER WORK EQUIPMENT AND PILOT CONTROL PUMP ASSEMBLY .1153
REMOVAL .1153
INSTALLATION 1153
REMOVAL AND INSTALLATION OF STEERING, SWITCH AND FAN PUMP ASSEMBLY 1154
REMOVAL .1154
INSTALLATION 1154
REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY 1155
REMOVAL 1155
INSTALLATION 1155
REMOVAL AND INSTALLATION OF STEERING VALVE OIL SEAL .1156
REMOVAL .1156
INSTALLATION 1157
REMOVAL AND INSTALLATION OF TRAVEL DUMPER VALVE ASSEMBLY 1158
REMOVAL .1158
INSTALLATION 1158
REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY .1159
REMOVAL 1159
INSTALLATION 1160
REMOVAL AND INSTALLATION OF HYDRAULIC TANK .1161
REMOVAL .1161
INSTALLATION 1162
REMOVAL AND INSTALLATION OF HYDRAULIC TANK 1163
REMOVAL 1163
INSTALLATION 1165
DISASSEMBLY AD ASSEMBLY OF HYDRAULIC CYLINDER .1169
SPECIAL TOOL 1169
DISASSEMBLY .1169
ASSEMBLY 1172
REMOVAL AND INSTALLATION OF COUNTER WEIGHT 1177
REMOVAL .1177
INSTALLATION 1177
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT 1178
SPECIAL TOOL 1178
REMOVAL .1178
INSTALLATION 1180
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY .1181
SPECIAL TOOL 1181
REMOVAL .1181
INSTALLATION 1182
DISASSEMBLY, ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY .1183
DISASSEMBLY .1183
ASSEMBLY 1188
90 OTHERS .1193
POWER TRAIN OIL CIRCUIT DIAGRAM(WITHOUT TORQUE CONVERTER LOCKUP CLUTCH) .1195
POWER TRAIN OIL CIRCUIT DIAGRAM(WITH TORQUE CONVERTER LOCKUP CLUTCH) 1197
BRAKE OIL CIRCUIT DIAGRAM .1199
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1201
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(FOR ELECTRIC WORK EQUIPMENT LEVER) .1203
ELECTRICAL CIRCUIT DIAGRAM(1/8)(1/4) 1205
ELECTRICAL CIRCUIT DIAGRAM(1/8)(2/4) 1207
ELECTRICAL CIRCUIT DIAGRAM(1/8)(3/4) 1209
ELECTRICAL CIRCUIT DIAGRAM(1/8)(4/4) 1211
ELECTRICAL CIRCUIT DIAGRAM(2/8)(1/4) 1213
ELECTRICAL CIRCUIT DIAGRAM(2/8)(2/4) 1215
ELECTRICAL CIRCUIT DIAGRAM(2/8)(3/4) 1217
ELECTRICAL CIRCUIT DIAGRAM(2/8)(4/4) 1219
ELECTRICAL CIRCUIT DIAGRAM(3/8) .1221
ELECTRICAL CIRCUIT DIAGRAM(4/8) .1223
ELECTRICAL CIRCUIT DIAGRAM(5/8) .1225
ELECTRICAL CIRCUIT DIAGRAM(6/8) .1227
ELECTRICAL CIRCUIT DIAGRAM(7/8) .1229
ELECTRICAL CIRCUIT DIAGRAM(8/8) .1231

DESCRIPTION:

Komatsu WA430-5 Wheel Loader Shop Manual SEBM025407  – PDF DOWNLOAD

Machine model Serial number

• WA430-5 60001 and up

G.B 26/12/24