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Komatsu WA430-6 Galeo Wheel Loader Service Repair Manual (SEN00837-03) – PDF DOWNLOAD
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- Komatsu WA430-6 Galeo Wheel Loader Service Repair Manual
- PUBLICATION NUMBER:SEN00837-03
- SERIAL NUMBERS WA430-6 65001 and up
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Description
Komatsu WA430-6 Galeo Wheel Loader Service Repair Manual (SEN00837-03)
KOMATSU WA430-6 GALEO WHEEL LOADER SERVICE REPAIR MANUAL (SEN00837-03) – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu WA430-6 Galeo Wheel Loader Service Repair Manual (SEN00837-03)
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 WA430-6 Galeo Wheel Loader Service Repair Manual (SEN00837-03)
MAIN MENU................................................................................................................................................ 0 COVER.................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 3 Index................................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 Foreword and general information..................................................................................................................... 21 Safety notice.................................................................................................................................... 22 How to read the shop manual...................................................................................................................... 27 Explanation of terms for maintenance standard.................................................................................................... 29 Handling electric equipment and hydraulic component.............................................................................................. 31 How to read electric wire code................................................................................................................... 43 Precautions when carrying out operation.......................................................................................................... 46 Method of disassembling and connecting push-pull type coupler.................................................................................... 49 Standard tightening torque table................................................................................................................. 52 Conversion table................................................................................................................................. 56 01 Specification......................................................................................................................................... 63 Specification and technical data..................................................................................................................... 63 Specification and technical data................................................................................................................. 65 Specification dimension drawing.................................................................................................................. 65 Specifications................................................................................................................................... 66 Weight table..................................................................................................................................... 70 Table of fuel, coolant and lubricants............................................................................................................ 72 10 Structure, function and maintenance standard.......................................................................................................... 75 Engine and cooling system............................................................................................................................ 75 Engine and cooling system........................................................................................................................ 76 Engine mount and transmission mount.......................................................................................................... 76 Cooling system............................................................................................................................... 77 Cooling fan pump............................................................................................................................. 78 Cooling fan motor............................................................................................................................ 86 Power train.......................................................................................................................................... 93 Power train...................................................................................................................................... 95 Power train.................................................................................................................................. 95 Power train system diagram................................................................................................................... 96 Drive shaft.................................................................................................................................. 98 Power train piping diagram................................................................................................................... 99 Torque converter............................................................................................................................. 100 Transmission................................................................................................................................. 104 Flow control valve........................................................................................................................... 120 Transmission control valve................................................................................................................... 124 ECMV......................................................................................................................................... 126 Main relief valve and torque converter relief valve.......................................................................................... 130 Axle......................................................................................................................................... 132 Differential................................................................................................................................. 134 Limited slip differential.................................................................................................................... 140 Final drive.................................................................................................................................. 146 Steering system...................................................................................................................................... 153 Steering system.................................................................................................................................. 154 Steering piping diagram...................................................................................................................... 154 Steering column.............................................................................................................................. 155 Steering pump................................................................................................................................ 156 Steering valve............................................................................................................................... 167 Orbit-roll valve............................................................................................................................. 182 Stop valve................................................................................................................................... 186 Steering relief valve........................................................................................................................ 187 Steering cylinder............................................................................................................................ 188 Emergency steering motor..................................................................................................................... 190 Emergency steering pump...................................................................................................................... 191 Brake system......................................................................................................................................... 193 Brake system..................................................................................................................................... 194 Brake piping diagram......................................................................................................................... 194 Charge valve................................................................................................................................. 195 Brake valve.................................................................................................................................. 202 Accumulator (for brake)...................................................................................................................... 207 Brake........................................................................................................................................ 208 Parking brake control........................................................................................................................ 213 Parking brake................................................................................................................................ 214 Parking brake solenoid valve................................................................................................................. 216 Emergency parking brake release valve........................................................................................................ 218 Undercarriage and frame.............................................................................................................................. 221 Undercarriage and frame.......................................................................................................................... 222 Axle mount and center hinge pin.............................................................................................................. 222 Tires........................................................................................................................................ 226 Hydraulic system, Part 1............................................................................................................................. 229 Hydraulic system, Part 1......................................................................................................................... 230 Hydraulic piping diagram..................................................................................................................... 230 Work equipment control lever linkage......................................................................................................... 233 Hydraulic tank............................................................................................................................... 234 Power train pump............................................................................................................................. 236 Work equipment pump.......................................................................................................................... 237 Work equipment control valve................................................................................................................. 248 CLSS......................................................................................................................................... 262 Each function and operation of each valve.................................................................................................... 266 Hydraulic system, Part 2............................................................................................................................. 289 Hydraulic system, Part 2......................................................................................................................... 290 PPC valve........................................................................................................................................ 290 Stabilizer valve................................................................................................................................. 296 Attachment PPC valve............................................................................................................................. 302 Accumulator (for PPC circuit).................................................................................................................... 304 Accumulator (for ECSS)........................................................................................................................... 305 Work equipment....................................................................................................................................... 307 Work equipment................................................................................................................................... 308 Work equipment linkage....................................................................................................................... 308 Bucket....................................................................................................................................... 310 Bucket positioner and boom kick-out.......................................................................................................... 311 Work equipment cylinder...................................................................................................................... 317 Cab and its attachments.............................................................................................................................. 319 Cab and its attachments.......................................................................................................................... 321 Cab.......................................................................................................................................... 321 Air conditioner.............................................................................................................................. 322 Electrical system, Part 1............................................................................................................................ 341 Electrical system, Part 1........................................................................................................................ 342 Machine monitor system........................................................................................................................... 342 Machine monitor.................................................................................................................................. 347 Electrical system, Part 2............................................................................................................................ 369 Electrical system, Part 2........................................................................................................................ 370 Electrical system (Transmission controller system)........................................................................................... 370 Transmission controller...................................................................................................................... 402 Electrical system, Part 3............................................................................................................................ 405 Electrical system, Part 3........................................................................................................................ 406 Electric transmission control................................................................................................................ 406 Kickdown switch and hold switch.............................................................................................................. 410 KOMTRAX terminal system...................................................................................................................... 412 Engine starting circuit...................................................................................................................... 414 Engine stopping circuit...................................................................................................................... 416 Preheating circuit........................................................................................................................... 417 Engine power mode selector circuit........................................................................................................... 418 Engine output derating function.............................................................................................................. 419 Automatic warm-up function................................................................................................................... 419 Parking brake circuit........................................................................................................................ 420 Sensor....................................................................................................................................... 422 20 Standard value table.................................................................................................................................. 431 Standard service value table......................................................................................................................... 432 Standard value table for engine.................................................................................................................. 432 Standard value table for chassis................................................................................................................. 433 30 Testing and adjusting................................................................................................................................. 441 Testing and adjusting, Part 1........................................................................................................................ 441 Testing and adjusting, Part 1.................................................................................................................... 443 Tools for testing, adjusting, and troubleshooting................................................................................................ 443 Measuring engine speed........................................................................................................................... 446 Measuring exhaust gas color...................................................................................................................... 448 Measuring exhaust temperature.................................................................................................................... 449 Adjusting valve clearance........................................................................................................................ 451 Testing compression pressure..................................................................................................................... 453 Measuring blow-by pressure....................................................................................................................... 456 Measuring engine oil pressure.................................................................................................................... 457 Measuring intake air (boost) pressure............................................................................................................ 458 Handling fuel system equipment................................................................................................................... 459 Releasing residual pressure in fuel system....................................................................................................... 459 Testing fuel pressure............................................................................................................................ 460 Testing fuel return and leak amount.............................................................................................................. 464 Bleeding air from fuel circuit................................................................................................................... 466 Testing leakage in fuel system................................................................................................................... 467 Handling reduced cylinder mode operation......................................................................................................... 468 Handling no-injection cranking operation......................................................................................................... 468 Handling controller high-voltage circuit......................................................................................................... 469 Check of muffler and muffler stack for looseness and damage...................................................................................... 470 Check of muffler function........................................................................................................................ 470 Check of installed condition of cylinder head and manifolds...................................................................................... 471 Check of engine piping for damage and looseness.................................................................................................. 471 Testing and adjusting air conditioner compressor belt tension.................................................................................... 472 Adjusting transmission speed sensor.............................................................................................................. 473 Adjusting directional lever length............................................................................................................... 474 Measuring directional lever...................................................................................................................... 475 Measuring and adjusting power train oil pressure................................................................................................. 476 Procedure for flushing torque converter and transmission hydraulic circuit....................................................................... 490 Method of moving machine when transmission valve is broken....................................................................................... 491 Check of axle final drive for oil leakage........................................................................................................ 493 Check of drive shafts for looseness, play and damage............................................................................................. 493 Testing and adjusting steering stop valve........................................................................................................ 494 Testing and adjusting steering wheel............................................................................................................. 496 Testing steering oil pressure.................................................................................................................... 498 Bleeding air from steering circuit............................................................................................................... 501 Testing and adjusting, Part 2........................................................................................................................ 503 Testing and adjusting, Part 2.................................................................................................................... 505 Testing hydraulic drive fan.................................................................................................................. 505 Bleeding air from hydraulic drive fan circuit................................................................................................ 507 Measuring brake pedal........................................................................................................................ 509 Testing and adjusting brake pedal linkage.................................................................................................... 510 Measuring brake performance.................................................................................................................. 511 Testing and adjusting accumulator charge pressure............................................................................................ 512 Testing wheel brake oil pressure............................................................................................................. 513 Measuring wear of wheel brake disc........................................................................................................... 515 Bleeding air from wheel brake circuit........................................................................................................ 516 Releasing residual pressure in brake accumulator circuit..................................................................................... 517 Testing parking brake performance............................................................................................................ 518 Measuring parking brake oil pressure......................................................................................................... 519 Testing wear of parking brake disc........................................................................................................... 521 Method of releasing parking brake manually................................................................................................... 522 Measuring and adjusting work equipment control lever......................................................................................... 523 Measuring and adjusting work equipment PPC oil pressure...................................................................................... 524 Measuring and adjusting work equipment oil pressure.......................................................................................... 527 Bleeding air from work equipment circuit..................................................................................................... 531 Releasing residual pressure in work equipment circuit........................................................................................ 532 Testing and adjusting bucket positioner...................................................................................................... 533 Testing and adjusting boom kick-out.......................................................................................................... 535 Checking proximity switch operation pilot lamp............................................................................................... 536 Procedure for testing diodes................................................................................................................. 537 Preparation work for troubleshooting for electrical system................................................................................... 538 Starting KOMTRAX terminal operations......................................................................................................... 543 Indicator lamps of KOMTRAX terminal.......................................................................................................... 547 Adjusting machine monitor.................................................................................................................... 550 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....................................................... 551 Testing and adjusting, Part 3........................................................................................................................ 555 Testing and adjusting, Part 3.................................................................................................................... 556 Special functions of machine monitor (EMMS).................................................................................................. 556 Pm-click inspection table.................................................................................................................... 618 40 Troubleshooting....................................................................................................................................... 621 Failure code table and fuse locations................................................................................................................ 621 Failure code table and fuse locations............................................................................................................ 622 Failure code table........................................................................................................................... 622 Fuse locations............................................................................................................................... 634 General information on troubleshooting............................................................................................................... 639 General information on troubleshooting........................................................................................................... 640 Points to remember when troubleshooting...................................................................................................... 640 Sequence of events in troubleshooting........................................................................................................ 641 Testing before troubleshooting............................................................................................................... 642 Classification and procedures of troubleshooting............................................................................................. 643 Information contained in troubleshooting table............................................................................................... 646 Connection table for connector pin numbers................................................................................................... 648 T-branch box and T-branch adapter table...................................................................................................... 671 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 675 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 677 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................ 677 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................ 678 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................ 680 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................ 682 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................ 684 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...................................................... 686 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...................................................... 688 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...................................................... 690 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...................................................... 692 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...................................................... 694 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...................................................... 696 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...................................................... 698 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...................................................... 700 Failure code [2F00MA] (Parking brake: Malfunction)........................................................................................... 702 Failure code [2G43ZG] (Accumulator: Low oil pressure)........................................................................................ 704 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)........................................................................... 706 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 709 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 712 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................ 712 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).......................................................... 714 Failure code [AB00MA] (Alternator: Malfunction).............................................................................................. 716 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)......................................................................... 718 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................ 719 Failure code [B@BCNS] (Coolant: Overheating)................................................................................................. 720 Failure code [B@BCZK] (Coolant: Low level)................................................................................................... 722 Failure code [B@BEBF] (Water in fuel error).................................................................................................. 724 Failure code [B@C7NS] (Brake oil: Overheating)............................................................................................... 726 Failure code [b@CENS] (Torque converter oil: Overheating).................................................................................... 728 Failure code [B@CENS] (Torque converter oil: Overheating).................................................................................... 730 Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................................... 732 Failure code [CA111] (Abnormality in engine controller)...................................................................................... 734 Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................................. 735 Failure code [CA122] (Charge pressure sensor high error)..................................................................................... 736 Failure code [CA123] (Charge pressure sensor low error)...................................................................................... 738 Failure code [CA131] (Throttle sensor high error)............................................................................................ 740 Failure code [CA132] (Throttle sensor low error)............................................................................................. 742 Failure code [CA144] (Coolant sensor high error)............................................................................................. 744 Failure code [CA145] (Coolant sensor low error).............................................................................................. 746 Failure code [CA153] (Charge temperature sensor high error).................................................................................. 748 Failure code [CA154] (Charge temperature sensor low error)................................................................................... 750 Failure code [CA155] (Derating of speed by abnormally high charge temperature)............................................................... 752 Failure code [CA187] (Sensor power supply 2 low error)....................................................................................... 754 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................ 756 Failure code [CA222] (Atmospheric sensor low error).......................................................................................... 758 Failure code [CA227] (Sensor power supply 2 high error)...................................................................................... 760 Failure code [CA234] (Engine overspeed)...................................................................................................... 761 Failure code [CA238] (Ne speed sensor power supply error).................................................................................... 762 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 765 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 767 Failure code [CA271] (IMV/PCV1 Short circuit)................................................................................................ 767 Failure code [CA272] (IMV/PCV1 Disconnection)................................................................................................ 768 Failure code [CA281] High pressure pump error................................................................................................ 770 Failure code [CA322] (Injector #1 open/short error).......................................................................................... 772 Failure code [CA323] (Injector #5 open/short error).......................................................................................... 774 Failure code [CA324] (Injector #3 open/short error).......................................................................................... 776 Failure code [CA325] (Injector #6 open/short error).......................................................................................... 778 Failure code [CA331] (Injector #2 open/short error).......................................................................................... 780 Failure code [CA332] (Injector #4 open/short error).......................................................................................... 782 Failure code [CA342] (Calibration code inconsistency)........................................................................................ 784 Failure code [CA351] (Injectors drive circuit error)......................................................................................... 785 Failure code [CA352] (Sensor power supply 1 low error)....................................................................................... 788 Failure code [CA386] (Sensor power supply 1 high error)...................................................................................... 790 Failure code [CA428] (Abnormally high level in water sensor)................................................................................. 792 Failure code [CA429] (Abnormally low level in water sensor).................................................................................. 794 Failure code [CA431] (Idle validation switch error).......................................................................................... 796 Failure code [CA432] (Idle validation action error).......................................................................................... 798 Failure code [CA435] (Engine oil pressure switch error)...................................................................................... 800 Failure code [CA441] (Battery voltage low error)............................................................................................. 801 Failure code [CA442] (Battery voltage high error)............................................................................................ 804 Failure code [CA449] Common rail pressure high error 2....................................................................................... 806 Failure code [CA451] (Common rail pressure sensor high error)................................................................................ 808 Failure code [CA452] (Common rail pressure sensor low error)................................................................................. 810 Failure code [CA488] (Derating of torque by abnormally high charge temperature).............................................................. 812 Failure code [CA553] (Common rail pressure high error 1)..................................................................................... 813 Failure code [CA559] (Supply pump pressure very low error)................................................................................... 814 Failure code [CA689] (Engine Ne speed sensor error).......................................................................................... 816 Failure code [CA731] (Engine Bkup speed sensor phase error).................................................................................. 818 Failure code [CA757] (All continuous data lost error)........................................................................................ 819 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................ 822 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................ 824 Failure code [CA2185] (Throttle sensor power supply voltage high error)...................................................................... 826 Failure code [CA2186] (Throttle sensor power supply voltage low error)....................................................................... 827 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 829 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 831 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................ 831 Failure code [CA2265] (Abnormally high level in electric lift pump).......................................................................... 832 Failure code [CA2266] (Abnormally low level in electric lift pump)........................................................................... 834 Failure code [CA2311] (Abnormality in IMV solenoid).......................................................................................... 836 Failure code [CA2555] (Intake heater relay disconnection error).............................................................................. 838 Failure code [CA2556] (Intake heater relay short circuit error).............................................................................. 840 Failure code [D150KA] (Emergency steering relay: Disconnection).............................................................................. 842 Failure code [D150KB] (Emergency steering relay: Short circuit).............................................................................. 844 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)....................................................... 846 Failure code [D160KA] (Backup lamp relay: Disconnection)..................................................................................... 848 Failure code [D160KB] (Backup lamp relay: Short circuit)..................................................................................... 850 Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit).................................................................... 852 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)................................................................ 854 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)................................................................ 856 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)......................................... 858 Failure code [D192KA] (ECSS solenoid: Disconnection)......................................................................................... 860 Failure code [D192KB] (ECSS solenoid: Short circuit)......................................................................................... 861 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line).................................................................. 862 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection).................................................................. 864 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit).................................................................. 866 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)........................................... 868 Failure code [D5ZHKA] (Terminal C signal: Disconnection)..................................................................................... 871 Failure code [D5ZHKB] (Terminal C signal: Short circuit)..................................................................................... 875 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit).................................................................... 878 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)............................................. 883 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...................................................................... 886 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).......................................................................... 888 Failure code [DAF5KP] (Machine monitor: Low output voltage).................................................................................. 890 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))............. 894 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 897 Troubleshooting by failure code (Display of code), Part 5........................................................................................ 900 Failure code [DAQ0KK] (Transmission controller: Low source voltage).......................................................................... 900 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)................................................................... 902 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))........................................... 903 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)..................................... 905 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))..... 906 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).................................................................. 908 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)............ 910 Failure code [DB90KK] Work equipment controller: Low source voltage (input).................................................................. 912 Failure code [DB90KT] Work equipment controller: Abnormality in controller................................................................... 914 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)........................................... 915 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range............................................... 917 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)................................... 920 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)).... 921 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................................................................ 923 Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation).................................................. 924 Failure code [DD15LD] __ switch (Panel switch 1): Switch is kept pressed for long time....................................................... 928 Failure code [DD16LD] __ switch (Panel switch 2): Switch is kept pressed for long time....................................................... 930 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time........................................................ 932 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time........................................................ 934 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time................................. 936 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time................................. 938 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time....................................................... 940 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time............................................ 942 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time............................................ 944 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)............................................. 946 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)............................................................. 948 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)................................................... 950 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).......................................................... 952 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)...................................... 956 Troubleshooting by failure code (Display of code), Part 6............................................................................................ 959 Troubleshooting by failure code (Display of code), Part 6........................................................................................ 962 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)............................................................................. 962 Failure code [DDK3KA] (Right FNR switch: Disconnection).......................................................................................... 964 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection).............................................................................. 967 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree).......................................................... 970 Failure code [DDK6KA] (FNR lever switch: Disconnection).......................................................................................... 972 Failure code [DDK6KB] (FNR lever switch: Short circuit).......................................................................................... 976 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...................................................................... 978 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time).................................................... 980 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)................................................................... 982 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................................................................ 984 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)........................................................... 986 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)............................................................................ 988 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)........................................................................... 992 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)........................................................................ 994 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)....................................................................... 996 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).............................................................. 998 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)..........................................................................1000 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).............................................................1002 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range).......................................................1004 Troubleshooting by failure code (Display of code), Part 7............................................................................................1007 Troubleshooting by failure code (Display of code), Part 7........................................................................................1010 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)..................................................1010 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)....................................................1012 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)......................................................1014 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).........................................................................1016 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit).........................................................................1018 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...............................................................1020 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)........................................1023 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).....................................................1026 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)................................................................1029 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).........................................1032 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).................................................................1035 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..........................................1038 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree).......................................................1041 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)..................................................................1044 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...........................................1047 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection).............................................1050 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)......................1054 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)...................................1056 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)..............................................1059 Failure code [DK5EKY] (3-spool valve (attachment) EPC lever potentiometer (Sub): Short circuit with power supply line).......................1062 Troubleshooting by failure code (Display of code), Part 8............................................................................................1065 Troubleshooting by failure code (Display of code), Part 8........................................................................................1067 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)......................................................1067 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...............................1070 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection).......................................................1072 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)................................1076 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)............................................1078 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).................................................................................1082 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..........................................................1084 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)................................................................................1086 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)................................................................1088 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)....................................................1090 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...................................................................1092 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)............................................................1094 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)............................................................1096 Failure code [DV00KB] (Alarm buzzer: Short circuit)..........................................................................................1098 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...........................................................................1100 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...........................................................................1102 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)....................................................1104 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...........................................................................1106 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...........................................................................1107 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)....................................................1108 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..............................................................................1110 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..............................................................................1111 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line).......................................................1112 Troubleshooting by failure code (Display of code), Part 9............................................................................................1115 Troubleshooting by failure code (Display of code), Part 9........................................................................................1117 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..............................................................................1117 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..............................................................................1118 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line).......................................................1119 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)..................................................................................1121 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)..................................................................................1122 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...........................................................1124 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)..................................................................1126 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)..................................................................1127 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)...........................................1128 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)..................................................................1130 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)..................................................................1132 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...........................................1134 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).................................................................1136 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).................................................................1138 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..........................................1140 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).................................................................1142 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).................................................................1144 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..........................................1146 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)....................................................................1148 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)....................................................................1150 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)....................................................1152 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).................................................................................1154 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).................................................................................1155 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..........................................................1156 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)..................................................................................1158 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)..................................................................................1160 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...........................................................1162 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..............................................................................1164 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..............................................................................1166 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line).......................................................1168 Troubleshooting by failure code (Display of code), Part 10...........................................................................................1171 Troubleshooting by failure code (Display of code), Part 10.......................................................................................1174 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..............................................................................1174 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..............................................................................1176 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line).......................................................1178 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..............................................................................1180 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..............................................................................1182 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line).......................................................1184 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)................................................................................1186 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)................................................................................1188 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).........................................................1190 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)................................................................................1192 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)................................................................................1194 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).........................................................1196 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..............................................................................1198 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..............................................................................1200 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line).......................................................1202 Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection).....................................................................1204 Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit).....................................................................1206 Failure code [DXHJKY] (3-spool valve extend EPC solenoid: Short circuit with power supply line)..............................................1208 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)....................................................................1210 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)....................................................................1212 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line).............................................1214 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)..................................................................1216 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)..................................................................1218 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...........................................1220 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...................................................................1222 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...................................................................1224 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)............................................1226 Troubleshooting of electrical system (E-mode)........................................................................................................1229 Troubleshooting of electrical system (E-mode)....................................................................................................1231 Installing positions of fuses....................................................................................................................1231 Information in troubleshooting table.............................................................................................................1234 E-1 Engine does not start........................................................................................................................1235 E-2 Wiper does not operate.......................................................................................................................1242 E-3 Windshield washer does not operate...........................................................................................................1246 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..............................................................1249 E-5 Working lamp does not light up or go off.....................................................................................................1257 E-6 Turn signal lamp and hazard lamp do not light up or go off...................................................................................1262 E-7 Brake lamp does not light or it keeps lighting up............................................................................................1268 E-8 Backup lamp does not light or it keeps lighting up...........................................................................................1270 E-9 Backup buzzer does not sound or it keeps sounding............................................................................................1272 E-10 Horn does not sound or it keeps sounding....................................................................................................1274 E-11 Alarm buzzer does not sound or it keeps sounding............................................................................................1276 E-12 Air conditioner does not operate or stop....................................................................................................1278 E-13 The KOMTRAX system does not work properly...................................................................................................1281 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1285 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1287 Method of using troubleshooting chart........................................................................................................1287 Table of failure modes and causes............................................................................................................1290 H-1 The machine does not start...............................................................................................................1294 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...................................1296 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]....................................................1297 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...................1298 H-5 Shocks are large at the times of starting and shifting gear..............................................................................1300 H-6 Time lag is large at the times of starting and shifting gear.............................................................................1302 H-7 The torque converter oil temperature is high.............................................................................................1304 H-8 Steering does not turn...................................................................................................................1305 H-9 Steering does not turn [Machine with joystick steering (if equipped)]....................................................................1306 H-10 Steering response is low................................................................................................................1307 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]....................................................1308 H-12 Steering is heavy.......................................................................................................................1309 H-13 When machine turns, it shakes or makes large shocks.....................................................................................1310 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]......................................1311 H-15 The wheel brake does not work or does not work well.....................................................................................1312 H-16 The wheel brake is not released or it drags.............................................................................................1313 H-17 The parking brake does not work or does not work well...................................................................................1314 H-18 The parking brake is not released or it drags (including emergency release system)......................................................1315 H-19 Lift arm does not rise..................................................................................................................1316 H-20 Lift arm speed is low or rising force of lift arm is insufficient.......................................................................1317 H-21 When rising, the lift arm comes to move slowly at specific height.......................................................................1318 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats).......................................................................1318 H-23 Hydraulic drifts of the lift arm is large...............................................................................................1318 H-24 The lift arm wobbles during operation...................................................................................................1318 H-25 Bucket does not tilt back...............................................................................................................1319 H-26 Bucket speed is low or tilting back force is insufficient...............................................................................1320 H-27 The bucket comes to operate slowly in the midst of tilting-back.........................................................................1321 H-28 The bucket cylinder cannot hold down the bucket.........................................................................................1321 H-29 Hydraulic drifts of the bucket is large.................................................................................................1321 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).................................................1321 H-31 Lift arm and bucket control levers do not move smoothly and are heavy...................................................................1322 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls........................................................1323 H-33 Large shock is made when work equipment starts and stops................................................................................1323 H-34 When work equipment circuit is relieved singly, other work equipment moves..............................................................1323 H-35 ECSS does not operate, and pitching, bouncing occur.....................................................................................1324 Troubleshooting of engine (S-mode)...................................................................................................................1327 Troubleshooting of engine (S-mode)...............................................................................................................1329 Method of using troubleshooting chart........................................................................................................1329 S-1 Engine does not start easily.............................................................................................................1332 S-2 Engine does not start....................................................................................................................1333 S-3 Engine does not pick up smoothly.........................................................................................................1336 S-4 Engine stops during operations...........................................................................................................1337 S-5 Engine does not rotate smoothly..........................................................................................................1338 S-6 Engine lacks output (or lacks power).....................................................................................................1339 S-7 Exhaust smoke is black (Incomplete combustion)...........................................................................................1340 S-8 Oil consumption is excessive (or exhaust smoke is blue)..................................................................................1341 S-9 Engine oil becomes contaminated quickly..................................................................................................1342 S-10 Fuel consumption is excessive...........................................................................................................1343 S-11 Coolant contains oil (blows back or reduces)............................................................................................1344 S-12 Oil pressure drops......................................................................................................................1345 S-13 Oil level rises (Water, fuel in oil)....................................................................................................1346 S-14 Coolant temperature rises too high (Overheating)........................................................................................1347 S-15 Abnormal noise is made..................................................................................................................1348 S-16 Vibration is excessive..................................................................................................................1349 50 Disassembly and assembly1.............................................................................................................................1351 General information on disassembly and assembly......................................................................................................1351 General information on disassembly and assembly..................................................................................................1352 How to read this manual......................................................................................................................1352 Coating materials list.......................................................................................................................1354 Special tools list...........................................................................................................................1357 Sketches of special tools....................................................................................................................1361 Engine and cooling system............................................................................................................................1375 Engine and cooling system........................................................................................................................1376 Removal and installation of fuel supply pump assembly........................................................................................1376 Removal and installation of fuel injector assembly...........................................................................................1379 Removal and installation of cylinder head assembly...........................................................................................1387 Removal and installation of engine hood and radiator guard assembly..........................................................................1399 Removal and installation of radiator assembly................................................................................................1401 Removal and installation of air aftercooler assembly.........................................................................................1403 Removal and installation of hydraulic oil cooler assembly....................................................................................1405 Removal and installation of engine assembly..................................................................................................1406 Removal and installation of front seal assembly..............................................................................................1411 Removal and installation of rear oil seal assembly...........................................................................................1413 Removal and installation of cooling fan and fan motor assembly...............................................................................1418 Removal and installation of fuel tank assembly...............................................................................................1421 Power train, Part 1..................................................................................................................................1425 Power train, Part 1..............................................................................................................................1426 Removal and installation of torque converter and transmission assembly.......................................................................1426 Disassembly and assembly of torque converter assembly (Standard specification)...............................................................1431 Disassembly and assembly of torque converter assembly (Lock-up specification)................................................................1435 Disassembly and assembly of transmission assembly............................................................................................1442 Disassembly and assembly of transmission clutch pack assembly................................................................................1457 Disassembly and assembly of parking brake assembly...........................................................................................1473 Power train, Part 2..................................................................................................................................1481 Power train, Part 2..............................................................................................................................1482 Removal and installation of front axle assembly..............................................................................................1482 Removal and installation of rear axle assembly...............................................................................................1484 Disassembly and assembly of axle housing.....................................................................................................1488 Disassembly and assembly of differential assembly............................................................................................1498 Steering system......................................................................................................................................1519 Steering system..................................................................................................................................1520 Removal and installation of steering demand valve assembly...................................................................................1520 Brake system.........................................................................................................................................1523 Brake system.....................................................................................................................................1524 Removal and installation of parking brake disc and plate.....................................................................................1524 Undercarriage and frame..............................................................................................................................1529 Undercarriage and frame..........................................................................................................................1530 Removal and installation of center hinge pin.................................................................................................1530 Removal and installation of counterweight....................................................................................................1538 Hydraulic system.....................................................................................................................................1541 Hydraulic system.................................................................................................................................1542 Removal and installation of work equipment control valve assembly............................................................................1542 Removal and installation of power train pump and work equipment pump assembly................................................................1545 Removal and installation of steering pump and cooling fan pump assembly......................................................................1546 Removal and installation of hydraulic tank assembly..........................................................................................1547 Work equipment.......................................................................................................................................1551 Work equipment...................................................................................................................................1552 Removal and installation of work equipment assembly..........................................................................................1552 Disassembly and assembly of hydraulic cylinder assembly......................................................................................1557 Cab and its attachments..............................................................................................................................1567 Cab and its attachments..........................................................................................................................1568 Removal and installation of operator's cab and floor frame assembly..........................................................................1568 Removal and installation of operator's cab glass (stuck glass)...............................................................................1571 Disassembly, assembly of operator's seat assembly............................................................................................1579 Removal and installation of air conditioner unit assembly....................................................................................1588 Electrical system....................................................................................................................................1595 Electrical system................................................................................................................................1596 Removal and installation of engine controller assembly.......................................................................................1596 Removal and installation of KOMTRAX terminal assembly........................................................................................1597 90 Diagrams and drawings.................................................................................................................................1599 Hydraulic diagrams and drawings......................................................................................................................1599 Hydraulic diagrams and drawings..................................................................................................................1600 Power train hydraulic circuit diagram........................................................................................................1600 Hydraulic circuit diagram....................................................................................................................1603 Electrical diagrams and drawings.....................................................................................................................1606 Electrical diagrams and drawings.................................................................................................................1608 Electrical circuit diagram (1/2).................................................................................................................1608 Electrical circuit diagram (2/2).................................................................................................................1609 Connector arrangement diagram....................................................................................................................1610
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