Komatsu WA430-6 Wheel Loader Shop Manual CEBM008201 PDF

Description

Komatsu WA430-6 Wheel Loader Shop Manual CEBM008201 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA430-6 Wheel Loader Shop Manual CEBM008201 – PDF DOWNLOAD 

Language : English
Pages : 1996
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA430-6 Wheel Loader Shop Manual CEBM008201 – PDF DOWNLOAD 

SERIAL NUMBERS WA430-6 A42001-UP
ENGINE SAA6D114E-3

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu WA430-6 Wheel Loader Shop Manual CEBM008201 – PDF DOWNLOAD 

SERIAL NUMBERS WA430-6 A42001-UP
ENGINE SAA6D114E-3

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

S.V 15/12/24