Komatsu Wa430-6 Wa 430 Wa430 Wheel Loader Service Repair Workshop Manual – PDF DOWNLOAD

Description

Komatsu Wa430-6 Wa 430 Wa430 Wheel Loader Service Repair Workshop Manual

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KOMATSU WA430-6 WA 430 WA430 WHEEL LOADER SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Wa430-6 Wa 430 Wa430 Wheel Loader Service Repair Workshop Manual

FOREWORD:

GENERAL:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.

• GENERAL
  This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
• STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
  This 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. In addition, this section gives the judgement standards when inspecting disassembled parts.
• 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.
• TESTING AND ADJUSTING
  This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
• TROUBLESHOOTING
  Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
• DISASSEMBLY AND ASSEMBLY
  This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
• OTHER
  This section has the foldout drawings for the machine.

TABLE OF CONTENTS:

Komatsu Wa430-6 Wa 430 Wa430 Wheel Loader Service Repair Workshop Manual

00 Index and foreword
Index SEN00832-08
Composition of shop manual 2
Table of contents 4
Foreword and general information SEN00833-04
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling of electric equipment and hydraulic component 11
Handling of connectors newly used for engines 20
How to read electric wire code 23
Precautions when carrying out operation 26
Method of disassembling and connecting push-pull type coupler 29
Standard tightening torque table 32
Conversion table 36
01 Specification
Specification and technical data SEN00834-02
Specification dimension drawing 3
Specifications 4
Weight table 8
Table of fuel, coolant and lubricants 10
10 Structure, function and maintenance standard
Engine and cooling system SEN01363-01
Engine mount and transmission mount 2
Cooling system 3
Cooling fan pump 4
Cooling fan motor 12
Power train SEN01364-02
Power train 3
Power train system diagram 4
Drive shaft 6
Power train piping diagram 7
Torque converter 8
Transmission 16
Flow control valve 33
Transmission control valve 36
ECMV 40
Main relief valve and torque converter relief valve 46
Axle 48
Differential 50
Limited slip differential 56
Final drive 62
Steering system SEN01365-02
Steering piping diagram 3
Steering column 4
Steering pump 5
Steering valve 17
Orbit-roll valve 32
Stop valve 36
Steering relief valve 37
Steering cylinder 38
Emergency steering motor 40
Emergency steering pump 41
00 Index and foreword SEN00832-08
WA430-6 5
Joystick steering lever linkage 42
Steering electric lever 43
Joystick EPC valve 44
Brake system SEN01366-02
Brake piping diagram 2
Charge valve 3
Brake valve 10
Accumulator (for brake) 15
Brake 16
Parking brake control 21
Parking brake 22
Parking brake solenoid valve 24
Emergency parking brake release valve 26
Undercarriage and frame SEN01367-02
Axle mount and center hinge pin 2
Tires 6
Hydraulic system, Part 1 SEN01368-02
Hydraulic piping diagram 2
Work equipment control lever linkage 5
Hydraulic tank 8
Power train pump 10
Work equipment pump 11
Work equipment control valve 22
CLSS 36
Each function and operation of each valve 40
Hydraulic system, Part 2 SEN01369-01
PPC valve 2
Stabilizer valve 10
Accumulator (for PPC circuit) 16
Accumulator (for ECSS) 17
Work equipment PPC cut-off solenoid valve 18
Work equipment SEN01370-01
Work equipment linkage 2
Bucket 4
Bucket positioner and boom kick-out 5
Work equipment cylinder 11
Cab and its attachments SEN01371-02
Cab 3
Air conditioner 4
Electrical system, Part 1 SEN01372-02
Machine monitor system 2
Machine monitor 6
Electrical system, Part 2 SEN01373-02
Electrical system (Transmission controller system) 2
Transmission controller 44
Electrical system (Work equipment controller system) 46
Work equipment controller 52
Electrical system, Part 3 SEN01374-02
Electric transmission control 2
Kickdown switch and hold switch 6
Multi-function knob 7
Joystick steering knob 8
KOMTRAX system 10
Engine starting circuit 12
Engine stopping circuit 14
Preheating circuit 15
Engine power mode selector circuit 16
SEN00832-08 00 Index and foreword
6 WA430-6
Engine output derating function 17
Automatic warm-up function 17
Parking brake circuit 18
Sensor 20
20 Standard value table
Standard service value table SEN01599-02
Standard value table for engine 2
Standard value table for chassis 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN01600-02
Tools for testing, adjusting, and troubleshooting 3
Testing engine speed 8
Testing exhaust gas color 10
Testing exhaust temperature 11
Adjusting valve clearance 13
Testing compression pressure 15
Testing blow-by pressure 19
Testing engine oil pressure 20
Testing intake air (boost) pressure 21
Handling fuel system equipment 22
Releasing residual pressure in fuel system 22
Testing fuel pressure 23
Testing fuel return and leak amount 29
Bleeding air from fuel circuit 31
Testing leakage in fuel system 32
Handling reduced cylinder mode operation 33
Handling no-injection cranking operation 33
Handling controller voltage circuit 34
Check of muffler and muffler stack for looseness and damage 35
Check of muffler function 35
Check of installed condition of cylinder head and manifolds 36
Check of engine piping for damage and looseness 36
Testing and adjusting air conditioner compressor belt tension 37
Replacing alternator belt 38
Adjusting transmission speed sensor 39
Adjusting directional lever length 40
Adjusting gear shift lever length 40
Testing directional lever 41
Testing and adjusting power train oil pressure 42
Procedure for flushing torque converter and transmission hydraulic circuit 56
Method of moving machine when transmission valve is broken 57
Checking axle final drive for oil leakage 59
Checking drive shafts for looseness, play and damage 59
Testing and adjusting steering stop valve 60
Testing and adjusting steering wheel 62
Testing and adjusting steering oil pressure 64
Bleeding air from steering circuit 67
Testing and adjusting, Part 2 SEN01601-02
Testing hydraulic drive fan 3
Bleeding air from hydraulic drive fan circuit 5
Testing brake pedal 7
Testing and adjusting brake pedal linkage 8
Testing brake performance 9
Testing and adjusting accumulator charge pressure 10
Testing wheel brake oil pressure 11
00 Index and foreword SEN00832-08
WA430-6 7
Testing wear of wheel brake disc 13
Bleeding air from wheel brake circuit 14
Releasing residual pressure in brake accumulator circuit 15
Testing parking brake performance 16
Testing parking brake oil pressure 17
Testing wear of parking brake disc 19
Method of releasing parking brake manually 20
Testing and adjusting work equipment control lever 21
Testing and adjusting work equipment PPC oil pressure 22
Testing and adjusting work equipment oil pressure 25
Bleeding air from work equipment circuit 29
Releasing residual pressure in work equipment circuit 30
Testing and adjusting bucket positioner 31
Testing and adjusting boom kick-out 33
Checking proximity switch operation pilot lamp 34
Procedure for testing diodes 35
Preparation work for troubleshooting for electrical system 36
Starting KOMTRAX terminal operations 41
Indicator lamps of KOMTRAX terminal 46
Testing and adjusting, Part 3 SEN01602-02
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 2
Special functions of machine monitor (EMMS) 5
Pm-clinic inspection table 73
40 Troubleshooting
Failure code table and fuse locations SEN01736-02
Failure code table 2
Fuse locations 13
General information on troubleshooting SEN01737-02
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Testing before troubleshooting 4
Classification and procedures of troubleshooting 5
Information contained in troubleshooting table 8
Connection table for connector pin numbers 10
T- branch box and T- branch adapter table 46
Troubleshooting by failure code (Display of code), Part 1 SEN01738-02
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 3
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 4
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 6
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 8
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 10
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 12
Failure code [15SELH] (ECMV 1st clutch:
When command current is ON, fill signal is OFF) 14
Failure code [15SFL1] (ECMV 2nd clutch:
When command current is OFF, fill signal is ON) 16
Failure code [15SFLH] (ECMV 2nd clutch:
When command current is ON, fill signal is OFF) 18
Failure code [15SGL1] (ECMV 3rd clutch:
When command current is OFF, fill signal is ON) 20
Failure code [15SGLH] (ECMV 3rd clutch:
When command current is ON, fill signal is OFF) 22
Failure code [15SHL1] (ECMV 4th clutch:
When command current is OFF, fill signal is ON) 24
Failure code [15SHLH] (ECMV 4th clutch:
When command current is ON, fill signal is OFF) 26
SEN00832-08 00 Index and foreword
8 WA430-6
Failure code [2F00MA] (Parking brake: Malfunction) 28
Failure code [2G43ZG] (Accumulator: Low oil pressure) 30
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 32
Troubleshooting by failure code (Display of code), Part 2 SEN01739-02
Failure code [AA1ANX] (Air cleaner: Clogging) 4
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 6
Failure code [AB00MA] (Alternator: Malfunction) 8
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 10
Failure code [B@BAZK] (Engine oil: Low level) 11
Failure code [B@BCNS] (Coolant: Overheating) 12
Failure code [B@BCZK] (Coolant: Low level) 14
Failure code [B@BEBF] (Water in fuel error) 16
Failure code [B@C7NS] (Brake oil: Overheating) 18
Failure code [b@CENS] (Torque converter oil: Overheating) 20
Failure code [B@CENS] (Torque converter oil: Overheating) 22
Failure code [B@HANS] (Hydraulic oil: Overheating) 24
Failure code [CA111] (Abnormality in engine controller) 26
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 27
Failure code [CA122] (Charge pressure sensor high error) 28
Failure code [CA123] (Charge pressure sensor low error) 30
Failure code [CA131] (Throttle sensor high error) 32
Failure code [CA132] (Throttle sensor low error) 34
Failure code [CA144] (Coolant sensor high error) 36
Failure code [CA145] (Coolant sensor low error) 38
Failure code [CA153] (Charge temperature sensor high error) 40
Failure code [CA154] (Charge temperature sensor low error) 42
Failure code [CA155] (Derating of speed by abnormally high charge temperature) 44
Failure code [CA187] (Sensor power supply 2 low error) 46
Failure code [CA221] (Atmospheric pressure sensor high error) 48
Failure code [CA222] (Atmospheric sensor low error) 50
Failure code [CA227] (Sensor power supply 2 high error) 52
Failure code [CA234] (Engine overspeed) 53
Failure code [CA238] (Ne speed sensor power supply error) 54
Troubleshooting by failure code (Display of code), Part 3 SEN01740-02
Failure code [CA271] (IMV/PCV1 Short circuit) 3
Failure code [CA272] (IMV/PCV1 Disconnection) 4
Failure code [CA281] High pressure pump error 6
Failure code [CA322] (Injector #1 open/short error) 8
Failure code [CA323] (Injector #5 open/short error) 10
Failure code [CA324] (Injector #3 open/short error) 12
Failure code [CA325] (Injector #6 open/short error) 14
Failure code [CA331] (Injector #2 open/short error) 16
Failure code [CA332] (Injector #4 open/short error) 18
Failure code [CA342] (Calibration code inconsistency) 20
Failure code [CA351] (Injectors drive circuit error) 22
Failure code [CA352] (Sensor power supply 1 low error) 24
Failure code [CA386] (Sensor power supply 1 high error) 26
Failure code [CA428] (Abnormally high level in water sensor) 27
Failure code [CA429] (Abnormally low level in water sensor) 28
Failure code [CA431] (Idle validation switch error) 30
Failure code [CA432] (Idle validation action error) 32
Failure code [CA435] (Engine oil pressure switch error) 34
Failure code [CA441] (Battery voltage low error) 35
Failure code [CA442] (Battery voltage high error) 38
Failure code [CA449] Common rail pressure high error 2 40
Failure code [CA451] (Common rail pressure sensor high error) 42
Failure code [CA452] (Common rail pressure sensor low error) 44
Failure code [CA488] (Derating of torque by abnormally high charge temperature) 46
00 Index and foreword SEN00832-08
WA430-6 9
Failure code [CA553] (Common rail pressure high error 1) 47
Failure code [CA559] (Supply pump pressure very low error) 48
Failure code [CA689] (Engine Ne speed sensor error) 50
Failure code [CA731] (Engine Bkup speed sensor phase error) 52
Failure code [CA757] (All continuous data lost error) 53
Failure code [CA778] (Engine Bkup speed sensor error) 56
Failure code [CA1633] (KOMNET datalink timeout error) 58
Failure code [CA2185] (Throttle sensor power supply voltage high error) 60
Failure code [CA2186] (Throttle sensor power supply voltage low error) 61
Troubleshooting by failure code (Display of code), Part 4 SEN01741-02
Failure code [CA2249] (Supply pump pressure very low error 2) 3
Failure code [CA2265] (Abnormally high level in electric lift pump) 4
Failure code [CA2266] (Abnormally low level in electric lift pump) 6
Failure code [CA2311] (Abnormality in IMV solenoid) 8
Failure code [CA2555] (Intake heater relay disconnection error) 10
Failure code [CA2556] (Intake heater relay short circuit error) 12
Failure code [D150KA] (Emergency steering relay: Disconnection) 14
Failure code [D150KB] (Emergency steering relay: Short circuit) 16
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 18
Failure code [D160KA] (Backup lamp relay: Disconnection) 20
Failure code [D160KB] (Backup lamp relay: Short circuit) 22
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) 24
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 26
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 28
Failure code [D191KY] (Joystick steering neutral safety relay:
Short circuit with power supply line) 30
Failure code [D192KA] (ECSS solenoid: Disconnection) 32
Failure code [D192KB] (ECSS solenoid: Short circuit) 33
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 34
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 36
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 38
Failure code [D193KY] (Joystick steering solenoid cut relay:
Short circuit with power supply line) 40
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 43
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 47
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 50
Failure code [D5ZHL6] (Terminal C signal:
Signal does not match engine running or stopped state) 55
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 58
Failure code [DAF3KK] (Machine monitor: Low source voltage (input) 60
Failure code [DAF5KP] (Machine monitor: Low output voltage) 62
Failure code [DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system) 66
Troubleshooting by failure code (Display of code), Part 5 SEN01742-02
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 4
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 6
Failure code [DAQ1KA] (Terminal ACC input: Disconnection) 7
Failure code [DAQ2KK] (Transmission controller load power supply line:
Low source voltage (input) 10
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals) 12
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system) 13
Failure code [DAQRMA] (Transmission controller option setting:
Disagreement of option selection) 16
Failure code [DB2RKR] (CAN communication with engine controller:
Defective communication (Abnormality in target component system) 18
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 20
SEN00832-08 00 Index and foreword
10 WA430-6
Failure code [DB90KT] Work equipment controller: Abnormality in controller 22
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input) 24
Failure code [DB95KX] Work equipment controller power supply output:
Out of input signal range 26
Failure code [DB99KQ] (Work equipment controller model selection:
Disagreement in model selection signals) 29
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system) 30
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) 32
Failure code [DB9RMC] (CAN communication with transmission controller,
engine controller and machine monitor: Defective operation) 33
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time 36
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time 38
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 40
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 42
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time 44
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time 46
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time 48
Failure code [DD1FLD] Load meter mode selector switch (A/B):
Switch is kept pressed for long time 50
Failure code [DD1GLD] Load meter mode selector switch (+/-):
Switch is kept pressed for long time 52
Failure code [DD1HLD] (Load meter display selector switch:
Switch is kept pressed for long time) 54
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) 56
Failure code [DD1NL4] (Fan automatic reverse switch:
Switch is kept pressed for long time) 58
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) 60
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) 64
Troubleshooting by failure code (Display of code), Part 6 SEN01743-02
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 4
Failure code [DDK3KA] (Right FNR switch: Disconnection) 6
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 9
Failure code [DDK5L4] (Joystick steering shift-up/down switch:
ON/OFF signals disagree) 12
Failure code [DDK6KA] (FNR lever switch: Disconnection) 14
Failure code [DDK6KB] (FNR lever switch: Short circuit) 18
Failure code [DDS5KA] (Steering pressure switch: Disconnected) 20
Failure code [DDS5KB] (Steering pressure switch: Short-circuit) 22
Failure code [DDS5L6] (Steering: Low oil pressure) 24
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 26
Failure code [DDT4LD] (Transmission cut-off set switch:
Switch is kept pressed for long time) 28
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 30
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 32
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 34
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) 36
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 40
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) 42
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 44
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 46
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) 48
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 50
00 Index and foreword SEN00832-08
WA430-6 11
Failure code [DGT1KX] (Torque converter oil temperature sensor:
Out of input signal range) 52
Troubleshooting by failure code (Display of code), Part 7 SEN01744-02
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) 4
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short) 6
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor:
Out of input signal range) 8
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 10
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) 12
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) 14
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) 16
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 18
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line) 21
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 24
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 27
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Short circuit with power supply line) 30
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 33
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Short circuit with power supply line) 36
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 39
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 42
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Short circuit with power supply line) 45
Troubleshooting by failure code (Display of code), Part 8 SEN01745-02
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main):
Disconnection) 3
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line) 6
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 8
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line) 12
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree) 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 18
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 20
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 22
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 24
Failure code [DLT3LC] (Transmission output shaft speed sensor:
Out of input signal range) 26
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 28
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 30
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 32
Failure code [DV00KB] (Alarm buzzer: Short circuit) 34
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 36
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 38
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 40
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 42
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 43
Failure code [DW4QKY] (Lift arm lower EPC solenoid:
Short circuit with power supply line) 44
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 46
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 47
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 48
Troubleshooting by failure code (Display of code), Part 9 SEN01746-01
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 4
SEN00832-08 00 Index and foreword
12 WA430-6
Failure code [DW4SKY] (Bucket dump EPC solenoid:
Short circuit with power supply line) 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 9
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 10
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) 11
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) 12
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid:
Short circuit with power supply line) 13
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 14
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 16
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Short circuit with power supply line) 18
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 20
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 22
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Short circuit with power supply line) 24
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 26
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 28
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Short circuit with power supply line) 30
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 32
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 34
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid:
Shorted with the power source) 36
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 38
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 39
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 40
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 42
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 44
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 46
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 48
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 50
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 52
Troubleshooting by failure code (Display of code), Part 10 SEN01747-02
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 28
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 30
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 32
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 34
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 36
Failure code [DXHLKY] (Joystick steering right EPC solenoid:
Short circuit with power supply line) 38
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 40
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 42
Failure code [DXHMKY] (Joystick steering left EPC solenoid:
Short circuit with power supply line) 44
00 Index and foreword SEN00832-08
WA430-6 13
Failure code [DY30MA] Motor-driven emergency steering pump failure
(During operation of machine) 46
Failure code [DY30MC] Motor-driven emergency steering pump failure
(Malfunction in manual mode) 49
Failure code [DY30ME] Emergency steering: Operating for more than 1 minute 52
Troubleshooting of electrical system (E-mode) SEN01748-02
Installing positions of fuses 3
Information in troubleshooting table 6
E-1 Engine does not start 8
E-2 Wiper does not operate 14
E-3 Windshield washer does not operate 18
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 21
E-5 Working lamp does not light up or go off 29
E-6 Turn signal lamp and hazard lamp do not light up or go off 34
E-7 Brake lamp does not light or it keeps lighting up 40
E-8 Backup lamp does not light or it keeps lighting up 42
E-9 Backup buzzer does not sound or it keeps sounding 44
E-10 Horn does not sound or it keeps sounding 46
E-11 Alarm buzzer does not sound or it keeps sounding 48
E-12 Air conditioner does not operate or stop 50
E-13 The KOMTRAX system does not work properly 53
E-14 When kick-down switch is turned ON, kick-down operation does not start 56
E-15 When hold switch is pressed, holding operation does not start 58
E-16 Transmission is kept in neutral, or brake drags
when directional lever is operated while parking brake is applied 60
E-17 Transmission cut-off mode cannot be set or reset 62
E-18 Transmission cut-off set cannot be reset 64
E-19 FNR switch mode cannot be set or reset 66
E-20 Fan reverse function cannot be used or reset 68
E-21 Discharge from loader pump does not rise from minimum level 70
E-22 ECSS function cannot be used or reset 72
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up 74
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate 78
E-25 Air cleaner clogging indicator lamp does not light up 80
E-26 Radiator coolant level caution lamp does not light up 82
E-27 Hydraulic oil temperature gauge does not rise and
hydraulic oil temperature caution lamp does not light up 83
E-28 Torque converter oil temperature gauge does not rise and
torque converter oil temperature caution lamp does not light up 84
E-29 Steering oil pressure caution lamp does not light up 86
E-30 Abnormality in t switch (panel switch 1) input 88
E-31 Abnormality in U switch (panel switch 2) input 90
E-32 Abnormality in < switch (panel switch 3) input 92
E-33 Abnormality in > switch (panel switch 4) input 94
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01749-02
Method of using troubleshooting chart 3
Table of failure modes and causes 6
H-1 The machine does not start 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)] 12
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] 13
H-4 The travel speed is slow, the thrusting force is weak,
the uphill traveling power is weak, and the gear is not shifted 14
H-5 Shocks are large at the times of starting and shifting gear 16
H-6 Time lag is large at the times of starting and shifting gear 18
H-7 The torque converter oil temperature is high 20
H-8 Steering does not turn 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 22
SEN00832-08 00 Index and foreword
14 WA430-6
H-10 Steering response is low 23
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)] 24
H-12 Steering is heavy 25
H-13 When machine turns, it shakes or makes large shocks 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)] 27
H-15 The wheel brake does not work or does not work well 28
H-16 The wheel brake is not released or it drags 29
H-17 The parking brake does not work or does not work well 30
H-18 The parking brake is not released or it drags (including emergency release system) 31
H-19 Lift arm does not rise 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient 33
H-21 When rising, the lift arm comes to move slowly at specific height 34
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 34
H-23 Hydraulic drifts of the lift arm is large 34
H-24 The lift arm wobbles during operation 34
H-25 Bucket does not tilt back 35
H-26 Bucket speed is low or tilting back force is insufficient 36
H-27 The bucket comes to operate slowly in the midst of tilting-back 37
H-28 The bucket cylinder cannot hold down the bucket 37
H-29 Hydraulic drifts of the bucket is large 37
H-30 The bucket wobbles during travel with cargo
(The work equipment valve is set to “HOLD”) 37
H-31 Lift arm and bucket control levers do not move smoothly and are heavy 38
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls 39
H-33 Large shock is made when work equipment starts and stops 39
H-34 When work equipment circuit is relieved singly, other work equipment moves 39
H-35 ECSS does not operate, and pitching, bouncing occur 40
Troubleshooting of engine (S-mode) SEN01750-02
Method of using troubleshooting charts 3
S-1 Engine does not start easily 6
S-2 Engine does not start 7
S-3 Engine does not pick up smoothly 10
S-4 Engine stops during operations 11
S-5 Engine does not rotate smoothly 12
S-6 Engine lacks output (or lacks power) 13
S-7 Exhaust smoke is black (Incomplete combustion) 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) 15
S-9 Engine oil becomes contaminated quickly 16
S-10 Fuel consumption is excessive 17
S-11 Coolant contains oil (blows back or reduces) 18
S-12 Oil pressure drops 19
S-13 Oil level rises (Water, fuel in oil) 20
S-14 Coolant temperature rises too high (Overheating) 21
S-15 Abnormal noise is made 22
S-16 Vibration is excessive 23
50 Disassembly and assembly
General information on disassembly and assembly SEN02191-02
How to read this manual 2
Coating materials list 4
Special tools list 7
Sketches of special tools 10
Engine and cooling system SEN02192-02
Removal and installation of fuel supply pump assembly 2
Removal and installation of fuel injector assembly 5
Removal and installation of cylinder head assembly 14
00 Index and foreword SEN00832-08
WA430-6 15
Removal and installation of engine hood and radiator guard assembly 27
Removal and installation of radiator assembly 29
Removal and installation of air aftercooler assembly 31
Removal and installation of hydraulic oil cooler assembly 33
Removal and installation of engine assembly 34
Removal and installation of front seal assembly 39
Removal and installation of rear oil seal assembly 41
Removal and installation of cooling fan and fan motor assembly 46
Removal and installation of fuel tank assembly 49
Power train, Part 1 SEN02193-02
Removal and installation of torque converter and transmission assembly 2
Disassembly and assembly of torque converter assembly (Standard specification) 7
Disassembly and assembly of torque converter assembly (Lock-up specification) 11
Disassembly and assembly of transmission assembly 18
Disassembly and assembly of transmission clutch pack assembly 33
Disassembly and assembly of parking brake assembly 49
Power train, Part 2 SEN02194-02
Removal and installation of front axle assembly 2
Removal and installation of rear axle assembly 4
Disassembly and assembly of axle housing 8
Disassembly and assembly of differential assembly 18
Steering system SEN02195-01
Removal and installation of steering demand valve assembly 2
Brake system SEN02196-01
Removal and installation of parking brake disc and plate 2
Undercarriage and frame SEN02197-02
Removal and installation of center hinge pin 2
Removal and installation of counterweight 10
Hydraulic system SEN02198-01
Removal and installation of work equipment control valve assembly 2
Removal and installation of power train pump and work equipment pump assembly 5
Removal and installation of steering pump and cooling fan pump assembly 6
Removal and installation of hydraulic tank assembly 7
Work equipment SEN02199-02
Removal and installation of work equipment assembly 2
Disassembly and assembly of hydraulic cylinder assembly 7
Cab and its attachments SEN02200-02
Removal and installation of operator’s cab and floor frame assembly 2
Removal and installation of operator’s cab glass (stuck glass) 6
Disassembly and assembly of operator’s seat assembly (Standard specification) 14
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER) 23
Removal and installation of air conditioner unit assembly 56
Electrical system SEN02201-01
Removal and installation of engine controller assembly 2
Removal and installation of KOMTRAX terminal assembly 3
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN00835-02
Power train hydraulic circuit diagram 2
Automatic greasing circuit diagram 6
Hydraulic circuit diagram 9
Electrical diagrams and drawings SEN00836-02
Electrical circuit diagram 3
Work equipment controller system electrical circuit diagram 31

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