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Komatsu WA430-6 WHEEL LOADER Service Repair Manual – PDF Download
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- Komatsu WA430-6 WHEEL LOADER Service Repair Manual
- SERIAL NUMBERS WA430-6 A42001-UP
- PUBLICATION NUMBER:CEBM008201
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Description
Komatsu WA430-6 WHEEL LOADER Service Repair Manual
Screenshot of the Manual:
KOMATSU WA430-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
Komatsu WA430-6 WHEEL LOADER Service Repair Manual
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
General
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant, and lubricant specification charts.
Structure, Function, and Maintenance Standard
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgment standards when inspecting disassembled parts.
Standard Value Table
This section explains the standard values for a new machine and the judgment criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and Adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting
Troubleshooting charts correlating Problems to Causes are also included in this section.
Disassembly and Assembly
This section explains the order to be followed when removing, installing, disassembling, or assembling each component, as well as precautions to be taken for these operations.
Other
This section has the foldout drawings for the machine.
Table of Contents:
Komatsu WA430-6 WHEEL LOADER Service Repair Manual
COVER................................................................................................................................... 0 CONTENTS............................................................................................................................ 2 REVISED PAGE LIST................................................................................................................... 3 SAFETY.............................................................................................................................. 19 Safety Notice................................................................................................................... 19 IMPORTANT SAFETY NOTICE..................................................................................................... 19 General Precautions......................................................................................................... 19 Preparations for Work....................................................................................................... 20 Precautions During Work..................................................................................................... 20 GENERAL............................................................................................................................. 21 HOW TO READ THE SHOP MANUAL......................................................................................................... 22 Volumes......................................................................................................................... 22 Distribution and Updating....................................................................................................... 22 Filing Method................................................................................................................... 22 Revised Edition Mark............................................................................................................ 22 Revisions....................................................................................................................... 22 Symbols......................................................................................................................... 22 HOISTING INSTRUCTIONS............................................................................................................... 23 Hoisting........................................................................................................................ 23 Making Signs.................................................................................................................... 23 Precautions..................................................................................................................... 23 Precautions for Sling Work.................................................................................................. 23 Precautions for Using Mobile Crane.......................................................................................... 24 Precautions for Using Overhead Hoist Crane.................................................................................. 24 Selecting Wire Ropes............................................................................................................ 25 AIR CONDITIONER CIRCUITS............................................................................................................ 26 Precautions for Handling Hoses and Tubes........................................................................................ 26 Disconnecting Hoses and Tubes............................................................................................... 26 Connecting Hoses and Tubes.................................................................................................. 26 MAINTENANCE STANDARD TERMS.......................................................................................................... 27 HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT........................................................................................... 29 Handling Electric Equipment..................................................................................................... 29 Handling Wiring Harnesses and Connectors.................................................................................... 29 Main Failures Occurring in Wiring Harness................................................................................... 29 Removing, Installing, and Drying Connectors and Wiring Harnesses............................................................ 30 Handling Controller......................................................................................................... 34 Troubleshooting Electric Circuits........................................................................................... 34 Handling Hydraulic Equipment.................................................................................................... 35 Handling Connectors Used for Engines............................................................................................ 36 Slide Lock Type............................................................................................................. 36 Pull Lock Type.............................................................................................................. 37 Push Lock Type.............................................................................................................. 37 Turn-housing Type (Round Green Connector)................................................................................... 39 PRECAUTIONS FOR OPERATIONS.......................................................................................................... 40 Precautions when Carrying Out Removal Work...................................................................................... 40 Precautions when Carrying Out Installation Work................................................................................. 41 Precautions when Completing the Operation....................................................................................... 42 PUSH-PULL COUPLER................................................................................................................... 43 Type 1.......................................................................................................................... 43 Disconnection............................................................................................................... 43 Connection.................................................................................................................. 43 Type 2.......................................................................................................................... 44 Disconnection............................................................................................................... 44 Connection.................................................................................................................. 44 Type 3.......................................................................................................................... 45 Disconnection............................................................................................................... 45 Connection.................................................................................................................. 45 COATING MATERIALS................................................................................................................... 46 STANDARD TIGHTENING TORQUE.......................................................................................................... 48 Standard Tightening Tables...................................................................................................... 48 For Bolts and Nuts.......................................................................................................... 48 For Split Flange Bolts...................................................................................................... 49 For O-Ring Boss Piping Joints............................................................................................... 49 For O-Ring Boss Plugs....................................................................................................... 50 For Hoses (Taper-Seal Type and Face-Seal Type).............................................................................. 50 For Face Seal Joints........................................................................................................ 51 For 102, 107, and 114 Engine Series (Bolts and Nuts)........................................................................ 51 For 102, 107, and 114 Engine Series (Eye Joints)............................................................................ 52 For 102, 107, and 114 Engine Series (Taper Screws).......................................................................... 52 CONVERSION TABLES................................................................................................................... 53 Method of Using the Conversion Table............................................................................................ 53 01 GENERAL.............................................................................................................................. 59 SPECIFICATIONS...................................................................................................................... 60 Dimension Drawing............................................................................................................... 60 Specification Tables............................................................................................................ 62 WEIGHT TABLE........................................................................................................................ 68 FUEL, COOLANT, AND LUBRICANTS....................................................................................................... 70 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD......................................................................................... 73 ENGINE AND COOLING SYSTEM........................................................................................................... 79 Engine and Transmission Mount................................................................................................... 79 Cooling System.................................................................................................................. 81 Cooling Fan Pump................................................................................................................ 82 Servo Valve................................................................................................................. 88 Cooling Fan Motor............................................................................................................... 92 Hydraulic Motor............................................................................................................. 95 Suction Valve............................................................................................................... 96 Pilot Valve................................................................................................................. 97 Safety Valve................................................................................................................ 98 POWER TRAIN SYSTEM.................................................................................................................. 99 Drive Line Components........................................................................................................... 99 Power Train System Diagram...................................................................................................... 100 Drive Shaft..................................................................................................................... 102 Power Train Piping System....................................................................................................... 104 Torque Converter (without lockup clutch)........................................................................................ 105 Power Transmitting Route.................................................................................................... 108 Oil Flow.................................................................................................................... 108 Torque Converter (with lockup Clutch)........................................................................................... 109 Power Transmitting Route.................................................................................................... 112 Oil Flow.................................................................................................................... 113 Transmission.................................................................................................................... 114 F and R Clutch Packs (without lockup clutch).................................................................................... 122 F and R Clutch Packs (with lockup clutch)....................................................................................... 124 1st and 4th Clutches........................................................................................................ 126 2nd and 3rd Clutches........................................................................................................ 128 Operation of Disc Clutch.................................................................................................... 130 Power Transmission Route........................................................................................................ 132 Forward 1st Speed........................................................................................................... 132 Forward 2nd Speed........................................................................................................... 134 Forward 3rd Speed........................................................................................................... 136 Forward 4th Speed........................................................................................................... 138 Reverse 1st Speed........................................................................................................... 140 Flow Control Valve (without bypass solenoid valve).............................................................................. 142 Flow Control Valve (with bypass solenoid valve)................................................................................. 144 Operation................................................................................................................... 146 Transmission Control Valve.................................................................................................. 148 ECMV............................................................................................................................ 151 ECMV for Gear Speed Clutch.................................................................................................. 152 ECMV and Proportional Solenoid.............................................................................................. 152 ECMV and Fill Switch........................................................................................................ 153 Operation of ECMV........................................................................................................... 153 ECMV for Lockup Clutch...................................................................................................... 155 Main Relief Valve and Torque Converter Relief Valve............................................................................. 158 Outline..................................................................................................................... 160 Operation................................................................................................................... 160 DRIVE AXLE SYSTEM................................................................................................................... 161 Front and Rear Axles............................................................................................................ 161 Front Axle.................................................................................................................. 161 Rear Axle................................................................................................................... 162 Differential.................................................................................................................... 163 Front Differential.......................................................................................................... 163 Rear Differential........................................................................................................... 166 Outline..................................................................................................................... 169 Limited Slip Differential (if equipped)......................................................................................... 170 Front Axle.................................................................................................................. 170 Rear Axle................................................................................................................... 172 Operation................................................................................................................... 174 Final Drives.................................................................................................................... 176 Front Axle.................................................................................................................. 176 Rear Axle................................................................................................................... 178 Outline..................................................................................................................... 180 STEERING SYSTEM..................................................................................................................... 181 Steering Piping Diagram......................................................................................................... 181 Steering Column................................................................................................................. 182 Steering Pump................................................................................................................... 184 Pump Unit................................................................................................................... 186 Servo Valve................................................................................................................. 191 LS Valve.................................................................................................................... 194 PC Valve.................................................................................................................... 194 Steering Valve.................................................................................................................. 198 Operation of Flow Amplifier................................................................................................. 202 Operation of Flow Control Spool............................................................................................. 204 Operation of Steering Valve................................................................................................. 208 Steering Relief Valve....................................................................................................... 211 Overload Relief Valve....................................................................................................... 212 Orbitrol Valve.................................................................................................................. 215 Outline..................................................................................................................... 216 Structure................................................................................................................... 216 Stop Valve...................................................................................................................... 219 Steering Relief Valve (if equipped)............................................................................................. 220 Steering Cylinder............................................................................................................... 221 Emergency Steering Motor (if equipped).......................................................................................... 223 Emergency Steering Pump (if equipped)........................................................................................... 224 Joystick Steering Lever Linkage (if equipped)................................................................................... 226 Steering Electric Lever (if equipped)........................................................................................... 227 Joystick EPC Valve (if equipped)................................................................................................ 228 SERVICE BRAKING SYSTEM.............................................................................................................. 229 Brake Piping Diagram............................................................................................................ 229 Charge Valve.................................................................................................................... 230 Function.................................................................................................................... 233 Operation................................................................................................................... 234 Main Relief Valve (R1)...................................................................................................... 236 PPC Relief Valve (R3)....................................................................................................... 237 Sequence Valve (H1)......................................................................................................... 237 Shuttle Valve (S1).......................................................................................................... 237 Brake Valve..................................................................................................................... 238 Outline..................................................................................................................... 238 Operation................................................................................................................... 239 Accumulator (for Brake)......................................................................................................... 243 Function.................................................................................................................... 243 Brakes.......................................................................................................................... 244 Front Brake................................................................................................................. 244 Rear Brake.................................................................................................................. 246 Parking Brake System............................................................................................................ 250 Parking Brake Control....................................................................................................... 250 Parking Brake............................................................................................................... 252 Parking Brake Solenoid Valve................................................................................................ 254 Operation................................................................................................................... 255 Emergency Parking Brake Release Valve....................................................................................... 256 UNDERCARRIAGE AND FRAME............................................................................................................. 258 Axle Mount and Center Hinge Pin................................................................................................. 258 Tires........................................................................................................................... 264 Radial Tire................................................................................................................. 264 Bias Tire................................................................................................................... 265 HYDRAULIC SYSTEM.................................................................................................................... 267 Hydraulic Piping Diagram........................................................................................................ 267 Work Equipment Control Lever System............................................................................................. 270 2-Lever Type................................................................................................................ 270 Multi-Function Monolever Type (if equipped)................................................................................. 271 Hydraulic Tank.................................................................................................................. 272 Breather.................................................................................................................... 274 Power Train Pump................................................................................................................ 275 Type: SAL (3)125............................................................................................................ 275 Work Equipment Pump............................................................................................................. 276 Type: LPV90................................................................................................................. 276 Pump Unit................................................................................................................... 278 Servo Valve................................................................................................................. 280 Function.................................................................................................................... 284 Structure................................................................................................................... 284 Operation of Pump........................................................................................................... 285 Control of Delivery......................................................................................................... 286 LS Valve.................................................................................................................... 286 PC Valve.................................................................................................................... 287 Work Equipment Control Valve.................................................................................................... 291 4-Spool Valve............................................................................................................... 292 Closed Center Loading-Sensing System (CLSS)..................................................................................... 308 Outline..................................................................................................................... 308 Basic Principle............................................................................................................. 309 Pressure Compensation Control............................................................................................... 310 Hydraulic Circuit Diagram and Valves............................................................................................ 311 Unload Valve.................................................................................................................... 314 When Control Valve is at Neutral............................................................................................ 314 When Control Valve is Controlled Finely..................................................................................... 316 When Control Valve is Operated.............................................................................................. 318 Work Equipment Valve (Lift Arm)................................................................................................. 320 Work Equipment Valve (Bucket and Attachment).................................................................................... 322 LS Bypass Plug.................................................................................................................. 324 Pressure Compensation Valve..................................................................................................... 325 Lift Arm Regeneration Circuit................................................................................................... 328 Variable Lift Check Valve....................................................................................................... 330 ECSS Control Valve.............................................................................................................. 332 Accumulator Pressure Relief Valve............................................................................................... 333 Restriction on Lift Arm Raise Stroke............................................................................................ 334 Accumulator Charge Valve........................................................................................................ 336 PPC Valve....................................................................................................................... 340 Work Equipment PPC Valve.................................................................................................... 340 Attachment PPC Valve (if equipped).......................................................................................... 346 Stabilizer Valve................................................................................................................ 348 Accumulator for PPC Circuit..................................................................................................... 354 Accumulator for ECSS............................................................................................................ 354 Work Equipment PPC Cutoff Solenoid Valve (if equipped).......................................................................... 355 WORK EQUIPMENT...................................................................................................................... 357 Work Equipment Linkage.......................................................................................................... 357 Bucket.......................................................................................................................... 360 Bucket Positioner and Boom Kickout.............................................................................................. 362 Bucket Positioner........................................................................................................... 363 Boom Kickout................................................................................................................ 363 Operation of Proximity Switch............................................................................................... 364 Function of Proximity Switch................................................................................................ 366 Function of Proximity Switch................................................................................................ 369 Work Equipment Cylinders........................................................................................................ 370 Lift Cylinder............................................................................................................... 370 Bucket Cylinder............................................................................................................. 370 CAB ENVIRONMENT..................................................................................................................... 371 Cab............................................................................................................................. 371 Air Conditioner................................................................................................................. 372 Air Conditioner Piping Diagram.............................................................................................. 372 Refrigerant Circuit Diagram................................................................................................. 374 Air Conditioner Unit........................................................................................................ 375 Functions of Major Components............................................................................................... 376 Blower and Intake Unit...................................................................................................... 378 Functions of Major Components............................................................................................... 379 Compressor.................................................................................................................. 380 Condenser................................................................................................................... 381 Receiver.................................................................................................................... 382 Automatic Air Conditioner Panel............................................................................................. 383 ELECTRICAL SYSTEM................................................................................................................... 387 Machine Monitor System.......................................................................................................... 387 System Circuit Diagram...................................................................................................... 389 Monitor Display Functions....................................................................................................... 392 Speedometer Specification................................................................................................... 392 List of Items Displayed on Monitor.......................................................................................... 394 Machine Monitor Operation Switches.............................................................................................. 403 Setting the Machine Monitor..................................................................................................... 404 Troubleshooting Function.................................................................................................... 405 Character Display Function.................................................................................................. 405 Operator Mode Functions..................................................................................................... 406 Service Mode Functions...................................................................................................... 409 Input And Output Signals.................................................................................................... 414 Transmission Controller System.................................................................................................. 422 Transmission Controller Gearshifting Control Function....................................................................... 422 Cooling Fan Control Function................................................................................................ 446 ECSS Function............................................................................................................... 456 Electric Emergency Steering Function (if equipped).......................................................................... 458 Power Train Pump Bypass Control Function (if equipped)...................................................................... 461 Directional Selector Switch Control Function (if equipped).................................................................. 462 Multi-Function Mono Lever Function (if equipped)............................................................................ 465 Joystick Steering Function (if equipped).................................................................................... 468 Transmission Controller..................................................................................................... 474 Work Equipment Controller System................................................................................................ 478 Work Equipment Controller................................................................................................... 483 ELECTRONIC TRANSMISSION CONTROL..................................................................................................... 486 Combination Switch.............................................................................................................. 488 Kickdown and Hold Switch........................................................................................................ 490 Multi-Function Knob (if equipped)............................................................................................... 491 Joystick Steering Knob (if equipped)............................................................................................ 492 KOMTRAX Terminal System......................................................................................................... 493 Engine Starting Circuit......................................................................................................... 496 Engine Stopping Circuit......................................................................................................... 498 Preheating Circuit.............................................................................................................. 499 Engine Power Mode Selector Circuit.............................................................................................. 500 Engine Output Derating Function................................................................................................. 501 Automatic Warm-up Function...................................................................................................... 501 Parking Brake Circuit........................................................................................................... 502 Sensors......................................................................................................................... 504 Speed Sensor................................................................................................................ 504 Torque Converter Oil Temperature Sensor..................................................................................... 505 Hydraulic Oil Temperature Sensor............................................................................................ 505 Transmission Oil Temperature Sensor......................................................................................... 505 Brake Oil Temperature Sensor................................................................................................ 505 Work Equipment Pump Oil Pressure Sensor..................................................................................... 506 Steering Pump Oil Pressure Sensor........................................................................................... 506 Transmission Cutoff Oil Pressure Sensor..................................................................................... 507 Coolant Level Sensor........................................................................................................ 508 Fuel Level Sensor........................................................................................................... 509 Air Cleaner Clogging Sensor................................................................................................. 510 Water-In Fuel Sensor........................................................................................................ 511 Accelerator Pedal Sensor.................................................................................................... 512 Boom Kickout Proximity Switch............................................................................................... 513 Bucket Positioner Proximity Switch.......................................................................................... 513 20 STANDARD VALUE TABLES................................................................................................................ 515 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 517 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................... 518 MACHINE POSTURE..................................................................................................................... 525 30 TESTING AND ADJUSTING................................................................................................................ 527 TOOLS............................................................................................................................... 532 ENGINE COMPONENTS................................................................................................................... 540 Engine Speed.................................................................................................................... 540 Measure Engine Speed (Low and High Idle).................................................................................... 540 Measure Torque Converter Stall Speed........................................................................................ 540 Measure Hydraulic Stall Speed............................................................................................... 541 Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed....................................................... 542 Exhaust Gas Color............................................................................................................... 543 Using Handy Smoke Checker A1................................................................................................ 543 Using Smoke Meter A2........................................................................................................ 544 Exhaust Temperature............................................................................................................. 546 Adjusting Valve Clearance....................................................................................................... 548 Measuring Engine Compression.................................................................................................... 552 Measuring Blow-by Pressure...................................................................................................... 556 Measuring Engine Oil Pressure................................................................................................... 558 Intake Air (Boost) Pressure..................................................................................................... 559 FUEL SYSTEM......................................................................................................................... 561 Handling Fuel System Equipment.................................................................................................. 561 Releasing Residual Pressure in Fuel System...................................................................................... 561 Measuring Fuel Pressure......................................................................................................... 562 Measuring Fuel Negative Pressure Circuit Pressure (Fuel Supply Connector)................................................... 562 Measuring Fuel Negative Pressure Circuit Pressure (Supply Pump)............................................................. 563 Measuring Fuel Low-Pressure Circuit Pressure (Fuel Filter Inlet Side)....................................................... 564 Measuring Fuel Low-Pressure Circuit Pressure (Fuel Filter Outlet Side)...................................................... 565 Measuring Drop of Fuel Low-Pressure Circuit Pressure........................................................................ 566 Fuel Return and Leak Rate....................................................................................................... 567 Measuring Return Rate from Supply Pump...................................................................................... 567 Measuring Leakage from Pressure Limiter..................................................................................... 568 Measuring Return Rate from Injector......................................................................................... 569 Bleeding Air from Fuel Circuit.................................................................................................. 570 Testing Leakage in Fuel System.................................................................................................. 572 Handling Reduced Cylinder Mode Operation........................................................................................ 573 Handling No-Injection Cranking Operation........................................................................................ 573 Handling Controller Voltage Circuit............................................................................................. 573 EXHAUST SYSTEM AND PIPING........................................................................................................... 574 Checking Muffler and Muffler Stack for Looseness and Damage..................................................................... 574 Checking Muffler Function....................................................................................................... 574 Checking Installed Condition of Cylinder Head and Manifolds..................................................................... 574 Checking Engine Piping for Damage and Looseness................................................................................. 574 BELTS............................................................................................................................... 575 Air Conditioner Compressor Belt................................................................................................. 575 Testing the Tension......................................................................................................... 575 Adjusting the Tension....................................................................................................... 575 Replacing Alternator Belt....................................................................................................... 576 TRANSMISSION SPEED SENSOR........................................................................................................... 577 LEVERS.............................................................................................................................. 578 Adjusting Directional Lever Length.............................................................................................. 578 Adjusting Gearshift Lever Length................................................................................................ 578 Testing Directional Lever....................................................................................................... 579 POWER TRAIN OIL PRESSURES........................................................................................................... 580 Measuring....................................................................................................................... 582 Transmission Main Relief Pressure........................................................................................... 583 Torque Converter Relief Pressure (Inlet Pressure)........................................................................... 584 Torque Converter Outlet Pressure............................................................................................ 585 F (Forward) Clutch Pressure................................................................................................. 586 R (Reverse) Clutch Pressure................................................................................................. 587 1st Clutch Pressure......................................................................................................... 588 2nd Clutch Pressure......................................................................................................... 589 3rd Clutch Pressure......................................................................................................... 590 4th Clutch Pressure......................................................................................................... 591 Lubrication Pressure........................................................................................................ 592 Adjusting....................................................................................................................... 593 Transmission Main Relief Valve.............................................................................................. 593 FLUSHING TRANSMISSION SYSTEM........................................................................................................ 594 Torque Converter and Hydraulic Circuit.......................................................................................... 594 WHEN TRANSMISSION VALVE FAILS....................................................................................................... 596 AXLE FINAL DRIVE.................................................................................................................... 598 DRIVE SHAFTS........................................................................................................................ 599 STEERING SYSTEM..................................................................................................................... 600 Steering Stop Valve............................................................................................................. 600 Testing..................................................................................................................... 600 Adjusting................................................................................................................... 600 Steering Wheel.................................................................................................................. 602 Measuring Play In Steering Wheel............................................................................................ 602 Measuring Operating Effort of Steering Wheel................................................................................ 603 Measuring Operating Time of Steering Wheel.................................................................................. 604 Steering Oil Pressure........................................................................................................... 605 Measuring Steering Relief Pressure.......................................................................................... 606 Measuring Steering Pilot Circuit Pressure................................................................................... 607 Adjusting Steering Relief Pressure.......................................................................................... 608 Adjusting Steering Control Circuit Pressure................................................................................. 608 Bleeding Air from Steering Circuit.............................................................................................. 609 Bleeding Air from Steering Pump............................................................................................. 609 Bleeding Air from Steering Cylinder Circuit................................................................................. 609 HYDRAULIC DRIVE FAN................................................................................................................. 610 Measuring Fan Speed............................................................................................................. 610 Measuring Fan Drive Oil Pressure................................................................................................ 611 Bleeding Air from Hydraulic Drive Fan Circuit................................................................................... 612 Bleeding Air from Fan Pump.................................................................................................. 612 Bleeding Air from Fan Motor Circuit......................................................................................... 613 WHEEL BRAKE SYSTEM.................................................................................................................. 614 Brake Pedal..................................................................................................................... 614 Measuring Pressing Angle of Pedal........................................................................................... 614 Brake Pedal Linkage............................................................................................................. 615 Testing..................................................................................................................... 615 Adjusting................................................................................................................... 615 Measuring Brake Performance..................................................................................................... 616 Accumulator Charge Pressure..................................................................................................... 617 Measuring................................................................................................................... 617 Adjusting................................................................................................................... 618 Measuring Brake Oil Pressure.................................................................................................... 619 Testing Wear of Wheel Brake Disc................................................................................................ 622 Bleeding Air from Brake Circuit................................................................................................. 623 Releasing Residual Pressure in Brake Accumulator Circuit........................................................................ 624 PARKING BRAKE SYSTEM................................................................................................................ 625 Testing Parking Brake Performance............................................................................................... 625 Measuring Parking Brake Oil Pressure............................................................................................ 626 Checking Wear of Parking Brake Disc............................................................................................. 628 Releasing Parking Brake Manually................................................................................................ 629 WORK EQUIPMENT...................................................................................................................... 630 Work Equipment Control Levers................................................................................................... 630 Operating Effort of Work Equipment Control Lever............................................................................ 630 Stroke of Work Equipment Control Lever...................................................................................... 631 PPC Oil Pressure................................................................................................................ 632 Measuring PPC Pump Basic Pressure........................................................................................... 632 Measuring PPC Valve Output Pressure......................................................................................... 634 Adjusting PPC Relief Valve.................................................................................................. 636 Work Equipment Oil Pressure..................................................................................................... 638 Preparation Work............................................................................................................ 638 Measuring Work Equipment Relief Pressure.................................................................................... 639 Measuring Unload Pressure................................................................................................... 640 Measuring Work Equipment LS Differential Pressure........................................................................... 641 Adjusting Work Equipment Relief Pressure.................................................................................... 642 Adjusting Unload Pressure................................................................................................... 642 Adjusting LS Differential Pressure.......................................................................................... 642 Bleeding Air from Work Equipment Circuit........................................................................................ 643 From Work Equipment Pump (Piston Pump)...................................................................................... 643 From Hydraulic Cylinder..................................................................................................... 643 Releasing Residual Pressure in Work Equipment Circuit........................................................................... 644 From the Circuit between Hydraulic Cylinders and Control Valve.............................................................. 644 From ECSS (Travel Damper) Circuit........................................................................................... 644 ECSS (Electronically Controlled Suspension System) Accumulator.................................................................. 646 ECSS Accumulator Nitrogen Gas Pressure...................................................................................... 646 Testing ECSS Accumulator Nitrogen Gas Pressure.............................................................................. 648 Charging ECSS Accumulator with Nitrogen Gas................................................................................. 649 Work Equipment Positioners...................................................................................................... 652 Testing and Adjusting Bucket Positioner..................................................................................... 652 Testing and Adjusting Boom Kickout.......................................................................................... 653 Proximity Switch Operation Pilot Lamp....................................................................................... 654 ELECTRICAL SYSTEM................................................................................................................... 656 Troubleshooting................................................................................................................. 656 Procedure for Testing Diodes................................................................................................ 656 Preparation for Troubleshooting Electric System................................................................................. 658 Machine Monitor............................................................................................................. 658 Transmission Controller..................................................................................................... 659 Work Equipment Controller (if equipped)..................................................................................... 660 KOMTRAX Terminal............................................................................................................ 660 Sensors......................................................................................................................... 661 Ambient Pressure Sensor (AMBAIR PRESSURE)................................................................................... 661 Engine Ne Speed Sensor (CRANK SENSOR)....................................................................................... 661 Engine Bkup Speed Sensor (CAM SENSOR)....................................................................................... 661 Engine Oil Pressure Switch (OIL PRESSURE SWITCH)............................................................................ 661 Boost Pressure And Temperature Sensor (BOOST PRESS & IMT)................................................................... 661 Supply Pump IMV Solenoid (FUEL REGULATOR)................................................................................... 662 Common Rail Pressure Sensor (FUEL RAIL PRESS)............................................................................... 662 Engine Coolant Temperature Sensor (COOLANT TEMP)............................................................................ 663 KOMTRAX TERMINAL SYSTEM............................................................................................................. 664 Terminal Installed at Plant Before Shipment..................................................................................... 664 Terminal Retrofitted on Machine After Shipment.................................................................................. 664 Starting Operation.............................................................................................................. 664 KOMTRAX Terminal Lamps.......................................................................................................... 669 7-segment and Dot Displays for CPU.......................................................................................... 671 MACHINE MONITOR SYSTEM.............................................................................................................. 672 Adjusting Machine Monitor....................................................................................................... 672 Adjusting for Replaced, Reassembled, or Added Sensor/Controller................................................................. 673 Adjustment for User’s Needs..................................................................................................... 674 Special Functions of Machine Monitor (EMMS)..................................................................................... 675 Normal Functions and Special Functions of Machine Monitor................................................................... 675 Functions and Flow of Service Mode.............................................................................................. 676 Operator Mode................................................................................................................... 679 Service Meter/Clock Display Function (1).................................................................................... 679 Load Meter Function (2) (if equipped)....................................................................................... 679 Odometer Display Function (3)............................................................................................... 679 Maintenance Monitoring Function (4)......................................................................................... 680 Telephone Number Input Function (5)......................................................................................... 680 Language Selection Function (6)............................................................................................. 680 Monitor Brightness Adjustment Function (7).................................................................................. 680 Time Adjustment Function (8)................................................................................................ 681 Travel Speed/Engine Speed Display Selecting Function (9).................................................................... 681 Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)....................................................... 681 Action Code Display Function (11)........................................................................................... 682 Failure Code Display Function (12).......................................................................................... 682 Service Mode.................................................................................................................... 684 Switching to Service Mode and Screen Display (1)............................................................................ 684 Electrical System Fault History Display Function (ELECTRIC FAULT) (2)....................................................... 686 Mechanical System Fault History Display Function (MACHINE FAULT) (3)........................................................ 688 Real-Time Monitoring Function (REAL-TIME MONITOR) (4)....................................................................... 689 Real-Time Monitoring Codes Tables........................................................................................... 692 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)..................................................................... 720 No-Injection Cranking Function (NO INJECTION) (6)........................................................................... 721 Adjustment Function (TUNING) (7)............................................................................................ 722 Maintenance Monitoring Function (MAINTENANCE MONITOR) (8)................................................................... 740 Operating Information Display Function (OPERATION INFO) (9)................................................................. 746 Optional Device Selecting Function (OPTIONAL SELECT) (10)................................................................... 749 Machine Serial Number Input Function (MACHINE NO. SET) (11)................................................................. 753 Model Select Function (MACHINE) (12)........................................................................................ 754 Initialize Function (13).................................................................................................... 755 PM-CLINIC INSPECTION TABLE.......................................................................................................... 756 40 TROUBLESHOOTING...................................................................................................................... 761 TROUBLESHOOTING POINTS.............................................................................................................. 777 TROUBLESHOOTING EVENTS.............................................................................................................. 779 MAINTENANCE PRECAUTIONS............................................................................................................. 780 Precautions when Handling Electrical Equipment.................................................................................. 780 Handling Electronic Control Unit................................................................................................ 785 Points to Remember when Troubleshooting Electrical Circuits..................................................................... 786 ELECTRIC WIRE CODE.................................................................................................................. 787 How to Read Electric Wire Code.................................................................................................. 787 Type, Symbol, and Material.................................................................................................. 787 Dimensions.................................................................................................................. 788 Color Codes Table........................................................................................................... 789 Circuits and Color Codes.................................................................................................... 790 HANDLING HYDRAULIC EQUIPMENT........................................................................................................ 791 CHECKS BEFORE TROUBLESHOOTING....................................................................................................... 793 Categories and Method of Using Troubleshooting Charts........................................................................... 794 Troubleshooting Individual Electrical Circuits.................................................................................. 795 Chart Use................................................................................................................... 797 Chart Tips.................................................................................................................. 797 Troubleshooting Individual Hydraulic Circuits................................................................................... 798 CONNECTOR PIN NUMBERS............................................................................................................... 800 Connection Tables for Connector Pin Numbers..................................................................................... 800 X-Type Connectors........................................................................................................... 800 SWP-Type Connectors......................................................................................................... 802 M-Type Connectors........................................................................................................... 804 S-Type Connectors........................................................................................................... 806 MIC-Type Connectors......................................................................................................... 808 AMP040-Type Connectors...................................................................................................... 810 AMP070-Type Connectors...................................................................................................... 812 AMP Connector............................................................................................................... 814 L-Type Connector............................................................................................................ 814 PA-Type Connector........................................................................................................... 815 Bendix (MS) Connector....................................................................................................... 815 KES1 (Automobile) Connectors................................................................................................ 816 F-Type Connector............................................................................................................ 817 Connectors for Relay (Socket-Type).......................................................................................... 818 HD30 Series Connectors...................................................................................................... 819 DT Series Connectors........................................................................................................ 825 DTM Series Connectors....................................................................................................... 827 DTHD Series Connectors...................................................................................................... 827 DTP Series Connectors....................................................................................................... 828 DRC26 Series Connectors..................................................................................................... 829 DRC12, 16 Series Connectors................................................................................................. 831 AMP Connectors for Pump Controller (CH700).................................................................................. 832 BOSCH Connectors for Engine................................................................................................. 833 SUMITOMO Connectors for Engine.............................................................................................. 834 CANNON Connector for Engine................................................................................................. 835 AMP Connectors for Engine................................................................................................... 836 FRAMATOME Connectors for Engine............................................................................................. 837 PACKARD Connectors for Engine............................................................................................... 839 DT Series Connectors for Engine............................................................................................. 840 T-BRANCH BOXES and ADAPTERS......................................................................................................... 841 T-Branch Box and T-Branch Adapter Table......................................................................................... 841 MODE CHART.......................................................................................................................... 846 INFORMATION IN TESTING PROCEDURES................................................................................................... 849 TROUBLESHOOTING BY FAILURE CODE..................................................................................................... 851 Failure Codes Table............................................................................................................. 851 FUSE BOX AND SLOW-BLOW FUSES........................................................................................................ 864 Connection Table................................................................................................................ 864 Fuse Box 1.................................................................................................................. 864 Fuse Box 2.................................................................................................................. 865 Slow-Blow Fuses............................................................................................................. 865 FAILURE CODES....................................................................................................................... 867 1500L0.......................................................................................................................... 867 TORQFLOW Transmission: Double Meshing....................................................................................... 867 15SAL1.......................................................................................................................... 868 ECMV F Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 868 15SALH.......................................................................................................................... 870 ECMV F Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 870 15SBL1.......................................................................................................................... 872 ECMV R Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 872 15SBLH.......................................................................................................................... 874 ECMV R Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 874 15SEL1.......................................................................................................................... 876 ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON............................................................. 876 15SELH.......................................................................................................................... 878 ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 878 15SFL1.......................................................................................................................... 880 ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON............................................................. 880 15SFLH.......................................................................................................................... 882 ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 882 15SGL1.......................................................................................................................... 884 ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON............................................................. 884 15SGLH.......................................................................................................................... 886 ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 886 15SHL1.......................................................................................................................... 888 ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON............................................................. 888 15SHLH.......................................................................................................................... 890 ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 890 2F00MA.......................................................................................................................... 892 Parking Brake: Malfunction.................................................................................................. 892 2G43ZG.......................................................................................................................... 894 Accumulator: Low Oil Pressure............................................................................................... 894 44K0L4.......................................................................................................................... 896 Bucket Positioner: ON/OFF Signals Disagree.................................................................................. 896 AA1ANX.......................................................................................................................... 900 Air Cleaner: Clogging....................................................................................................... 900 AB00L6.......................................................................................................................... 902 Alternator: Signal Disagrees with Operating State of Engine................................................................. 902 AB00MA.......................................................................................................................... 904 Alternator: Malfunction..................................................................................................... 904 B@BAZG.......................................................................................................................... 906 Rotation Derating by Low Engine Oil Pressure................................................................................ 906 B@BAZK.......................................................................................................................... 908 Engine Oil: Low Level....................................................................................................... 908 B@BCNS.......................................................................................................................... 910 Coolant: Overheating........................................................................................................ 910 B@BCZK.......................................................................................................................... 912 Coolant: Low Level.......................................................................................................... 912 B@BEBF.......................................................................................................................... 914 Water in Fuel Error......................................................................................................... 914 B@C7NS.......................................................................................................................... 916 Brake Oil: Overheating...................................................................................................... 916 b@CENS.......................................................................................................................... 918 Torque Converter Oil: Overheating........................................................................................... 918 B@CENS.......................................................................................................................... 920 Torque Converter Oil: Overheating........................................................................................... 920 B@HANS.......................................................................................................................... 922 Hydraulic Oil: Overheating.................................................................................................. 922 CA111........................................................................................................................... 924 Abnormality in Engine Controller............................................................................................ 924 CA115........................................................................................................................... 926 Engine Ne or Bkup Speed Sensor Error........................................................................................ 926 CA122........................................................................................................................... 928 Charge Pressure Sensor High Error........................................................................................... 928 CA123........................................................................................................................... 930 Charge Pressure Sensor Low Error............................................................................................ 930 CA131........................................................................................................................... 932 Throttle Sensor High Error.................................................................................................. 932 CA132........................................................................................................................... 934 Throttle Sensor Low Error................................................................................................... 934 CA144........................................................................................................................... 936 Coolant Sensor High Error................................................................................................... 936 CA145........................................................................................................................... 938 Coolant Sensor Low Error.................................................................................................... 938 CA153........................................................................................................................... 940 Charge Temperature Sensor High Error........................................................................................ 940 CA154........................................................................................................................... 942 Charge Temperature Sensor Low Error......................................................................................... 942 CA155........................................................................................................................... 944 Derating of Speed by Abnormally High Charge Temperature..................................................................... 944 CA187........................................................................................................................... 946 Sensor Power Supply 2 Low Error............................................................................................. 946 CA221........................................................................................................................... 948 Atmospheric Pressure Sensor High Error...................................................................................... 948 CA222........................................................................................................................... 950 Atmospheric Pressure Sensor Low Error....................................................................................... 950 CA227........................................................................................................................... 952 Sensor Power Supply 2 High Error............................................................................................ 952 CA234........................................................................................................................... 954 Engine Overspeed............................................................................................................ 954 CA238........................................................................................................................... 956 Ne Speed Sensor Power Supply Error.......................................................................................... 956 CA271........................................................................................................................... 958 IMV/PCV1 Short Circuit...................................................................................................... 958 CA272........................................................................................................................... 960 IMV/PCV1 Disconnection...................................................................................................... 960 CA281........................................................................................................................... 962 High Pressure Pump Error.................................................................................................... 962 CA322........................................................................................................................... 964 Injector #1 Open/Short Error................................................................................................ 964 CA323........................................................................................................................... 966 Injector #5 Open/Short Error................................................................................................ 966 CA324........................................................................................................................... 968 Injector #3 Open/Short Error................................................................................................ 968 CA325........................................................................................................................... 970 Injector #6 Open/Short Error................................................................................................ 970 CA331........................................................................................................................... 972 Injector #2 Open/Short Error................................................................................................ 972 CA332........................................................................................................................... 974 Injector #4 Open/Short Error................................................................................................ 974 CA342........................................................................................................................... 976 Calibration Code Inconsistency.............................................................................................. 976 CA351........................................................................................................................... 978 Injectors Drive Circuit Error............................................................................................... 978 CA352........................................................................................................................... 980 Sensor Power Supply 1 Low Error............................................................................................. 980 CA386........................................................................................................................... 982 Sensor Power Supply 1 High Error............................................................................................ 982 CA428........................................................................................................................... 984 Abnormally High Level in Water Sensor....................................................................................... 984 CA429........................................................................................................................... 986 Abnormally Low Level in Water Sensor........................................................................................ 986 CA431........................................................................................................................... 988 Idle Validation Switch Error................................................................................................ 988 CA432........................................................................................................................... 990 Idle Validation Action Error................................................................................................ 990 CA435........................................................................................................................... 992 Engine Oil Pressure Switch Error............................................................................................ 992 CA441........................................................................................................................... 994 Battery Voltage Low Error................................................................................................... 994 CA442........................................................................................................................... 998 Battery Voltage High Error.................................................................................................. 998 CA449...........................................................................................................................1000 Common Rail Pressure High Error 2...........................................................................................1000 CA451...........................................................................................................................1004 Common Rail Pressure Sensor High Error......................................................................................1004 CA452...........................................................................................................................1006 Common Rail Pressure Sensor Low Error.......................................................................................1006 CA488...........................................................................................................................1008 Derating of Torque by Abnormally High Charge Temperature....................................................................1008 CA553...........................................................................................................................1010 Common Rail Pressure High Error 1...........................................................................................1010 CA559...........................................................................................................................1012 Supply Pump Pressure Very Low Error.........................................................................................1012 CA689...........................................................................................................................1014 Engine Ne Speed Sensor Error................................................................................................1014 CA731...........................................................................................................................1016 Engine Bkup Speed Sensor Phase Error........................................................................................1016 CA757...........................................................................................................................1018 All Continuous Data Lost Error..............................................................................................1018 CA778...........................................................................................................................1022 Engine Bkup Speed Sensor Error..............................................................................................1022 CA1633..........................................................................................................................1024 KOMNET Datalink Timeout Error...............................................................................................1024 CA2185..........................................................................................................................1026 Throttle Sensor Power Supply Voltage High Error.............................................................................1026 CA2186..........................................................................................................................1028 Throttle Sensor Power Supply Voltage Low Error..............................................................................1028 CA2249..........................................................................................................................1030 Supply Pump Pressure Very Low Error 2.......................................................................................1030 CA2265..........................................................................................................................1032 Abnormally High Level in Electric Lift Pump.................................................................................1032 CA2266..........................................................................................................................1034 Abnormally Low Level in Electric Lift Pump..................................................................................1034 CA2311..........................................................................................................................1036 Abnormality in IMV Solenoid.................................................................................................1036 CA2555..........................................................................................................................1038 Intake Heater Relay Disconnection Error.....................................................................................1038 CA2556..........................................................................................................................1040 Intake Heater Relay Short Circuit Error.....................................................................................1040 D150KA..........................................................................................................................1042 Emergency Steering Relay: Disconnection.....................................................................................1042 D150KB..........................................................................................................................1044 Emergency Steering Relay: Short Circuit.....................................................................................1044 D150KY..........................................................................................................................1046 Emergency Steering Relay: Short Circuit with Power Supply Line..............................................................1046 D160KA..........................................................................................................................1048 Backup Lamp Relay: Disconnection............................................................................................1048 D160KB..........................................................................................................................1050 Backup Lamp Relay: Short Circuit............................................................................................1050 D160KZ..........................................................................................................................1052 Backup Lamp Relay: Disconnection or Short Circuit...........................................................................1052 D191KA..........................................................................................................................1054 Joystick Steering Neutral Safety Relay: Disconnection.......................................................................1054 D191KB..........................................................................................................................1056 Joystick Steering Neutral Safety Relay: Short Circuit.......................................................................1056 D191KY..........................................................................................................................1058 Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line................................................1058 D192KA..........................................................................................................................1060 ECSS Solenoid: Disconnection................................................................................................1060 D192KB..........................................................................................................................1062 ECSS Solenoid: Short Circuit................................................................................................1062 D192KY..........................................................................................................................1064 ECSS Solenoid: Short Circuit with Power Supply Line.........................................................................1064 D193KA..........................................................................................................................1066 Joystick Steering Solenoid Cutout Relay: Disconnection......................................................................1066 D193KB..........................................................................................................................1068 Joystick Steering Solenoid Cutout Relay: Short Circuit......................................................................1068 D193KY..........................................................................................................................1070 Joystick Steering Solenoid Cutout Relay: Short Circuit with Power Supply Line...............................................1070 D5ZHKA..........................................................................................................................1072 Terminal C Signal: Disconnection............................................................................................1072 D5ZHKB..........................................................................................................................1076 Terminal C Signal: Short Circuit............................................................................................1076 D5ZHKZ..........................................................................................................................1080 Terminal C Signal: Disconnection or Short Circuit...........................................................................1080 D5ZHL6..........................................................................................................................1084 Terminal C Signal: Signal Does Not Match Engine Running or Stopped State....................................................1084 DA80L4..........................................................................................................................1088 Auto-Grease Controller: ON/OFF Signals Disagree.............................................................................1088 DAF3KK..........................................................................................................................1090 Machine Monitor: Low Source Voltage (input).................................................................................1090 DAF5KP..........................................................................................................................1092 Machine Monitor: Low Output Voltage.........................................................................................1092 DAFRKR..........................................................................................................................1096 Machine Monitor: CAN Defective Communication................................................................................1096 DAQ0KK..........................................................................................................................1100 Transmission Controller: Low Source Voltage.................................................................................1100 DAQ0KT..........................................................................................................................1102 Transmission Controller: Abnormality in Controller..........................................................................1102 DAQ1KA..........................................................................................................................1103 Terminal ACC Input: Disconnection...........................................................................................1103 DAQ2KK..........................................................................................................................1106 Transmission Controller Load Power Supply Line: Low Source Voltage (input)..................................................1106 DAQ9KQ..........................................................................................................................1108 Transmission Controller: Disagreement of Model Selection Signals............................................................1108 DAQRKR..........................................................................................................................1110 CAN Communication with Transmission Controller: Defective Communication.....................................................1110 DAQRMA..........................................................................................................................1114 Transmission Controller Option Setting: Malfunction.........................................................................1114 DB2RKR..........................................................................................................................1116 CAN Communication with Engine Controller: Defective Communication...........................................................1116 DB90KK..........................................................................................................................1120 Work Equipment Controller: Low Source Voltage (input).......................................................................1120 DB90KT..........................................................................................................................1122 Work Equipment Controller: Abnormality in Controller........................................................................1122 DB92KK..........................................................................................................................1124 Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)................................................1124 DB95KX..........................................................................................................................1126 Work Equipment Controller Power Supply Output: Out-of-Input Signal Range....................................................1126 DB99KQ..........................................................................................................................1130 Work Equipment Controller: Disagreement in Model Selection Signals..........................................................1130 DB9RKR..........................................................................................................................1132 CAN Communication with Work Equipment Controller: Defective Communication...................................................1132 DB9RMA..........................................................................................................................1136 Work Equipment Controller Option Setting: Malfunction.......................................................................1136 DB9RMC..........................................................................................................................1138 CAN Communication: Defective Operation......................................................................................1138 DD15LD..........................................................................................................................1142 Switch (Panel Switch 1 n): Switch is Pressed for Long Time..................................................................1142 DD16LD..........................................................................................................................1144 Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time..................................................................1144 DD17LD..........................................................................................................................1146 Switch (Panel Switch 3 <): Switch is Pressed for Long Time..................................................................1146 DD18LD..........................................................................................................................1148 Switch (Panel Switch 4 >): Switch is Pressed for Long Time..................................................................1148 DD1ALD..........................................................................................................................1150 Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time...........................................1150 DD1BLD..........................................................................................................................1152 Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time...........................................1152 DD1CLD..........................................................................................................................1154 Load Meter Subtotal Switch: Switch is Pressed for Long Time.................................................................1154 DD1FLD..........................................................................................................................1156 Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time......................................................1156 DD1GLD..........................................................................................................................1158 Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time......................................................1158 DD1HLD..........................................................................................................................1160 Load Meter Display Selector Switch: Switch is Pressed for Long Time.........................................................1160 DD1NLD..........................................................................................................................1162 Fan Reverse Switch: Switch is Pressed for Long Time.........................................................................1162 DD1NL4..........................................................................................................................1164 Fan Automatic Reverse Switch: Switch is Pressed for Long Time...............................................................1164 DDB6L4..........................................................................................................................1166 Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree.................................................................1166 DDD1LD..........................................................................................................................1170 Remote Positioner Bucket Angle Set Switch: Switch is Pressed for Long Time..................................................1170 DDE5MA..........................................................................................................................1172 Emergency Steering Drive Switch: Malfunction................................................................................1172 DDK3KA..........................................................................................................................1174 Right FNR Switch: Disconnection.............................................................................................1174 DDK4KA..........................................................................................................................1178 Joystick Steering FNR Switch: Disconnection.................................................................................1178 DDK5L4..........................................................................................................................1182 Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree.............................................................1182 DDK6KA..........................................................................................................................1184 FNR Lever Switch: Disconnection.............................................................................................1184 DDK6KB..........................................................................................................................1188 FNR Lever Switch: Short Circuit.............................................................................................1188 DDS5KA..........................................................................................................................1192 Steering Pressure Switch: Disconnection.....................................................................................1192 DDS5KB..........................................................................................................................1194 Steering Pressure Switch: Grounded..........................................................................................1194 DDS5L6..........................................................................................................................1196 Steering: Low Oil Pressure..................................................................................................1196 DDT0L4..........................................................................................................................1198 Shift Mode Selector Switch: ON/OFF Signals Disagree.........................................................................1198 DDT4LD..........................................................................................................................1200 Transmission Cutoff Set Switch: Switch is Pressed for Long Time.............................................................1200 DDW9LD..........................................................................................................................1202 Kickdown Switch: Switch is Pressed for Long Time............................................................................1202 DDWLLD..........................................................................................................................1204 Hold Switch: Switch is Pressed Down for Long Time...........................................................................1204 DDY0LD..........................................................................................................................1206 Load Meter Cancel Switch: Switch is Pressed for Long Time...................................................................1206 DF10KA..........................................................................................................................1208 Transmission Shift Lever Switch: Disconnection..............................................................................1208 DF10KB..........................................................................................................................1212 Transmission Shift Lever Switch: Short Circuit..............................................................................1212 DGF1KA..........................................................................................................................1216 Transmission Oil Temperature Sensor: Disconnection..........................................................................1216 DGF1KB..........................................................................................................................1218 Transmission Oil Temperature Sensor: Short Circuit..........................................................................1218 DGH2KX..........................................................................................................................1220 Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range.................................................................1220 DGR2KA..........................................................................................................................1222 Rear Brake Oil Temperature Sensor: Disconnection............................................................................1222 DGR2KX..........................................................................................................................1224 Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range...................................................................1224 DGT1KX..........................................................................................................................1226 Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range..........................................................1226 DH21KA..........................................................................................................................1228 Loader Pump Pressure Sensor: Disconnection..................................................................................1228 DH21KB..........................................................................................................................1230 Loader Pump Pressure Sensor: Power Supply Line Short........................................................................1230 DHPCKX..........................................................................................................................1232 Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range.........................................................1232 DHPDKX..........................................................................................................................1234 Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range...........................................................1234 DHT1KX..........................................................................................................................1236 Transmission Cutoff Pressure Sensor: Out-of-Input Signal....................................................................1236 DHT8KA..........................................................................................................................1238 Steering Pump Pressure Sensor: Disconnection................................................................................1238 DHT8KB..........................................................................................................................1240 Steering Pump Pressure Sensor: Short Circuit................................................................................1240 DK59KA..........................................................................................................................1242 Lift Arm EPC Lever Potentiometer (Main): Disconnection......................................................................1242 DK59KY..........................................................................................................................1246 Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...............................................1246 DK59L8..........................................................................................................................1250 Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree............................................................1250 DK5AKA..........................................................................................................................1254 Lift Arm EPC Lever Potentiometer (Sub): Disconnection.......................................................................1254 DK5AKY..........................................................................................................................1258 Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne................................................1258 DK5BKA..........................................................................................................................1262 Bucket EPC Lever Potentiometer (Main): Disconnection........................................................................1262 DK5BKY..........................................................................................................................1266 Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line.................................................1266 DK5BL8..........................................................................................................................1270 Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree..............................................................1270 DK5CKA..........................................................................................................................1274 Bucket EPC Lever Potentiometer (Sub): Disconnection.........................................................................1274 DK5CKY..........................................................................................................................1278 Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line..................................................1278 DK5FKA..........................................................................................................................1282 Joystick Steering EPC Lever Potentiometer (Main): Disconnection.............................................................1282 DK5FKY..........................................................................................................................1286 Joystick Steering EPC Lever Potentiometer (Main): Power Supply Line Short...................................................1286 DK5GKA..........................................................................................................................1290 Joystick Steering EPC Lever Potentiometer (Sub): Disconnection..............................................................1290 DK5GKY..........................................................................................................................1294 Joystick Steering EPC Lever Potentiometer (Sub): Power Supply Line Short....................................................1294 DK5FL8..........................................................................................................................1298 Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree...................................................1298 DKA0KA..........................................................................................................................1302 Lift Arm Angle Sensor: Disconnection........................................................................................1302 DKA0KY..........................................................................................................................1306 Lift Arm Angle Sensor: Short Circuit with Power Supply Line.................................................................1306 DKA0L0..........................................................................................................................1308 Lift Arm Angle Sensor: Double Meshing.......................................................................................1308 DLT3KA..........................................................................................................................1310 Transmission Output Shaft Speed Sensor: Disconnection.......................................................................1310 DLT3LC..........................................................................................................................1312 Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range...........................................................1312 DT20KB..........................................................................................................................1314 Transmission Cutoff Indicator Lamp: Short Circuit...........................................................................1314 DUM1KB..........................................................................................................................1316 Remote Positioner Raise Set Indicator Lamp: Short Circuit...................................................................1316 DUM2KB..........................................................................................................................1318 Remote Positioner Lower Set Indicator Lamp: Short Circuit...................................................................1318 DV00KB..........................................................................................................................1320 Alarm Buzzer: Short Circuit.................................................................................................1320 DW4PKA..........................................................................................................................1322 Lift Arm Raise EPC Solenoid: Disconnection..................................................................................1322 DW4PKB..........................................................................................................................1324 Lift Arm Raise EPC Solenoid: Short Circuit..................................................................................1324 DW4PKY..........................................................................................................................1326 Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line...........................................................1326 DW4QKA..........................................................................................................................1328 Lift Arm Lower EPC Solenoid: Disconnection..................................................................................1328 DW4QKB..........................................................................................................................1330 Lift Arm Lower EPC Solenoid: Short Circuit..................................................................................1330 DW4QKY..........................................................................................................................1332 Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line...........................................................1332 DW4RKA..........................................................................................................................1334 Bucket Tilt EPC Solenoid: Disconnection.....................................................................................1334 DW4RKB..........................................................................................................................1336 Bucket Tilt EPC Solenoid: Short Circuit.....................................................................................1336 DW4RKY..........................................................................................................................1338 Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line..............................................................1338 DW4SKA..........................................................................................................................1340 Bucket Dump EPC Solenoid: Disconnection.....................................................................................1340 DW4SKB..........................................................................................................................1342 Bucket Dump EPC Solenoid: Short Circuit.....................................................................................1342 DW4SKY..........................................................................................................................1344 Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line..............................................................1344 DW7BKA..........................................................................................................................1346 Fan Reverse Solenoid: Disconnection.........................................................................................1346 DW7BKB..........................................................................................................................1348 Fan Reverse Solenoid: Short Circuit.........................................................................................1348 DW7BKY..........................................................................................................................1350 Fan Reverse Solenoid: Short Circuit with Power Supply Line..................................................................1350 DW7DKA..........................................................................................................................1352 Hydraulic Drive Fan Neutral Solenoid: Disconnection.........................................................................1352 DW7DKB..........................................................................................................................1354 Hydraulic Drive Fan Neutral Solenoid: Short Circuit.........................................................................1354 DW7DKY..........................................................................................................................1356 Hydraulic Drive Fan Neutral Solenoid: Short Circuit with Power Supply Line..................................................1356 DWM1KA..........................................................................................................................1358 Work Equipment Neutral Lock Solenoid: Disconnection.........................................................................1358 DWM1KB..........................................................................................................................1360 Work Equipment Neutral Lock Solenoid: Short Circuit.........................................................................1360 DWM1KY..........................................................................................................................1362 Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line..................................................1362 DWN6KA..........................................................................................................................1364 Lift Arm Raise Magnet Detent Solenoid: Disconnection........................................................................1364 DWN6KB..........................................................................................................................1366 Lift Arm Raise Magnet Detent Solenoid: Short Circuit........................................................................1366 DWN6KY..........................................................................................................................1368 Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line.................................................1368 DWN7KA..........................................................................................................................1370 Lift Arm Float Magnet Detent Solenoid: Disconnection........................................................................1370 DWN7KB..........................................................................................................................1372 Lift Arm Float Magnet Detent Solenoid: Short Circuit........................................................................1372 DWN7KY..........................................................................................................................1374 Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line.................................................1374 DWN8KA..........................................................................................................................1376 Bucket Tilt Magnet Detent Solenoid: Disconnection...........................................................................1376 DWN8KB..........................................................................................................................1378 Bucket Tilt Magnet Detent Solenoid: Short Circuit...........................................................................1378 DWN8KY..........................................................................................................................1380 Bucket Tilt Magnet Detent Solenoid: Shorted with Power Source...............................................................1380 DX16KA..........................................................................................................................1382 Fan Pump EPC Solenoid: Disconnection........................................................................................1382 DX16KB..........................................................................................................................1384 Fan Pump EPC Solenoid: Short Circuit........................................................................................1384 DX16KY..........................................................................................................................1386 Fan Pump EPC Solenoid: Short Circuit with Power Supply Line.................................................................1386 DXH1KA..........................................................................................................................1388 Lockup ECMV Solenoid: Disconnection.........................................................................................1388 DXH1KB..........................................................................................................................1390 Lockup ECMV Solenoid: Short Circuit.........................................................................................1390 DXH1KY..........................................................................................................................1392 Lockup ECMV Solenoid: Short Circuit with Power Supply Line..................................................................1392 DXH4KA..........................................................................................................................1394 1st Clutch ECMV Solenoid: Disconnection.....................................................................................1394 DXH4KB..........................................................................................................................1396 1st Clutch ECMV Solenoid: Short Circuit.....................................................................................1396 DXH4KY..........................................................................................................................1398 1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1398 DXH5KA..........................................................................................................................1400 2nd Clutch ECMV Solenoid: Disconnection.....................................................................................1400 DXH5KB..........................................................................................................................1402 2nd Clutch ECMV Solenoid: Short Circuit.....................................................................................1402 DXH5KY..........................................................................................................................1404 2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1404 DXH6KA..........................................................................................................................1406 3rd Clutch ECMV Solenoid: Disconnection.....................................................................................1406 DXH6KB..........................................................................................................................1408 3rd Clutch ECMV Solenoid: Short Circuit.....................................................................................1408 DXH6KY..........................................................................................................................1410 3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1410 DXH7KA..........................................................................................................................1412 R Clutch ECMV Solenoid: Disconnection.......................................................................................1412 DXH7KB..........................................................................................................................1414 R Clutch ECMV Solenoid: Short Circuit.......................................................................................1414 DXH7KY..........................................................................................................................1416 R Clutch ECMV Solenoid: Short Circuit with Power Supply Line................................................................1416 DXH8KA..........................................................................................................................1418 F Clutch ECMV Solenoid: Disconnection.......................................................................................1418 DXH8KB..........................................................................................................................1420 F Clutch ECMV Solenoid: Short Circuit.......................................................................................1420 DXH8KY..........................................................................................................................1422 F Clutch ECMV Solenoid: Short Circuit with Power Supply Line................................................................1422 DXHHKA..........................................................................................................................1424 4th Clutch ECMV Solenoid: Disconnection.....................................................................................1424 DXHHKB..........................................................................................................................1426 4th Clutch ECMV Solenoid: Short Circuit.....................................................................................1426 DXHHKY..........................................................................................................................1428 4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1428 DXHLKA..........................................................................................................................1430 Joystick Steering Right EPC Solenoid: Disconnection.........................................................................1430 DXHLKB..........................................................................................................................1432 Joystick Steering Right EPC Solenoid: Short Circuit.........................................................................1432 DXHLKY..........................................................................................................................1434 Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line..................................................1434 DXHMKA..........................................................................................................................1436 Joystick Steering Left EPC Solenoid: Disconnection..........................................................................1436 DXHMKB..........................................................................................................................1438 Joystick Steering Left EPC Solenoid: Short Circuit..........................................................................1438 DXHMKY..........................................................................................................................1440 Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line...................................................1440 DY30MA..........................................................................................................................1442 Motor-Driven Emergency Steering Pump Failure (during Operation of machine)..................................................1442 DY30MC..........................................................................................................................1446 Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)...................................................1446 TROUBLESHOOTING: E-MODE.............................................................................................................1450 E-1.............................................................................................................................1456 Engine Does Not Start.......................................................................................................1456 E-2.............................................................................................................................1462 Wiper Does Not Operate......................................................................................................1462 E-3.............................................................................................................................1466 Windshield Washer Does Not Operate..........................................................................................1466 E-4.............................................................................................................................1470 Lamps Do Not Light Up or Go Off.............................................................................................1470 E-5.............................................................................................................................1478 Working Lamp Does Not Light Up or Go Off....................................................................................1478 E-6.............................................................................................................................1484 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off..................................................................1484 E-7.............................................................................................................................1492 Brake Lamp Does Not Light or It Keeps Lighting Up...........................................................................1492 E-8.............................................................................................................................1496 Backup Lamp Does Not Light or It Keeps Lighting Up..........................................................................1496 E-9.............................................................................................................................1500 Backup Buzzer Does Not Sound or It Keeps Sounding...........................................................................1500 E-10............................................................................................................................1504 Horn Does Not Sound or It Keeps Sounding....................................................................................1504 E-11............................................................................................................................1508 Alarm Buzzer Does Not Sound or It Keeps Sounding............................................................................1508 E-12............................................................................................................................1510 Air Conditioner Does Not Operate or Stop....................................................................................1510 E-13............................................................................................................................1514 KOMTRAX System Does Not Work Properly.......................................................................................1514 Indicator Lamps of KOMTRAX Terminal.....................................................................................1515 E-14............................................................................................................................1518 When Kickdown Switch is Turned ON, Kickdown Operation Does Not Start........................................................1518 E-15............................................................................................................................1520 When Hold Switch is Pressed, Holding Operation Does Not Start...............................................................1520 E-16............................................................................................................................1522 Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied...............1522 E-17............................................................................................................................1524 Transmission Cutoff Mode Cannot Be Set or Reset.............................................................................1524 E-18............................................................................................................................1526 Transmission Cutoff Set Cannot be Reset.....................................................................................1526 E-19............................................................................................................................1528 FN Switch Mode Cannot Be Set or Reset.......................................................................................1528 E-20............................................................................................................................1530 Fan Reverse Function Cannot Be Used or Reset................................................................................1530 E-21............................................................................................................................1532 Discharge from Loader Pump Does Not Rise from Minimum Level.................................................................1532 E-22............................................................................................................................1534 ECSS Function Cannot Be Used or Reset.......................................................................................1534 E-23............................................................................................................................1536 When Parking Brake is Turned On, Parking Brake Lamp Does Not Light Up.......................................................1536 E-24............................................................................................................................1540 When Emergency Brake Operates, Brake Oil Pressure Lamp Does Not Operate.....................................................1540 E-25............................................................................................................................1542 Air Cleaner Clogging Indicator Lamp Does Not Light Up.......................................................................1542 E-26............................................................................................................................1544 Radiator Coolant Level Caution Lamp Does Not Light Up.......................................................................1544 E-27............................................................................................................................1546 Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up..................1546 E-28............................................................................................................................1548 Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up....1548 E-29............................................................................................................................1550 Steering Oil Pressure Caution Lamp Does Not Light Up........................................................................1550 E-30............................................................................................................................1552 Abnormality in Switch (n) (Panel Switch 1) Input............................................................................1552 E-31............................................................................................................................1554 Abnormality in Switch (‡) (Panel Switch 2) Input............................................................................1554 E-32............................................................................................................................1556 Abnormality in Switch (<) (Panel Switch 3) Input............................................................................1556 E-33............................................................................................................................1558 Abnormality in Switch (>) (Panel Switch 4) Input............................................................................1558 Troubleshooting Electrical System...............................................................................................1450 Information in Troubleshooting Table........................................................................................1450 Installation Position of Fuses..............................................................................................1452 TROUBLESHOOTING: H-MODE.............................................................................................................1560 Troubleshooting Hydraulic and Mechanical Systems................................................................................1560 Using Troubleshooting Chart.................................................................................................1560 Failure Modes and Causes Table..................................................................................................1562 H-1.............................................................................................................................1566 Machine Does Not Start......................................................................................................1566 H-2.............................................................................................................................1570 Torque Converter Lockup is Not Switched OFF (Engine Stalls).................................................................1570 H-3.............................................................................................................................1571 Torque Converter Lockup is Not Switched ON..................................................................................1571 H-4.............................................................................................................................1572 Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted..........................1572 H-5.............................................................................................................................1576 Large Shocks When Starting and Shifting Gears...............................................................................1576 H-6.............................................................................................................................1580 Large Time Lag When Starting and Shifting Gear..............................................................................1580 H-7.............................................................................................................................1584 Torque Converter Oil Temperature is High....................................................................................1584 H-8.............................................................................................................................1585 Steering Does Not Turn......................................................................................................1585 H-9.............................................................................................................................1586 Steering Does Not Turn (Joystick Steering, if equipped).....................................................................1586 H-10............................................................................................................................1587 Steering Response is Poor...................................................................................................1587 H-11............................................................................................................................1588 Steering, Turning Response is Poor (Joystick Steering, if Equipped).........................................................1588 H-12............................................................................................................................1589 Steering is Heavy...........................................................................................................1589 H-13............................................................................................................................1590 When Machine Turns, It Shakes or Jerks......................................................................................1590 H-14............................................................................................................................1591 When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped).....................................................1591 H-15............................................................................................................................1592 Wheel Brake Does Not Work or Does Not Work Well.............................................................................1592 H-16............................................................................................................................1593 Wheel Brake is Not Released or It Drags.....................................................................................1593 H-17............................................................................................................................1594 Parking Brake Does Not Work or Does Not Work Well...........................................................................1594 H-18............................................................................................................................1595 Parking Brake is Not Released or It Drags...................................................................................1595 H-19............................................................................................................................1596 Lift Arm Does Not Rise......................................................................................................1596 H-20............................................................................................................................1597 Lift Arm Speed is Low or Rising Force is Insufficient.......................................................................1597 H-21............................................................................................................................1598 When Rising, Lift Arm Starts to Move Slowly at a Specific Height............................................................1598 H-22............................................................................................................................1598 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)...................................................................1598 H-23............................................................................................................................1598 Hydraulic Drifts of the Lift Arm Are Large..................................................................................1598 H-24............................................................................................................................1599 Lift Arm Wobbles During Operation...........................................................................................1599 H-25............................................................................................................................1600 Bucket Does Not Tilt Back...................................................................................................1600 H-26............................................................................................................................1601 Bucket Speed is Low or Tilting-Back Force Is Insufficient...................................................................1601 H-27............................................................................................................................1602 Bucket Starts to Operate Slowly in the Midst of Tilting Back................................................................1602 H-28............................................................................................................................1602 Bucket Cylinder Cannot Hold Down the Bucket.................................................................................1602 H-29............................................................................................................................1602 Hydraulic Drifts of the Bucket Are Large....................................................................................1602 H-30............................................................................................................................1603 Bucket Wobbles During Travel with Load......................................................................................1603 H-31............................................................................................................................1604 Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy.......................................................1604 H-32............................................................................................................................1605 During Operation of Machine, Engine Speed Drops Drastically or Engine Stalls................................................1605 H-33............................................................................................................................1605 Large Shocks When Work Equipment Starts and Stops...........................................................................1605 H-34............................................................................................................................1605 When Work Equipment Circuit is Relieved Individually, Other Work Equipment Moves............................................1605 H-35............................................................................................................................1606 ECSS Does Not Operate - Pitching and Bouncing Occur.........................................................................1606 TROUBLESHOOTING: S-MODE.............................................................................................................1607 Troubleshooting Engine..........................................................................................................1607 Using Troubleshooting Charts................................................................................................1607 S-1.............................................................................................................................1610 Engine Does Not Start Easily................................................................................................1610 S-2.............................................................................................................................1612 Engine Does Not Start.......................................................................................................1612 S-3.............................................................................................................................1616 Engine Does Not Pick Up Smoothly............................................................................................1616 S-4.............................................................................................................................1618 Engine Stops During Operation...............................................................................................1618 S-5.............................................................................................................................1620 Engine Does Not Rotate Smoothly.............................................................................................1620 S-6.............................................................................................................................1622 Engine Lacks Output (or Lacks Power)........................................................................................1622 S-7.............................................................................................................................1624 Exhaust Smoke is Black (Incomplete Combustion)..............................................................................1624 S-8.............................................................................................................................1626 Oil Consumption is Excessive (or Exhaust Smoke is Blue).....................................................................1626 S-9.............................................................................................................................1627 Engine Oil Becomes Contaminated Quickly.....................................................................................1627 S-10............................................................................................................................1628 Fuel Consumption is Excessive...............................................................................................1628 S-11............................................................................................................................1629 Coolant Contains Oil (Blows Back or Reduces)................................................................................1629 S-12............................................................................................................................1630 Oil Pressure Drops..........................................................................................................1630 S-13............................................................................................................................1631 Oil Level Rises (Water, Fuel in Oil)........................................................................................1631 S-14............................................................................................................................1632 Coolant Temperature Rises Too High (Overheating)............................................................................1632 S-15............................................................................................................................1634 Abnormal Noise is Made......................................................................................................1634 S-16............................................................................................................................1636 Vibration is Excessive......................................................................................................1636 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1637 HOW TO READ THIS MANUAL.............................................................................................................1640 Removal and Installation of Assemblies..........................................................................................1640 Disassembly and Assembly of Assemblies..........................................................................................1642 COATING MATERIALS LIST..............................................................................................................1644 SPECIAL TOOLS LIST..................................................................................................................1648 SKETCHES OF SPECIAL TOOLS...........................................................................................................1654 CONNECTOR REPAIR PROCEDURES.........................................................................................................1667 Stripping Insulation............................................................................................................1667 Wire Inspection.................................................................................................................1667 Contact Terminal Removal (HD30 Type)............................................................................................1668 Crimping Contact Terminal (HD30 Type)...........................................................................................1669 Insertion Of Contact Terminal (HD30 Type).......................................................................................1670 Contact Terminal Removal (DT Type)..............................................................................................1671 Crimping Contact Terminal (DT Type).............................................................................................1672 Insertion Of Contact Terminal (DT Type).........................................................................................1673 ENGINE AND COOLING SYSTEM...........................................................................................................1674 Cylinder Head...................................................................................................................1674 Removal.....................................................................................................................1674 Installation................................................................................................................1684 Engine Hood and Radiator Guard..................................................................................................1692 Removal.....................................................................................................................1692 Installation................................................................................................................1694 Radiator........................................................................................................................1695 Removal.....................................................................................................................1695 Installation................................................................................................................1697 Air Aftercooler.................................................................................................................1698 Removal.....................................................................................................................1698 Installation................................................................................................................1699 Hydraulic Oil Cooler............................................................................................................1700 Removal.....................................................................................................................1700 Installation................................................................................................................1700 Engine..........................................................................................................................1701 Removal.....................................................................................................................1701 Installation................................................................................................................1707 Front Seal......................................................................................................................1708 Removal.....................................................................................................................1708 Installation................................................................................................................1710 Rear Oil Seal...................................................................................................................1711 Removal.....................................................................................................................1711 Installation................................................................................................................1712 Cooling Fan and Fan Motor.......................................................................................................1716 Removal.....................................................................................................................1716 Installation................................................................................................................1720 FUEL SUPPLY SYSTEM..................................................................................................................1721 Fuel Supply Pump................................................................................................................1721 Removal.....................................................................................................................1721 Installation................................................................................................................1724 Fuel Injector...................................................................................................................1725 Removal.....................................................................................................................1725 Installation................................................................................................................1730 Fuel Tank.......................................................................................................................1737 Removal.....................................................................................................................1737 Installation................................................................................................................1739 POWER TRAIN.........................................................................................................................1740 Torque Converter and Transmission Assembly......................................................................................1740 Removal.....................................................................................................................1740 Installation................................................................................................................1746 Torque Converter (Standard Specification).......................................................................................1747 Disassembly.................................................................................................................1747 Assembly....................................................................................................................1749 Torque Converter (Lockup Specification).........................................................................................1752 Disassembly.................................................................................................................1752 Assembly....................................................................................................................1755 Transmission....................................................................................................................1760 Disassembly.................................................................................................................1760 Assembly....................................................................................................................1768 Transmission Clutch Pack........................................................................................................1778 Forward and Reverse Clutch Packs: Disassembly...............................................................................1778 1st and 4th Clutch Pack: Disassembly........................................................................................1781 2nd and 3rd Clutch Pack: Disassembly........................................................................................1784 Forward and Reverse Clutch Packs: Assembly..................................................................................1787 1st and 4th Clutch Pack: Assembly...........................................................................................1791 2nd and 3rd Clutch Pack: Assembly...........................................................................................1795 Parking Brake...................................................................................................................1799 Disassembly.................................................................................................................1799 Assembly....................................................................................................................1802 Front Axle......................................................................................................................1808 Removal.....................................................................................................................1808 Installation................................................................................................................1809 Rear Axle.......................................................................................................................1810 Removal.....................................................................................................................1810 Installation................................................................................................................1813 Axle Housing....................................................................................................................1815 Disassembly.................................................................................................................1815 Assembly....................................................................................................................1820 Differential....................................................................................................................1827 Disassembly.................................................................................................................1827 Assembly....................................................................................................................1836 STEERING SYSTEM.....................................................................................................................1852 Steering Demand Valve...........................................................................................................1852 Removal.....................................................................................................................1852 Installation................................................................................................................1854 BRAKE SYSTEM........................................................................................................................1856 Parking Brake Disc and Plate....................................................................................................1856 Removal.....................................................................................................................1856 Installation................................................................................................................1859 UNDERCARRIAGE AND FRAME.............................................................................................................1860 Center Hinge Pin................................................................................................................1860 Removal.....................................................................................................................1860 Installation................................................................................................................1866 Counterweight...................................................................................................................1871 Removal.....................................................................................................................1871 Installation................................................................................................................1873 HYDRAULIC SYSTEM....................................................................................................................1874 Work Equipment Control Valve....................................................................................................1874 Removal.....................................................................................................................1874 Installation................................................................................................................1877 Power Train Pump and Work Equipment Pump Assembly...............................................................................1878 Removal.....................................................................................................................1878 Installation................................................................................................................1879 Steering Pump and Cooling Fan Pump Assembly.....................................................................................1880 Removal.....................................................................................................................1880 Installation................................................................................................................1881 Hydraulic Tank..................................................................................................................1882 Removal.....................................................................................................................1882 Installation................................................................................................................1884 WORK EQUIPMENT......................................................................................................................1886 Work Equipment Assembly.........................................................................................................1886 Removal.....................................................................................................................1886 Installation................................................................................................................1890 Hydraulic Cylinder..............................................................................................................1892 Disassembly.................................................................................................................1892 Assembly....................................................................................................................1897 CAB AND ATTACHMENTS.................................................................................................................1902 Cab and Floor Frame.............................................................................................................1902 Removal.....................................................................................................................1902 Installation................................................................................................................1906 Cab Glass (Stuck Glass).........................................................................................................1907 Removal.....................................................................................................................1907 Installation................................................................................................................1908 Operator Seat Assembly (Standard Specification) (ISRING HAUSEN).................................................................1916 Disassembly.................................................................................................................1916 Assembly....................................................................................................................1923 Operator Seat Assembly (GRAMMER)................................................................................................1929 Upper Seat..................................................................................................................1929 Suspension..................................................................................................................1937 AIR CONDITIONER UNIT ASSEMBLY.......................................................................................................1965 Removal.........................................................................................................................1965 Installation....................................................................................................................1970 ELECTRICAL SYSTEM...................................................................................................................1971 Engine Controller Assembly......................................................................................................1971 Removal.....................................................................................................................1971 Installation................................................................................................................1971 KOMTRAX Terminal Assembly.......................................................................................................1972 Removal.....................................................................................................................1972 Installation................................................................................................................1972 90 DIAGRAMS AND SCHEMATICS..............................................................................................................1973 AUTOMATIC GREASING..................................................................................................................1975 Automatic Greasing Circuit Diagram..............................................................................................1975 HYDRAULIC SYSTEM....................................................................................................................1976 Power Train Hydraulic Circuit Diagram...........................................................................................1976 Without Lockup Clutch.......................................................................................................1976 With Lockup Clutch..........................................................................................................1977 Hydraulic Circuit Diagram.......................................................................................................1978 ELECTRICAL SYSTEM...................................................................................................................1979 Electrical Circuit Diagram (1/14)...............................................................................................1979 Electrical Circuit Diagram (2/14)...............................................................................................1980 Electrical Circuit Diagram (3/14)...............................................................................................1981 Electrical Circuit Diagram (4/14)...............................................................................................1982 Electrical Circuit Diagram (1/14)...............................................................................................1983 Electrical Circuit Diagram (6/14)...............................................................................................1984 Electrical Circuit Diagram (7/14)...............................................................................................1985 Electrical Circuit Diagram (8/14)...............................................................................................1986 Electrical Circuit Diagram (9/14)...............................................................................................1987 Electrical Circuit Diagram (10/14)..............................................................................................1988 Electrical Circuit Diagram (11/14)..............................................................................................1989 Electrical Circuit Diagram (12/14)..............................................................................................1990 Electrical Circuit Diagram (13/14)..............................................................................................1991 Electrical Circuit Diagram (14/14)..............................................................................................1992 Work Equipment Controller System Electrical Circuit Diagram.....................................................................1993 Connector List and Stereogram...................................................................................................1994 Chassis.....................................................................................................................1994 Operator's Compartment......................................................................................................1995 Engine and Transmission.....................................................................................................1996
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
