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Komatsu WA430-6 Wheel Loader Shop Manual PDF Download
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- Komatsu WA430-6 Wheel Loader Service Repair Manual
- SERIAL NUMBERS:65001 and up
- PUBLICATION NUMBER:SEN00823-13
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Description
Komatsu WA430-6 Wheel Loader Service Repair Manual
KOMATSU WA430-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
Komatsu WA430-6 Wheel Loader Service Repair Manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA430-6 Wheel Loader Service Repair Manual
COVER ................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 0 Index................................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 Foreword and general information..................................................................................................................... 19 Safety notice.................................................................................................................................... 20 How to read the shop manual...................................................................................................................... 25 Explanation of terms for maintenance standard.................................................................................................... 27 Handling of electric equipment and hydraulic component........................................................................................... 29 Handling of connectors newly used for engines.................................................................................................... 38 How to read electric wire code................................................................................................................... 41 Precautions when carrying out operation.......................................................................................................... 44 Method of disassembling and connecting push-pull type coupler.................................................................................... 47 Standard tightening torque table................................................................................................................. 50 Conversion table................................................................................................................................. 54 01 Specification......................................................................................................................................... 0 Specification and technical data..................................................................................................................... 61 Specification dimension drawing.................................................................................................................. 63 Specifications................................................................................................................................... 64 Weight table..................................................................................................................................... 68 Table of fuel, coolant and lubricants............................................................................................................ 70 10 Structure, function and maintenance standard.......................................................................................................... 0 Engine and cooling system............................................................................................................................ 73 Engine mount and transmission mount.............................................................................................................. 74 Cooling system................................................................................................................................... 75 Cooling fan pump................................................................................................................................. 76 Cooling fan motor................................................................................................................................ 84 Power train.......................................................................................................................................... 91 Power train...................................................................................................................................... 93 Power train system diagram....................................................................................................................... 94 Drive shaft...................................................................................................................................... 96 Power train piping diagram....................................................................................................................... 97 Torque converter................................................................................................................................. 98 Transmission..................................................................................................................................... 106 Flow control valve............................................................................................................................... 123 Transmission control valve....................................................................................................................... 126 ECMV............................................................................................................................................. 130 Main relief valve and torque converter relief valve.............................................................................................. 136 Axle............................................................................................................................................. 138 Differential..................................................................................................................................... 140 Limited slip differential........................................................................................................................ 146 Final drive...................................................................................................................................... 152 Steering system...................................................................................................................................... 159 Steering piping diagram.......................................................................................................................... 161 Steering column.................................................................................................................................. 162 Steering pump.................................................................................................................................... 163 Steering valve................................................................................................................................... 175 Orbit-roll valve................................................................................................................................. 190 Stop valve....................................................................................................................................... 194 Steering relief valve............................................................................................................................ 195 Steering cylinder................................................................................................................................ 196 Emergency steering motor......................................................................................................................... 198 Emergency steering pump.......................................................................................................................... 199 Joystick steering lever linkage.................................................................................................................. 200 Steering electric lever.......................................................................................................................... 201 Joystick EPC valve............................................................................................................................... 202 Brake system......................................................................................................................................... 205 Brake piping diagram............................................................................................................................. 206 Charge valve..................................................................................................................................... 207 Brake valve...................................................................................................................................... 214 Accumulator (for brake).......................................................................................................................... 219 Brake............................................................................................................................................ 220 Parking brake control............................................................................................................................ 225 Parking brake.................................................................................................................................... 226 Parking brake solenoid valve..................................................................................................................... 228 Emergency parking brake release valve............................................................................................................ 230 Undercarriage and frame.............................................................................................................................. 233 Axle mount and center hinge pin.................................................................................................................. 234 Tires............................................................................................................................................ 238 Hydraulic system, Part 1............................................................................................................................. 241 Hydraulic piping diagram......................................................................................................................... 242 Work equipment control lever linkage............................................................................................................. 245 Hydraulic tank................................................................................................................................... 248 Power train pump................................................................................................................................. 250 Work equipment pump.............................................................................................................................. 251 Work equipment control valve..................................................................................................................... 262 CLSS............................................................................................................................................. 276 Each function and operation of each valve........................................................................................................ 280 Hydraulic system, Part 2............................................................................................................................. 303 PPC valve........................................................................................................................................ 304 Stabilizer valve................................................................................................................................. 312 Accumulator (for PPC circuit).................................................................................................................... 318 Accumulator (for ECSS)........................................................................................................................... 319 Work equipment PPC cut-off solenoid valve........................................................................................................ 320 Work equipment....................................................................................................................................... 323 Work equipment linkage........................................................................................................................... 324 Bucket........................................................................................................................................... 326 Bucket positioner and boom kick-out.............................................................................................................. 327 Work equipment cylinder.......................................................................................................................... 333 Cab and its attachments.............................................................................................................................. 335 Cab.............................................................................................................................................. 337 Air conditioner.................................................................................................................................. 338 Electrical system, Part 1............................................................................................................................ 357 Machine monitor system........................................................................................................................... 358 Machine monitor.................................................................................................................................. 362 Electrical system, Part 2............................................................................................................................ 395 Electrical system (Transmission controller system)............................................................................................... 396 Transmission controller.......................................................................................................................... 438 Electrical system (Work equipment controller system)............................................................................................. 440 Work equipment controller........................................................................................................................ 446 Electrical system, Part 3............................................................................................................................ 449 Electric transmission control.................................................................................................................... 450 Kickdown switch and hold switch.................................................................................................................. 454 Multi-function knob.............................................................................................................................. 455 Joystick steering knob........................................................................................................................... 456 KOMTRAX system................................................................................................................................... 458 Engine starting circuit.......................................................................................................................... 460 Engine stopping circuit.......................................................................................................................... 462 Preheating circuit............................................................................................................................... 463 Engine power mode selector circuit............................................................................................................... 464 Engine output derating function.................................................................................................................. 465 Automatic warm-up function....................................................................................................................... 465 Parking brake circuit............................................................................................................................ 466 Sensor........................................................................................................................................... 468 20 Standard value table.................................................................................................................................. 0 Standard service value table......................................................................................................................... 479 Standard value table for engine.................................................................................................................. 480 Standard value table for chassis................................................................................................................. 481 30 Testing and adjusting................................................................................................................................. 0 Testing and adjusting, Part 1........................................................................................................................ 489 Tools for testing, adjusting, and troubleshooting................................................................................................ 491 Sketch of special tool........................................................................................................................... 496 Testing exhaust gas color........................................................................................................................ 499 Testing exhaust temperature...................................................................................................................... 500 Adjusting valve clearance........................................................................................................................ 502 Testing compression pressure..................................................................................................................... 504 Testing blow-by pressure......................................................................................................................... 508 Testing engine oil pressure...................................................................................................................... 509 Testing intake air (boost) pressure.............................................................................................................. 510 Handling fuel system equipment................................................................................................................... 511 Releasing residual pressure in fuel system....................................................................................................... 511 Testing fuel pressure............................................................................................................................ 512 Testing fuel return and leak amount.............................................................................................................. 518 Bleeding air from fuel circuit................................................................................................................... 520 Testing leakage in fuel system................................................................................................................... 521 Handling reduced cylinder mode operation......................................................................................................... 522 Handling no-injection cranking operation......................................................................................................... 522 Handling controller voltage circuit.............................................................................................................. 523 Check of muffler and muffler stack for looseness and damage...................................................................................... 524 Check of muffler function........................................................................................................................ 524 Check of installed condition of cylinder head and manifolds...................................................................................... 525 Check of engine piping for damage and looseness.................................................................................................. 525 Testing and adjusting air conditioner compressor belt tension.................................................................................... 526 Replacing alternator belt........................................................................................................................ 527 Adjusting transmission speed sensor.............................................................................................................. 528 Adjusting directional lever length............................................................................................................... 529 Adjusting gear shift lever length................................................................................................................ 529 Testing directional lever........................................................................................................................ 530 Testing and adjusting power train oil pressure................................................................................................... 531 Procedure for flushing torque converter and transmission hydraulic circuit....................................................................... 545 Method of moving machine when transmission valve is broken....................................................................................... 546 Checking axle final drive for oil leakage........................................................................................................ 548 Checking drive shafts for looseness, play and damage............................................................................................. 548 Testing and adjusting steering stop valve........................................................................................................ 549 Testing and adjusting steering wheel............................................................................................................. 551 Testing and adjusting steering oil pressure...................................................................................................... 553 Bleeding air from steering circuit............................................................................................................... 556 Testing and adjusting, Part 2........................................................................................................................ 559 Testing hydraulic drive fan...................................................................................................................... 561 Bleeding air from hydraulic drive fan circuit.................................................................................................... 563 Testing brake pedal.............................................................................................................................. 565 Testing and adjusting brake pedal linkage........................................................................................................ 566 Testing brake performance........................................................................................................................ 567 Testing and adjusting accumulator charge pressure................................................................................................ 568 Testing wheel brake oil pressure................................................................................................................. 569 Testing wear of wheel brake disc................................................................................................................. 571 Bleeding air from wheel brake circuit............................................................................................................ 572 Releasing residual pressure in brake accumulator circuit......................................................................................... 573 Testing parking brake performance................................................................................................................ 574 Testing parking brake oil pressure............................................................................................................... 575 Testing wear of parking brake disc............................................................................................................... 577 Method of releasing parking brake manually....................................................................................................... 578 Testing and adjusting work equipment control lever............................................................................................... 579 Testing and adjusting work equipment PPC oil pressure............................................................................................ 580 Testing and adjusting work equipment oil pressure................................................................................................ 583 Bleeding air from work equipment circuit......................................................................................................... 587 Releasing residual pressure in work equipment circuit............................................................................................ 588 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator.... 589 Testing and adjusting bucket positioner.......................................................................................................... 595 Testing and adjusting boom kickout............................................................................................................... 597 Checking proximity switch operation pilot lamp................................................................................................... 598 Procedure for testing diodes..................................................................................................................... 599 Preparation work for troubleshooting for electrical system....................................................................................... 600 Starting KOMTRAX terminal operations............................................................................................................. 605 Indicator lamps of KOMTRAX terminal.............................................................................................................. 610 Testing and adjusting, Part 3........................................................................................................................ 615 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................................... 616 Special functions of machine monitor (EMMS)...................................................................................................... 619 Pm-clinic inspection table....................................................................................................................... 687 40 Troubleshooting....................................................................................................................................... 0 Failure code table and fuse locations................................................................................................................ 691 Failure code table............................................................................................................................... 692 Fuse locations................................................................................................................................... 703 General information on troubleshooting............................................................................................................... 707 Points to remember when troubleshooting.......................................................................................................... 708 Sequence of events in troubleshooting............................................................................................................ 709 Testing before troubleshooting................................................................................................................... 710 Classification and procedures of troubleshooting................................................................................................. 711 Information contained in troubleshooting table................................................................................................... 714 Connection table for connector pin numbers....................................................................................................... 716 T- branch box and T- branch adapter table........................................................................................................ 752 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 757 Failure code [1500L0] (TORQFLOW transmission: Double meshing).................................................................................... 759 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)............................................................ 760 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)............................................................ 762 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)............................................................ 764 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)............................................................ 766 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).......................................................... 768 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).......................................................... 770 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).......................................................... 772 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).......................................................... 774 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).......................................................... 776 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF).......................................................... 778 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).......................................................... 780 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).......................................................... 782 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................... 784 Failure code [2G43ZG] (Accumulator: Low oil pressure)............................................................................................ 786 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................... 788 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 793 Failure code [AA1ANX] (Air cleaner: Clogging).................................................................................................... 796 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............................................................. 798 Failure code [AB00MA] (Alternator: Malfunction).................................................................................................. 800 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)............................................................................. 802 Failure code [B@BAZK] (Engine oil: Low level).................................................................................................... 803 Failure code [B@BCNS] (Coolant: Overheating)..................................................................................................... 804 Failure code [B@BCZK] (Coolant: Low level)....................................................................................................... 806 Failure code [B@BEBF] (Water in fuel error)...................................................................................................... 808 Failure code [B@C7NS] (Brake oil: Overheating)................................................................................................... 810 Failure code [b@CENS] (Torque converter oil: Overheating)........................................................................................ 812 Failure code [B@CENS] (Torque converter oil: Overheating)........................................................................................ 814 Failure code [B@HANS] (Hydraulic oil: Overheating)............................................................................................... 816 Failure code [CA111] (Abnormality in engine controller).......................................................................................... 818 Failure code [CA115] (Engine Ne or Bkup speed sensor error)...................................................................................... 819 Failure code [CA122] (Charge pressure sensor high error)......................................................................................... 820 Failure code [CA123] (Charge pressure sensor low error).......................................................................................... 822 Failure code [CA131] (Throttle sensor high error)................................................................................................ 824 Failure code [CA132] (Throttle sensor low error)................................................................................................. 826 Failure code [CA144] (Coolant sensor high error)................................................................................................. 828 Failure code [CA145] (Coolant sensor low error).................................................................................................. 830 Failure code [CA153] (Charge temperature sensor high error)...................................................................................... 832 Failure code [CA154] (Charge temperature sensor low error)....................................................................................... 834 Failure code [CA155] (Derating of speed by abnormally high charge temperature)................................................................... 836 Failure code [CA187] (Sensor power supply 2 low error)........................................................................................... 838 Failure code [CA221] (Atmospheric pressure sensor high error).................................................................................... 840 Failure code [CA222] (Atmospheric sensor low error).............................................................................................. 842 Failure code [CA227] (Sensor power supply 2 high error).......................................................................................... 844 Failure code [CA234] (Engine overspeed).......................................................................................................... 845 Failure code [CA238] (Ne speed sensor power supply error)........................................................................................ 846 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 849 Failure code [CA271] (IMV/PCV1 Short circuit).................................................................................................... 851 Failure code [CA272] (IMV/PCV1 Disconnection).................................................................................................... 852 Failure code [CA281] High pressure pump error.................................................................................................... 854 Failure code [CA322] (Injector #1 open/short error).............................................................................................. 856 Failure code [CA323] (Injector #5 open/short error).............................................................................................. 858 Failure code [CA324] (Injector #3 open/short error).............................................................................................. 860 Failure code [CA325] (Injector #6 open/short error).............................................................................................. 862 Failure code [CA331] (Injector #2 open/short error).............................................................................................. 864 Failure code [CA332] (Injector #4 open/short error).............................................................................................. 866 Failure code [CA342] (Calibration code inconsistency)............................................................................................ 868 Failure code [CA351] (Injectors drive circuit error)............................................................................................. 870 Failure code [CA352] (Sensor power supply 1 low error)........................................................................................... 872 Failure code [CA386] (Sensor power supply 1 high error).......................................................................................... 874 Failure code [CA428] (Abnormally high level in water sensor)..................................................................................... 875 Failure code [CA429] (Abnormally low level in water sensor)...................................................................................... 876 Failure code [CA431] (Idle validation switch error).............................................................................................. 878 Failure code [CA432] (Idle validation action error).............................................................................................. 880 Failure code [CA435] (Engine oil pressure switch error).......................................................................................... 882 Failure code [CA441] (Battery voltage low error)................................................................................................. 883 Failure code [CA442] (Battery voltage high error)................................................................................................ 886 Failure code [CA449] Common rail pressure high error 2........................................................................................... 888 Failure code [CA451] (Common rail pressure sensor high error).................................................................................... 892 Failure code [CA452] (Common rail pressure sensor low error)..................................................................................... 894 Failure code [CA488] (Derating of torque by abnormally high charge temperature).................................................................. 896 Failure code [CA553] (Common rail pressure high error 1)......................................................................................... 897 Failure code [CA559] (Supply pump pressure very low error)....................................................................................... 898 Failure code [CA689] (Engine Ne speed sensor error).............................................................................................. 900 Failure code [CA731] (Engine Bkup speed sensor phase error)...................................................................................... 902 Failure code [CA757] (All continuous data lost error)............................................................................................ 903 Failure code [CA778] (Engine Bkup speed sensor error)............................................................................................ 906 Failure code [CA1633] (KOMNET datalink timeout error)............................................................................................ 908 Failure code [CA2185] (Throttle sensor power supply voltage high error).......................................................................... 910 Failure code [CA2186] (Throttle sensor power supply voltage low error)........................................................................... 911 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 913 Failure code [CA2249] (Supply pump pressure very low error 2).................................................................................... 915 Failure code [CA2265] (Abnormally high level in electric lift pump).............................................................................. 916 Failure code [CA2266] (Abnormally low level in electric lift pump)............................................................................... 918 Failure code [CA2311] (Abnormality in IMV solenoid).............................................................................................. 920 Failure code [CA2555] (Intake heater relay disconnection error).................................................................................. 922 Failure code [CA2556] (Intake heater relay short circuit error).................................................................................. 924 Failure code [D150KA] (Emergency steering relay: Disconnection).................................................................................. 926 Failure code [D150KB] (Emergency steering relay: Short circuit).................................................................................. 928 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)........................................................... 930 Failure code [D160KA] (Backup lamp relay: Disconnection)......................................................................................... 932 Failure code [D160KB] (Backup lamp relay: Short circuit)......................................................................................... 934 Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)........................................................................ 936 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection).................................................................... 938 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit).................................................................... 940 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)............................................. 942 Failure code [D192KA] (ECSS solenoid: Disconnection)............................................................................................. 944 Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................................................. 945 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...................................................................... 946 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...................................................................... 948 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...................................................................... 950 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)............................................... 952 Failure code [D5ZHKA] (Terminal C signal: Disconnection)......................................................................................... 955 Failure code [D5ZHKB] (Terminal C signal: Short circuit)......................................................................................... 959 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)........................................................................ 962 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)................................................. 967 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).......................................................................... 970 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)............................................................................... 972 Failure code [DAF5KP] (Machine monitor: Low output voltage)...................................................................................... 974 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system).................. 978 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 981 Failure code [DAQ0KK] (Transmission controller: Low source voltage).............................................................................. 984 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)....................................................................... 986 Failure code [DAQ1KA] (Terminal ACC input: Disconnection)........................................................................................ 987 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)................................................ 990 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)......................................... 992 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system).......... 993 Failure code [DAQRMA] (Transmission controller option setting: Disagreement of option selection)................................................. 996 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)................ 998 Failure code [DB90KK] Work equipment controller: Low source voltage (input)......................................................................1000 Failure code [DB90KT] Work equipment controller: Abnormality in controller.......................................................................1002 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...............................................1004 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...................................................1006 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals).......................................1009 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system).........1010 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)....................................................................1012 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...............1013 Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time............................................................1016 Failure code [DD16LD] ◇ switch (Panel switch 2): Switch is kept pressed for long time............................................................1018 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time............................................................1020 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time............................................................1022 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time.....................................1024 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time.....................................1026 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...........................................................1028 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time................................................1030 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time................................................1032 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time).................................................1034 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time).................................................................1036 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time).......................................................1038 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)..............................................................1040 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)..........................................1044 Troubleshooting by failure code (Display of code), Part 6............................................................................................1047 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).............................................................................1050 Failure code [DDK3KA] (Right FNR switch: Disconnection)..........................................................................................1052 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)..............................................................................1055 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)..........................................................1058 Failure code [DDK6KA] (FNR lever switch: Disconnection)..........................................................................................1060 Failure code [DDK6KB] (FNR lever switch: Short circuit)..........................................................................................1064 Failure code [DDS5KA] (Steering pressure switch: Disconnected)...................................................................................1066 Failure code [DDS5KB] (Steering pressure switch: Short-circuit)..................................................................................1068 Failure code [DDS5L6] (Steering: Low oil pressure)...............................................................................................1070 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)......................................................................1072 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)....................................................1074 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...................................................................1076 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................................................................1078 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...........................................................1080 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)............................................................................1082 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...........................................................................1086 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)........................................................................1088 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).......................................................................1090 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)..............................................................1092 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)..........................................................................1094 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).............................................................1096 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range).......................................................1098 Troubleshooting by failure code (Display of code), Part 7............................................................................................1101 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...............................................................................1104 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short).....................................................................1106 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)......................................................1108 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)........................................................1110 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)..........................................................1112 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................................................................1114 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit).............................................................................1116 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...................................................................1118 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)............................................1121 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).........................................................1124 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)....................................................................1127 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).............................................1130 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).....................................................................1133 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..............................................1136 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...........................................................1139 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)......................................................................1142 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...............................................1145 Troubleshooting by failure code (Display of code), Part 8............................................................................................1149 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)..........................................................1151 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...................................1154 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...........................................................1156 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1160 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)................................................1162 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).....................................................................................1166 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..............................................................1168 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)....................................................................................1170 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)....................................................................1172 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)........................................................1174 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).......................................................................1176 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)................................................................1178 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)................................................................1180 Failure code [DV00KB] (Alarm buzzer: Short circuit)..............................................................................................1182 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...............................................................................1184 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...............................................................................1186 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)........................................................1188 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...............................................................................1190 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...............................................................................1191 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)........................................................1192 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..................................................................................1194 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..................................................................................1195 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...........................................................1196 Troubleshooting by failure code (Display of code), Part 9............................................................................................1199 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..................................................................................1201 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..................................................................................1202 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...........................................................1204 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)......................................................................................1206 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)......................................................................................1207 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...............................................................1208 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)......................................................................1209 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)......................................................................1210 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)...............................................1211 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)......................................................................1212 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)......................................................................1214 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...............................................1216 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).....................................................................1218 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).....................................................................1220 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..............................................1222 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).....................................................................1224 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).....................................................................1226 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..............................................1228 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)........................................................................1230 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)........................................................................1232 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)........................................................1234 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).....................................................................................1236 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).....................................................................................1237 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..............................................................1238 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)......................................................................................1240 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)......................................................................................1242 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...............................................................1244 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..................................................................................1246 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................................................1248 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...........................................................1250 Troubleshooting by failure code (Display of code), Part 10...........................................................................................1253 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..................................................................................1256 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..................................................................................1258 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1260 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..................................................................................1262 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..................................................................................1264 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1266 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....................................................................................1268 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....................................................................................1270 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).............................................................1272 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....................................................................................1274 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....................................................................................1276 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).............................................................1278 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..................................................................................1280 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..................................................................................1282 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...........................................................1284 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)......................................................................1286 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)......................................................................1288 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...............................................1290 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection).......................................................................1292 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit).......................................................................1294 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)................................................1296 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine).................................................1298 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)..................................................1301 Failure code [DY30ME] Emergency steering: Operating for more than 1 minute.......................................................................1304 Troubleshooting of electrical system (E-mode)........................................................................................................1309 Installing positions of fuses....................................................................................................................1311 Information in troubleshooting table.............................................................................................................1314 E-1 Engine does not start........................................................................................................................1316 E-2 Wiper does not operate.......................................................................................................................1322 E-3 Windshield washer does not operate...........................................................................................................1326 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..............................................................1329 E-5 Working lamp does not light up or go off.....................................................................................................1337 E-6 Turn signal lamp and hazard lamp do not light up or go off...................................................................................1342 E-7 Brake lamp does not light or it keeps lighting up............................................................................................1348 E-8 Backup lamp does not light or it keeps lighting up...........................................................................................1350 E-9 Backup buzzer does not sound or it keeps sounding............................................................................................1352 E-10 Horn does not sound or it keeps sounding....................................................................................................1354 E-11 Alarm buzzer does not sound or it keeps sounding............................................................................................1356 E-12 Air conditioner does not operate or stop....................................................................................................1358 E-13 The KOMTRAX system does not work properly...................................................................................................1361 E-14 When kick-down switch is turned ON, kick-down operation does not start......................................................................1364 E-15 When hold switch is pressed, holding operation does not start...............................................................................1366 E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...........................1368 E-17 Transmission cut-off mode cannot be set or reset............................................................................................1370 E-18 Transmission cut-off set cannot be reset....................................................................................................1372 E-19 FNR switch mode cannot be set or reset......................................................................................................1374 E-20 Fan reverse function cannot be used or reset................................................................................................1376 E-21 Discharge from loader pump does not rise from minimum level.................................................................................1378 E-22 ECSS function cannot be used or reset.......................................................................................................1380 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up.............................................................1382 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate.............................................................1386 E-25 Air cleaner clogging indicator lamp does not light up.......................................................................................1388 E-26 Radiator coolant level caution lamp does not light up.......................................................................................1390 E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up..................................1391 E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up....................1392 E-29 Steering oil pressure caution lamp does not light up........................................................................................1394 E-30 Abnormality in ■ switch (panel switch 1) input..............................................................................................1396 E-31 Abnormality in ◇ switch (panel switch 2) input..............................................................................................1398 E-32 Abnormality in < switch (panel switch 3) input..............................................................................................1400 E-33 Abnormality in > switch (panel switch 4) input..............................................................................................1402 E-34 Air conditioner does not operate............................................................................................................1404 E-35 Air is not cooled...........................................................................................................................1408 E-36 No air comes out or air flow is abnormal....................................................................................................1412 E-37 Temperature cannot be controlled............................................................................................................1418 E-38 Spurting out mode cannot be switched........................................................................................................1422 E-39 Recirc/Fresh cannot be changed over.........................................................................................................1426 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1429 Method of using troubleshooting chart............................................................................................................1431 Table of failure modes and causes................................................................................................................1434 H-1 The machine does not start...................................................................................................................1438 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)].......................................1440 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]........................................................1441 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted.......................1442 H-5 Shocks are large at the times of starting and shifting gear..................................................................................1444 H-6 Time lag is large at the times of starting and shifting gear.................................................................................1446 H-7 The torque converter oil temperature is high.................................................................................................1448 H-8 Steering does not turn.......................................................................................................................1449 H-9 Steering does not turn [Machine with joystick steering (if equipped)]........................................................................1450 H-10 Steering response is low....................................................................................................................1451 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]........................................................1452 H-12 Steering is heavy...........................................................................................................................1453 H-13 When machine turns, it shakes or makes large shocks.........................................................................................1454 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]..........................................1455 H-15 The wheel brake does not work or does not work well.........................................................................................1456 H-16 The wheel brake is not released or it drags.................................................................................................1457 H-17 The parking brake does not work or does not work well.......................................................................................1458 H-18 The parking brake is not released or it drags (including emergency release system)..........................................................1459 H-19 Lift arm does not rise......................................................................................................................1460 H-20 Lift arm speed is low or rising force of lift arm is insufficient...........................................................................1461 H-21 When rising, the lift arm comes to move slowly at specific height...........................................................................1462 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...........................................................................1462 H-23 Hydraulic drifts of the lift arm is large...................................................................................................1462 H-24 The lift arm wobbles during operation.......................................................................................................1462 H-25 Bucket does not tilt back...................................................................................................................1463 H-26 Bucket speed is low or tilting back force is insufficient...................................................................................1464 H-27 The bucket comes to operate slowly in the midst of tilting-back.............................................................................1465 H-28 The bucket cylinder cannot hold down the bucket.............................................................................................1465 H-29 Hydraulic drifts of the bucket is large.....................................................................................................1465 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).....................................................1465 H-31 Lift arm and bucket control levers do not move smoothly and are heavy.......................................................................1466 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls............................................................1467 H-33 Large shock is made when work equipment starts and stops....................................................................................1467 H-34 When work equipment circuit is relieved singly, other work equipment moves..................................................................1467 H-35 ECSS does not operate, and pitching, bouncing occur.........................................................................................1468 Troubleshooting of engine (S-mode)...................................................................................................................1471 Method of using troubleshooting charts...........................................................................................................1473 S-1 Engine does not start easily.................................................................................................................1476 S-2 Engine does not start........................................................................................................................1477 S-3 Engine does not pick up smoothly.............................................................................................................1480 S-4 Engine stops during operations...............................................................................................................1481 S-5 Engine does not rotate smoothly..............................................................................................................1482 S-6 Engine lacks output (or lacks power).........................................................................................................1483 S-7 Exhaust smoke is black (Incomplete combustion)...............................................................................................1484 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................................................1485 S-9 Engine oil becomes contaminated quickly......................................................................................................1486 S-10 Fuel consumption is excessive...............................................................................................................1487 S-11 Coolant contains oil (blows back or reduces)................................................................................................1488 S-12 Oil pressure drops..........................................................................................................................1489 S-13 Oil level rises (Water, fuel in oil)........................................................................................................1490 S-14 Coolant temperature rises too high (Overheating)............................................................................................1491 S-15 Abnormal noise is made......................................................................................................................1492 S-16 Vibration is excessive......................................................................................................................1493 50 Disassembly and assembly.............................................................................................................................. 0 General information on disassembly and assembly......................................................................................................1495 How to read this manual..........................................................................................................................1496 Coating materials list...........................................................................................................................1498 Special tools list...............................................................................................................................1501 Sketches of special tools........................................................................................................................1504 Engine and cooling system............................................................................................................................1519 Removal and installation of fuel supply pump assembly............................................................................................1520 Removal and installation of fuel injector assembly...............................................................................................1523 Removal and installation of cylinder head assembly...............................................................................................1532 Removal and installation of engine hood and radiator guard assembly..............................................................................1545 Removal and installation of radiator assembly....................................................................................................1547 Removal and installation of air aftercooler assembly.............................................................................................1549 Removal and installation of hydraulic oil cooler assembly........................................................................................1551 Removal and installation of engine assembly......................................................................................................1552 Removal and installation of front seal assembly..................................................................................................1557 Removal and installation of rear oil seal assembly...............................................................................................1559 Removal and installation of cooling fan and fan motor assembly...................................................................................1564 Removal and installation of fuel tank assembly...................................................................................................1567 Power train, Part 1..................................................................................................................................1571 Removal and installation of torque converter and transmission assembly...........................................................................1572 Disassembly and assembly of torque converter assembly (Standard specification)...................................................................1577 Disassembly and assembly of torque converter assembly (Lock-up specification)....................................................................1581 Disassembly and assembly of transmission assembly................................................................................................1588 Disassembly and assembly of transmission clutch pack assembly....................................................................................1603 Disassembly and assembly of parking brake assembly...............................................................................................1619 Power train, Part 2..................................................................................................................................1627 Removal and installation of front axle assembly..................................................................................................1628 Removal and installation of rear axle assembly...................................................................................................1630 Disassembly and assembly of axle housing.........................................................................................................1634 Disassembly and assembly of differential assembly................................................................................................1644 Steering system......................................................................................................................................1665 Removal and installation of steering demand valve assembly.......................................................................................1666 Brake system.........................................................................................................................................1669 Removal and installation of parking brake disc and plate.........................................................................................1670 Undercarriage and frame..............................................................................................................................1675 Removal and installation of center hinge pin.....................................................................................................1676 Removal and installation of counterweight........................................................................................................1684 Hydraulic system.....................................................................................................................................1687 Removal and installation of work equipment control valve assembly................................................................................1688 Removal and installation of power train pump and work equipment pump assembly....................................................................1691 Removal and installation of steering pump and cooling fan pump assembly..........................................................................1692 Removal and installation of hydraulic tank assembly..............................................................................................1693 Work equipment.......................................................................................................................................1697 Removal and installation of work equipment assembly..............................................................................................1698 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................1703 Cab and its attachments..............................................................................................................................1711 Removal and installation of operator's cab and floor frame assembly..............................................................................1712 Removal and installation of operator's cab glass (stuck glass)...................................................................................1716 Disassembly and assembly of operator's seat assembly (Standard specification)....................................................................1724 Disassembly and assembly of operator's seat assembly (Manufactured by GRAMMER)...................................................................1733 Removal and installation of air conditioner unit assembly........................................................................................1766 Electrical system....................................................................................................................................1773 Removal and installation of engine controller assembly...........................................................................................1774 Removal and installation of KOMTRAX terminal assembly............................................................................................1775 90 Diagrams and drawings................................................................................................................................. 0 Hydraulic diagrams and drawings......................................................................................................................1777 Power train hydraulic circuit diagram............................................................................................................1778 Automatic greasing circuit diagram...............................................................................................................1782 Hydraulic circuit diagram........................................................................................................................1785 Electrical diagrams and drawings.....................................................................................................................1788 Electrical circuit diagram.......................................................................................................................1790 Work equipment controller system electrical circuit diagram......................................................................................1804 Connector list and sterogram.....................................................................................................................1805
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⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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