Komatsu WA430-6 Wheel Loader Shop Manual CEBM019402 PDF

Description

Komatsu WA430-6 Wheel Loader Shop Manual CEBM019402 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA430-6 Wheel Loader Shop Manual CEBM019402 – PDF DOWNLOAD

Language : English
Pages : 1975
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA430-6 Wheel Loader Shop Manual CEBM019402 – PDF DOWNLOAD 

SERIAL NUMBERS WA430-6 A41001 and UP

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 CEBM019402 – PDF DOWNLOAD 

SERIAL NUMBERS WA430-6 A41001 and UP

CEBM019402 – WA430-6 sn A41001 and UP 1
CONTENTS 2
REVISED PAGES 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 ANDMAINTENANCE STANDARD 73
ENGINE AND COOLING SYSTEM 79
Engine and Transmission Mount 79
Cooling System 81
Cooling Fan Pump 81
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 312
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 376
Functions of Major Components 377
Blower and Intake Unit 379
Functions of Major Components 380
Compressor 381
Condenser 382
Receiver 383
Automatic Air Conditioner Panel 384
ELECTRICAL SYSTEM 389
Machine Monitor System 389
System Circuit Diagram 391
Monitor Display Functions 394
Speedometer Specification 394
List of Items Displayed on Monitor 396
Machine Monitor Operation Switches 405
Setting the Machine Monitor 406
Troubleshooting Function 407
Character Display Function 407
Operator Mode Functions 408
Service Mode Functions 411
Input And Output Signals 416
Transmission Controller System 424
Transmission Controller Gearshifting Control Function 424
Cooling Fan Control Function 448
ECSS Function 458
Electric Emergency Steering Function (if equipped) 460
Power Train Pump Bypass Control Function (if equipped) 463
Directional Selector Switch Control Function (if equipped) 464
Multi-Function Mono Lever Function (if equipped) 467
Joystick Steering Function (if equipped) 470
Transmission Controller 477
Work Equipment Controller System 481
Work Equipment Controller 487
ELECTRONIC TRANSMISSION CONTROL 490
Combination Switch 492
Kickdown and Hold Switch 494
Multi-Function Knob (if equipped) 495
Joystick Steering Knob (if equipped) 496
KOMTRAX Terminal System 497
Engine Starting Circuit 500
Engine Stopping Circuit 502
Preheating Circuit 503
Engine Power Mode Selector Circuit 504
Engine Output Derating Function 505
Automatic Warm-up Function 505
Parking Brake Circuit 506
Sensors 508
Speed Sensor 508
Torque Converter Oil Temperature Sensor 509
Hydraulic Oil Temperature Sensor 509
Transmission Oil Temperature Sensor 509
Brake Oil Temperature Sensor 509
Work Equipment Pump Oil Pressure Sensor 510
Steering Pump Oil Pressure Sensor 510
Transmission Cutoff Oil Pressure Sensor 511
Coolant Level Sensor 512
Fuel Level Sensor 513
Air Cleaner Clogging Sensor 514
Water-In Fuel Sensor 515
Accelerator Pedal Sensor 516
Boom Kickout Proximity Switch 517
Bucket Positioner Proximity Switch 517
20 STANDARD VALUE TABLES 519
STANDARD VALUE TABLE FOR ENGINE 521
STANDARD VALUE TABLE FOR CHASSIS 522
MACHINE POSTURE 529
30 TESTING AND ADJUSTING 531
TOOLS 537
ENGINE COMPONENTS 543
Engine Speed 543
Measure Engine Speed (Low and High Idle) 543
Measure Torque Converter Stall Speed 543
Measure Hydraulic Stall Speed 544
Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed 545
Exhaust Gas Color 546
Using Handy Smoke Checker A1 546
Using Smoke Meter A2 546
Exhaust Temperature 548
Adjusting Valve Clearance 550
Measuring Engine Compression 553
Measuring Blow-by Pressure 557
Measuring Engine Oil Pressure 559
Intake Air (Boost) Pressure 560
FUEL SYSTEM 562
Handling Fuel System Equipment 562
Releasing Residual Pressure in Fuel System 562
Measuring Fuel Pressure 563
Measuring Fuel Negative Pressure Circuit Pressure (Fuel Supply Connector) 563
Measuring Fuel Negative Pressure Circuit Pressure (Supply Pump) 564
Measuring Fuel Low-Pressure Circuit Pressure (Fuel Filter Inlet Side) 565
Measuring Fuel Low-Pressure Circuit Pressure (Fuel Filter Outlet Side) 566
Measuring Drop of Fuel Low-Pressure Circuit Pressure 567
Fuel Return and Leak Rate 568
Measuring Return Rate from Supply Pump 568
Measuring Leakage from Pressure Limiter 569
Measuring Return Rate from Injector 570
Bleeding Air from Fuel Circuit 571
Testing Leakage in Fuel System 573
Handling Reduced Cylinder Mode Operation 574
Handling No-Injection Cranking Operation 574
Handling Controller Voltage Circuit 574
EXHAUST SYSTEM AND PIPING 575
Checking Muffler and Muffler Stack for Looseness and Damage 575
Checking Muffler Function 575
Checking Installed Condition of Cylinder Head and Manifolds 575
Checking Engine Piping for Damage and Looseness 575
BELTS 576
Air Conditioner Compressor Belt 576
Testing the Tension 576
Adjusting the Tension 576
Replacing Alternator Belt 577
TRANSMISSION SPEED SENSOR 578
LEVERS 579
Adjusting Directional Lever Length 579
Adjusting Gearshift Lever Length 579
Testing Directional Lever 580
POWER TRAIN OIL PRESSURES 581
Measuring 583
Transmission Main Relief Pressure 584
Torque Converter Relief Pressure (Inlet Pressure) 585
Torque Converter Outlet Pressure 586
F (Forward) Clutch Pressure 587
R (Reverse) Clutch Pressure 588
1st Clutch Pressure 589
2nd Clutch Pressure 590
3rd Clutch Pressure 591
4th Clutch Pressure 592
Lubrication Pressure 593
Adjusting 594
Transmission Main Relief Valve 594
FLUSHING TRANSMISSION SYSTEM 595
Torque Converter and Hydraulic Circuit 595
WHEN TRANSMISSION VALVE FAILS 597
AXLE FINAL DRIVE 599
DRIVE SHAFTS 600
STEERING SYSTEM 601
Steering Stop Valve 601
Testing 601
Steering Wheel 603
Measuring Play In Steering Wheel 603
Measuring Operating Effort of Steering Wheel 604
Measuring Operating Time of Steering Wheel 605
Steering Oil Pressure 606
Measuring Steering Relief Pressure 607
Measuring Steering Pilot Circuit Pressure 608
Adjusting Steering Relief Pressure 609
Adjusting Steering Control Circuit Pressure 609
Bleeding Air from Steering Circuit 610
Bleeding Air from Steering Pump 610
Bleeding Air from Steering Cylinder Circuit 610
HYDRAULIC DRIVE FAN 611
Measuring Fan Speed 611
Measuring Fan Drive Oil Pressure 612
Bleeding Air from Hydraulic Drive Fan Circuit 613
Bleeding Air from Fan Pump 613
Bleeding Air from Fan Motor Circuit 614
WHEEL BRAKE SYSTEM 615
Brake Pedal 615
Measuring Pressing Angle of Pedal 615
Brake Pedal Linkage 616
Testing 616
Adjusting 616
Measuring Brake Performance 617
Accumulator Charge Pressure 618
Measuring 618
Adjusting 619
Measuring Brake Oil Pressure 620
Testing Wear of Wheel Brake Disc 623
Bleeding Air from Brake Circuit 624
Releasing Residual Pressure in Brake Accumulator Circuit 625
PARKING BRAKE SYSTEM 626
Testing Parking Brake Performance 626
Measuring Parking Brake Oil Pressure 627
Checking Wear of Parking Brake Disc 629
Releasing Parking Brake Manually 630
WORK EQUIPMENT 631
Work Equipment Control Levers 631
Operating Effort of Work Equipment Control Lever 631
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 635
Work Equipment Oil Pressure 636
Preparation Work 636
Measuring Work Equipment Relief Pressure 637
Measuring Unload Pressure 638
Measuring Work Equipment LS Differential Pressure 639
Adjusting Work Equipment Relief Pressure 640
Adjusting Unload Pressure 640
Adjusting LS Differential Pressure 640
Bleeding Air from Work Equipment Circuit 641
From Work Equipment Pump (Piston Pump) 641
From Hydraulic Cylinder 641
Releasing Residual Pressure in Work Equipment Circuit 642
From the Circuit between Hydraulic Cylinders and Control Valve 642
From ECSS (Travel Damper) Circuit 642
Work Equipment Positioners 644
Testing and Adjusting Bucket Positioner 644
Testing and Adjusting Boom Kickout 645
Proximity Switch Operation Pilot Lamp 646
ELECTRICAL SYSTEM 647
Troubleshooting 647
Procedure for Testing Diodes 647
Preparation for Troubleshooting Electric System 649
Machine Monitor 649
Transmission Controller 650
Work Equipment Controller (if equipped) 651
KOMTRAX Terminal 651
Sensors 652
Ambient Pressure Sensor (AMBAIR PRESSURE) 652
Engine Ne Speed Sensor (CRANK SENSOR) 652
Engine Bkup Speed Sensor (CAM SENSOR) 652
Engine Oil Pressure Switch (OIL PRESSURE SWITCH) 652
Boost Pressure And Temperature Sensor (BOOST PRESS & IMT) 652
Supply Pump IMV Solenoid (FUEL REGULATOR) 653
Common Rail Pressure Sensor (FUEL RAIL PRESS) 653
Engine Coolant Temperature Sensor (COOLANT TEMP) 654
KOMTRAX TERMINAL SYSTEM 655
Terminal Installed at Plant Before Shipment 655
Terminal Retrofitted on Machine After Shipment 655
Starting Operation 655
KOMTRAX Terminal Lamps 660
7-segment and Dot Displays for CPU 662
MACHINE MONITOR SYSTEM 663
Adjusting Machine Monitor 663
Adjusting for Replaced, Reassembled, or Added Sensor/Controller 664
Adjustment for User’s Needs 665
Special Functions of Machine Monitor (EMMS) 666
Normal Functions and Special Functions of Machine Monitor 666
Functions and Flow of Service Mode 667
Operator Mode 670
Service Meter/Clock Display Function (1) 670
Load Meter Function (2) (if equipped) 670
Odometer Display Function (3) 670
Maintenance Monitoring Function (4) 671
Telephone Number Input Function (5) 671
Language Selection Function (6) 671
Monitor Brightness Adjustment Function (7) 671
Time Adjustment Function (8) 672
Travel Speed/Engine Speed Display Selecting Function (9) 672
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10) 672
Action Code Display Function (11) 673
Failure Code Display Function (12) 673
Service Mode 675
Switching to Service Mode and Screen Display (1) 675
Electrical System Fault History Display Function (ELECTRIC FAULT) (2) 677
Mechanical System Fault History Display Function (MACHINE FAULT) (3) 679
Real-Time Monitoring Function (REAL-TIME MONITOR) (4) 680
Real-Time Monitoring Codes Tables 684
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5) 713
No-Injection Cranking Function (NO INJECTION) (6) 714
Adjustment Function (TUNING) (7) 715
Maintenance Monitoring Function (MAINTENANCE MONITOR) (8) 733
Operating Information Display Function (OPERATION INFO) (9) 739
Optional Device Selecting Function (OPTIONAL SELECT) (10) 742
Machine Serial Number Input Function (MACHINE NO SET) (11) 746
Model Select Function (MACHINE) (12) 747
Initialize Function (13) 748
PM-CLINIC INSPECTION TABLE 749
40 TROUBLESHOOTING 755
TROUBLESHOOTING POINTS 771
TROUBLESHOOTING EVENTS 773
MAINTENANCE PRECAUTIONS 774
Precautions when Handling Electrical Equipment 774
Handling Electronic Control Unit 779
Points to Remember when Troubleshooting Electrical Circuits 780
ELECTRIC WIRE CODE 781
How to Read Electric Wire Code 781
Type, Symbol, and Material 781
Dimensions 782
Color Codes Table 783
Circuits and Color Codes 784
HANDLING HYDRAULIC EQUIPMENT 785
CHECKS BEFORE TROUBLESHOOTING 787
Categories and Method of Using Troubleshooting Charts 788
Troubleshooting Individual Electrical Circuits 789
Chart Use 791
Chart Tips 791
Troubleshooting Individual Hydraulic Circuits 792
CONNECTOR PIN NUMBERS 794
Connection Tables for Connector Pin Numbers 794
X-Type Connectors 794
SWP-Type Connectors 796
M-Type Connectors 798
S-Type Connectors 800
MIC-Type Connectors 802
AMP040-Type Connectors 804
AMP070-Type Connectors 806
AMP Connector 808
L-Type Connector 808
PA-Type Connector 809
Bendix (MS) Connector 809
KES1 (Automobile) Connectors 810
F-Type Connector 811
Connectors for Relay (Socket-Type) 812
HD30 Series Connectors 813
DT Series Connectors 819
DTM Series Connectors 821
DTHD Series Connectors 821
DTP Series Connectors 822
DRC26 Series Connectors 823
DRC12, 16 Series Connectors 825
AMP Connectors for Pump Controller (CH700) 826
BOSCH Connectors for Engine 827
SUMITOMO Connectors for Engine 828
CANNON Connector for Engine 829
AMP Connectors for Engine 830
FRAMATOME Connectors for Engine 831
PACKARD Connectors for Engine 833
DT Series Connectors for Engine 834
T-BRANCH BOXES and ADAPTERS 835
T-Branch Box and T-Branch Adapter Table 835
MODE CHART 840
INFORMATION IN TESTING PROCEDURES 843
TROUBLESHOOTING BY FAILURE CODE 845
Failure Codes Table 845
FUSE BOX AND SLOW-BLOW FUSES 858
Connection Table 858
Fuse Box 1 858
Fuse Box 2 859
Slow-Blow Fuses 859
FAILURE CODES 861
1500L0 862
TORQFLOW Transmission: Double Meshing 862
15SAL1 864
ECMV F Clutch: When Command Current is OFF, Fill Signal is ON 864
15SALH 866
ECMV F Clutch: When Command Current is ON, Fill Signal is OFF 866
15SBL1 868
ECMV R Clutch: When Command Current is OFF, Fill Signal is ON 868
15SBLH 870
ECMV R Clutch: When Command Current is ON, Fill Signal is OFF 870
15SEL1 872
ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON 872
15SELH 874
ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF 874
15SFL1 876
ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON 876
15SFLH 878
ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF 878
15SGL1 880
ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON 880
15SGLH 882
ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF 882
15SHL1 884
ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON 884
15SHLH 886
ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF 886
2F00MA 888
Parking Brake: Malfunction 888
2G43ZG 890
Accumulator: Low Oil Pressure 890
44K0L4 892
Bucket Positioner: ON/OFF Signals Disagree 892
AA1ANX 896
Air Cleaner: Clogging 896
AB00L6 898
Alternator: Signal Disagrees with Operating State of Engine 898
AB00MA 900
Alternator: Malfunction 900
B@BAZG 902
Rotation Derating by Low Engine Oil Pressure 902
B@BAZK 904
Engine Oil: Low Level 904
B@BCNS 906
Coolant: Overheating 906
B@BCZK 908
Coolant: Low Level 908
B@BEBF 910
Water in Fuel Error 910
B@C7NS 912
Brake Oil: Overheating 912
b@CENS 914
Torque Converter Oil: Overheating 914
B@CENS 916
Torque Converter Oil: Overheating 916
B@HANS 918
Hydraulic Oil: Overheating 918
CA111 920
Abnormality in Engine Controller 920
CA115 922
Engine Ne or Bkup Speed Sensor Error 922
CA122 924
Charge Pressure Sensor High Error 924
CA123 926
Charge Pressure Sensor Low Error 926
CA131 928
Throttle Sensor High Error 928
CA132 930
Throttle Sensor Low Error 930
CA144 932
Coolant Sensor High Error 932
CA145 934
Coolant Sensor Low Error 934
CA153 936
Charge Temperature Sensor High Error 936
CA154 938
Charge Temperature Sensor Low Error 938
CA155 940
Derating of Speed by Abnormally High Charge Temperature 940
CA187 942
Sensor Power Supply 2 Low Error 942
CA221 944
Atmospheric Pressure Sensor High Error 944
CA222 946
Atmospheric Pressure Sensor Low Error 946
CA227 948
Sensor Power Supply 2 High Error 948
CA234 950
Engine Overspeed 950
CA238 952
Ne Speed Sensor Power Supply Error 952
CA271 954
IMV/PCV1 Short Circuit 954
CA272 956
IMV/PCV1 Disconnection 956
CA281 958
High Pressure Pump Error 958
CA322 960
Injector #1 Open/Short Error 960
CA323 962
Injector #5 Open/Short Error 962
CA324 964
Injector #3 Open/Short Error 964
CA325 966
Injector #6 Open/Short Error 966
CA331 968
Injector #2 Open/Short Error 968
CA332 970
Injector #4 Open/Short Error 970
CA342 972
Calibration Code Inconsistency 972
CA351 974
Injectors Drive Circuit Error 974
CA352 976
Sensor Power Supply 1 Low Error 976
CA386 978
Sensor Power Supply 1 High Error 978
CA428 980
Abnormally High Level in Water Sensor 980
CA429 982
Abnormally Low Level in Water Sensor 982
CA431 984
Idle Validation Switch Error 984
CA432 986
Idle Validation Action Error 986
CA435 988
Engine Oil Pressure Switch Error 988
CA441 990
Battery Voltage Low Error 990
CA442 994
Battery Voltage High Error 994
CA449 996
Common Rail Pressure High Error 2 996
CA451 1000
Common Rail Pressure Sensor High Error 1000
CA452 1002
Common Rail Pressure Sensor Low Error 1002
CA488 1004
Derating of Torque by Abnormally High Charge Temperature 1004
CA553 1006
Common Rail Pressure High Error 1 1006
CA559 1008
Supply Pump Pressure Very Low Error 1008
CA689 1010
Engine Ne Speed Sensor Error 1010
CA731 1012
Engine Bkup Speed Sensor Phase Error 1012
CA757 1014
All Continuous Data Lost Error 1014
CA778 1018
Engine Bkup Speed Sensor Error 1018
CA1633 1020
KOMNET Datalink Timeout Error 1020
CA2185 1022
Throttle Sensor Power Supply Voltage High Error 1022
CA2186 1024
Throttle Sensor Power Supply Voltage Low Error 1024
CA2249 1026
Supply Pump Pressure Very Low Error 2 1026
CA2265 1028
Abnormally High Level in Electric Lift Pump 1028
CA2266 1030
Abnormally Low Level in Electric Lift Pump 1030
CA2311 1032
Abnormality in IMV Solenoid 1032
CA2555 1034
Intake Heater Relay Disconnection Error 1034
CA2556 1036
Intake Heater Relay Short Circuit Error 1036
D150KA 1038
Emergency Steering Relay: Disconnection 1038
D150KB 1040
Emergency Steering Relay: Short Circuit 1040
D150KY 1042
Emergency Steering Relay: Short Circuit with Power Supply Line 1042
D160KA 1044
Backup Lamp Relay: Disconnection 1044
D160KB 1046
Backup Lamp Relay: Short Circuit 1046
D160KZ 1048
Backup Lamp Relay: Disconnection or Short Circuit 1048
D191KA 1050
Joystick Steering Neutral Safety Relay: Disconnection 1050
D191KB 1052
Joystick Steering Neutral Safety Relay: Short Circuit 1052
D191KY 1054
Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line 1054
D192KA 1056
ECSS Solenoid: Disconnection 1056
D192KB 1058
ECSS Solenoid: Short Circuit 1058
D192KY 1060
ECSS Solenoid: Short Circuit with Power Supply Line 1060
D193KA 1062
Joystick Steering Solenoid Cutout Relay: Disconnection 1062
D193KB 1064
Joystick Steering Solenoid Cutout Relay: Short Circuit 1064
D193KY 1066
Joystick Steering Solenoid Cutout Relay: Short Circuit with Power Supply Line 1066
D5ZHKA 1068
Terminal C Signal: Disconnection 1068
D5ZHKB 1072
Terminal C Signal: Short Circuit 1072
D5ZHKZ 1076
Terminal C Signal: Disconnection or Short Circuit 1076
D5ZHL6 1080
Terminal C Signal: Signal Does Not Match Engine Running or Stopped State 1080
DA80L4 1084
Auto-Grease Controller: ON/OFF Signals Disagree 1084
DAF3KK 1086
Machine Monitor: Low Source Voltage (input) 1086
DAF5KP 1088
Machine Monitor: Low Output Voltage 1088
DAFRKR 1092
Machine Monitor: CAN Defective Communication 1092
DAQ0KK 1096
Transmission Controller: Low Source Voltage 1096
DAQ0KT 1098
Transmission Controller: Abnormality in Controller 1098
DAQ2KK 1100
Transmission Controller Load Power Supply Line: Low Source Voltage (input) 1100
DAQ9KQ 1102
Transmission Controller: Disagreement of Model Selection Signals 1102
DAQRKR 1104
CAN Communication with Transmission Controller: Defective Communication 1104
DAQRMA 1108
Transmission Controller Option Setting: Malfunction 1108
DB2RKR 1110
CAN Communication with Engine Controller: Defective Communication 1110
DB90KK 1114
Work Equipment Controller: Low Source Voltage (input) 1114
DB90KT 1116
Work Equipment Controller: Abnormality in Controller 1116
DB92KK 1118
Work Equipment Controller Load Power Supply Line: Low Source Voltage (input) 1118
DB95KX 1120
Work Equipment Controller Power Supply Output: Out-of-Input Signal Range 1120
DB99KQ 1124
Work Equipment Controller: Disagreement in Model Selection Signals 1124
DB9RKR 1126
CAN Communication with Work Equipment Controller: Defective Communication 1126
DB9RMA 1130
Work Equipment Controller Option Setting: Malfunction 1130
DB9RMC 1132
CAN Communication: Defective Operation 1132
DD15LD 1136
Switch (Panel Switch 1 n): Switch is Pressed for Long Time 1136
DD16LD 1138
Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time 1138
DD17LD 1140
Switch (Panel Switch 3 <): Switch is Pressed for Long Time 1140
DD18LD 1142
Switch (Panel Switch 4 >): Switch is Pressed for Long Time 1142
DD1ALD 1144
Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time 1144
DD1BLD 1146
Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time 1146
DD1CLD 1148
Load Meter Subtotal Switch: Switch is Pressed for Long Time 1148
DD1FLD 1150
Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time 1150
DD1GLD 1152
Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time 1152
DD1HLD 1154
Load Meter Display Selector Switch: Switch is Pressed for Long Time 1154
DD1NLD 1156
Fan Reverse Switch: Switch is Pressed for Long Time 1156
DD1NL4 1158
Fan Automatic Reverse Switch: Switch is Pressed for Long Time 1158
DDB6L4 1160
Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree 1160
DDD1LD 1164
Remote Positioner Bucket Angle Set Switch: Switch is Pressed for Long Time 1164
DDE5MA 1166
Emergency Steering Drive Switch: Malfunction 1166
DDK3KA 1168
Right FNR Switch: Disconnection 1168
DDK4KA 1172
Joystick Steering FNR Switch: Disconnection 1172
DDK5L4 1176
Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree 1176
DDK6KA 1178
FNR Lever Switch: Disconnection 1178
DDK6KB 1182
FNR Lever Switch: Short Circuit 1182
DDS5KA 1186
Steering Pressure Switch: Disconnection 1186
DDS5KB 1188
Steering Pressure Switch: Grounded 1188
DDT0L4 1190
Shift Mode Selector Switch: ON/OFF Signals Disagree 1190
DDT4LD 1192
Transmission Cutoff Set Switch: Switch is Pressed for Long Time 1192
DDW9LD 1194
Kickdown Switch: Switch is Pressed for Long Time 1194
DDWLLD 1196
Hold Switch: Switch is Pressed Down for Long Time 1196
DDY0LD 1198
Load Meter Cancel Switch: Switch is Pressed for Long Time 1198
DF10KA 1200
Transmission Shift Lever Switch: Disconnection 1200
DF10KB 1204
Transmission Shift Lever Switch: Short Circuit 1204
DGF1KA 1208
Transmission Oil Temperature Sensor: Disconnection 1208
DGF1KB 1210
Transmission Oil Temperature Sensor: Short Circuit 1210
DGH2KX 1212
Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range 1212
DGR2KA 1214
Rear Brake Oil Temperature Sensor: Disconnection 1214
DGR2KX 1216
Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range 1216
DGT1KX 1218
Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range 1218
DHPCKX 1220
Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range 1220
DHPDKX 1222
Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range 1222
DHT1KX 1224
Transmission Cutoff Pressure Sensor: Out-of-Input Signal 1224
DHT8KA 1226
Steering Pump Pressure Sensor: Disconnection 1226
DHT8KB 1228
Steering Pump Pressure Sensor: Short Circuit 1228
DK59KA 1230
Lift Arm EPC Lever Potentiometer (Main): Disconnection 1230
DK59KY 1234
Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line 1234
DK59L8 1238
Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree 1238
DK5AKA 1242
Lift Arm EPC Lever Potentiometer (Sub): Disconnection 1242
DK5AKY 1246
Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne 1246
DK5BKA 1250
Bucket EPC Lever Potentiometer (Main): Disconnection 1250
DK5BKY 1254
Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line 1254
DK5BL8 1258
Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree 1258
DK5CKA 1262
Bucket EPC Lever Potentiometer (Sub): Disconnection 1262
DK5CKY 1266
Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line 1266
DK5FKA 1270
Joystick Steering EPC Lever Potentiometer (Main): Disconnection 1270
DK5FKY 1274
Joystick Steering EPC Lever Potentiometer (Main): Power Supply Line Short 1274
DK5GKA 1278
Joystick Steering EPC Lever Potentiometer (Sub): Disconnection 1278
DK5GKY 1282
Joystick Steering EPC Lever Potentiometer (Sub): Power Supply Line Short 1282
DK5FL8 1286
Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree 1286
DKA0KA 1290
Lift Arm Angle Sensor: Disconnection 1290
DKA0KY 1294
Lift Arm Angle Sensor: Short Circuit with Power Supply Line 1294
DKA0L0 1296
Lift Arm Angle Sensor: Double Meshing 1296
DLT3KA 1298
Transmission Output Shaft Speed Sensor: Disconnection 1298
DLT3LC 1300
Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range 1300
DT20KB 1302
Transmission Cutoff Indicator Lamp: Short Circuit 1302
DUM1KB 1304
Remote Positioner Raise Set Indicator Lamp: Short Circuit 1304
DUM2KB 1306
Remote Positioner Lower Set Indicator Lamp: Short Circuit 1306
DV00KB 1308
Alarm Buzzer: Short Circuit 1308
DW4PKA 1310
Lift Arm Raise EPC Solenoid: Disconnection 1310
DW4PKB 1312
Lift Arm Raise EPC Solenoid: Short Circuit 1312
DW4PKY 1314
Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line 1314
DW4QKA 1316
Lift Arm Lower EPC Solenoid: Disconnection 1316
DW4QKB 1318
Lift Arm Lower EPC Solenoid: Short Circuit 1318
DW4QKY 1320
Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line 1320
DW4RKA 1322
Bucket Tilt EPC Solenoid: Disconnection 1322
DW4RKB 1324
Bucket Tilt EPC Solenoid: Short Circuit 1324
DW4RKY 1326
Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line 1326
DW4SKA 1328
Bucket Dump EPC Solenoid: Disconnection 1328
DW4SKB 1330
Bucket Dump EPC Solenoid: Short Circuit 1330
DW4SKY 1332
Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line 1332
DW7BKA 1334
Fan Reverse Solenoid: Disconnection 1334
DW7BKB 1336
Fan Reverse Solenoid: Short Circuit 1336
DW7BKY 1338
Fan Reverse Solenoid: Short Circuit with Power Supply Line 1338
DW7DKA 1340
Hydraulic Drive Fan Neutral Solenoid: Disconnection 1340
DW7DKB 1342
Hydraulic Drive Fan Neutral Solenoid: Short Circuit 1342
DW7DKY 1344
Hydraulic Drive Fan Neutral Solenoid: Short Circuit with Power Supply Line 1344
DWM1KA 1346
Work Equipment Neutral Lock Solenoid: Disconnection 1346
DWM1KB 1348
Work Equipment Neutral Lock Solenoid: Short Circuit 1348
DWM1KY 1350
Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line 1350
DWN6KA 1352
Lift Arm Raise Magnet Detent Solenoid: Disconnection 1352
DWN6KB 1354
Lift Arm Raise Magnet Detent Solenoid: Short Circuit 1354
DWN6KY 1356
Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line 1356
DWN7KA 1358
Lift Arm Float Magnet Detent Solenoid: Disconnection 1358
DWN7KB 1360
Lift Arm Float Magnet Detent Solenoid: Short Circuit 1360
DWN7KY 1362
Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line 1362
DWN8KA 1364
Bucket Tilt Magnet Detent Solenoid: Disconnection 1364
DWN8KB 1366
Bucket Tilt Magnet Detent Solenoid: Short Circuit 1366
DWN8KY 1368
Bucket Tilt Magnet Detent Solenoid: Shorted with Power Source 1368
DX16KA 1370
Fan Pump EPC Solenoid: Disconnection 1370
DX16KB 1372
Fan Pump EPC Solenoid: Short Circuit 1372
DX16KY 1374
Fan Pump EPC Solenoid: Short Circuit with Power Supply Line 1374
DXH1KA 1376
Lockup ECMV Solenoid: Disconnection 1376
DXH1KB 1378
Lockup ECMV Solenoid: Short Circuit 1378
DXH1KY 1380
Lockup ECMV Solenoid: Short Circuit with Power Supply Line 1380
DXH4KA 1382
1st Clutch ECMV Solenoid: Disconnection 1382
DXH4KB 1384
1st Clutch ECMV Solenoid: Short Circuit 1384
DXH4KY 1386
1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1386
DXH5KA 1388
2nd Clutch ECMV Solenoid: Disconnection 1388
DXH5KB 1390
2nd Clutch ECMV Solenoid: Short Circuit 1390
DXH5KY 1392
2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1392
DXH6KA 1394
3rd Clutch ECMV Solenoid: Disconnection 1394
DXH6KB 1396
3rd Clutch ECMV Solenoid: Short Circuit 1396
DXH6KY 1398
3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1398
DXH7KA 1400
R Clutch ECMV Solenoid: Disconnection 1400
DXH7KB 1402
R Clutch ECMV Solenoid: Short Circuit 1402
DXH7KY 1404
R Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1404
DXH8KA 1406
F Clutch ECMV Solenoid: Disconnection 1406
DXH8KB 1408
F Clutch ECMV Solenoid: Short Circuit 1408
DXH8KY 1410
F Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1410
DXHHKA 1412
4th Clutch ECMV Solenoid: Disconnection 1412
DXHHKB 1414
4th Clutch ECMV Solenoid: Short Circuit 1414
DXHHKY 1416
4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1416
DXHLKA 1418
Joystick Steering Right EPC Solenoid: Disconnection 1418
DXHLKB 1420
Joystick Steering Right EPC Solenoid: Short Circuit 1420
DXHLKY 1422
Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line 1422
DXHMKA 1424
Joystick Steering Left EPC Solenoid: Disconnection 1424
DXHMKB 1426
Joystick Steering Left EPC Solenoid: Short Circuit 1426
DXHMKY 1428
Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line 1428
DY30MA 1430
Motor-Driven Emergency Steering Pump Failure (during Operation of machine) 1430
DY30MC 1434
Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode) 1434
TROUBLESHOOTING: E-MODE 1438
Troubleshooting Electrical System 1438
Information in Troubleshooting Table 1438
Installation Position of Fuses 1440
E-1 1444
Engine Does Not Start 1444
E-2 1450
Wiper Does Not Operate 1450
E-3 1454
Windshield Washer Does Not Operate 1454
E-4 1458
Lamps Do Not Light Up or Go Off 1458
E-5 1466
Working Lamp Does Not Light Up or Go Off 1466
E-6 1472
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off 1472
E-7 1480
Brake Lamp Does Not Light or It Keeps Lighting Up 1480
E-8 1484
Backup Lamp Does Not Light or It Keeps Lighting Up 1484
E-9 1488
Backup Buzzer Does Not Sound or It Keeps Sounding 1488
E-10 1492
Horn Does Not Sound or It Keeps Sounding 1492
E-11 1496
Alarm Buzzer Does Not Sound or It Keeps Sounding 1496
E-12 1498
Air Conditioner Does Not Operate or Stop 1498
E-13 1502
KOMTRAX System Does Not Work Properly 1502
Indicator Lamps of KOMTRAX Terminal 1503
E-14 1506
When Kickdown Switch is Turned ON, Kickdown Operation Does Not Start 1506
E-15 1508
When Hold Switch is Pressed, Holding Operation Does Not Start 1508
E-16 1510
Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied 1510
E-17 1512
Transmission Cutoff Mode Cannot Be Set or Reset 1512
E-18 1514
Transmission Cutoff Set Cannot be Reset 1514
E-19 1516
FN Switch Mode Cannot Be Set or Reset 1516
E-20 1518
Fan Reverse Function Cannot Be Used or Reset 1518
E-21 1520
Discharge from Loader Pump Does Not Rise from Minimum Level 1520
E-22 1522
ECSS Function Cannot Be Used or Reset 1522
E-23 1524
When Parking Brake is Turned On, Parking Brake Lamp Does Not Light Up 1524
E-24 1528
When Emergency Brake Operates, Brake Oil Pressure Lamp Does Not Operate 1528
E-25 1530
Air Cleaner Clogging Indicator Lamp Does Not Light Up 1530
E-26 1532
Radiator Coolant Level Caution Lamp Does Not Light Up 1532
E-27 1534
Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up 1534
E-28 1536
Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up 1536
E-29 1538
Steering Oil Pressure Caution Lamp Does Not Light Up 1538
E-30 1540
Abnormality in Switch (n) (Panel Switch 1) Input 1540
E-31 1542
Abnormality in Switch (‡) (Panel Switch 2) Input 1542
E-32 1544
Abnormality in Switch (<) (Panel Switch 3) Input 1544
E-33 1546
Abnormality in Switch (>) (Panel Switch 4) Input 1546
TROUBLESHOOTING: H-MODE 1548
Troubleshooting Hydraulic and Mechanical Systems 1548
Using Troubleshooting Chart 1548
Failure Modes and Causes Table 1550
H-1 1554
Machine Does Not Start 1554
H-2 1558
Torque Converter Lockup is Not Switched OFF (Engine Stalls) 1558
H-3 1559
Torque Converter Lockup is Not Switched ON 1559
H-4 1560
Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted 1560
H-5 1564
Large Shocks When Starting and Shifting Gears 1564
H-6 1568
Large Time Lag When Starting and Shifting Gear 1568
H-7 1572
Torque Converter Oil Temperature is High 1572
H-8 1573
Steering Does Not Turn 1573
H-9 1574
Steering Does Not Turn (Joystick Steering, if equipped) 1574
H-10 1575
Steering Response is Poor 1575
H-11 1576
Steering, Turning Response is Poor (Joystick Steering, if Equipped) 1576
H-12 1577
Steering is Heavy 1577
H-13 1578
When Machine Turns, It Shakes or Jerks 1578
H-14 1579
When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped) 1579
H-15 1580
Wheel Brake Does Not Work or Does Not Work Well 1580
H-16 1581
Wheel Brake is Not Released or It Drags 1581
H-17 1582
Parking Brake Does Not Work or Does Not Work Well 1582
H-18 1583
Parking Brake is Not Released or It Drags 1583
H-19 1584
Lift Arm Does Not Rise 1584
H-20 1585
Lift Arm Speed is Low or Rising Force is Insufficient 1585
H-21 1586
When Rising, Lift Arm Starts to Move Slowly at a Specific Height 1586
H-22 1586
Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats) 1586
H-23 1586
Hydraulic Drifts of the Lift Arm Are Large 1586
H-24 1587
Lift Arm Wobbles During Operation 1587
H-25 1588
Bucket Does Not Tilt Back 1588
H-26 1589
Bucket Speed is Low or Tilting-Back Force Is Insufficient 1589
H-27 1590
Bucket Starts to Operate Slowly in the Midst of Tilting Back 1590
H-28 1590
Bucket Cylinder Cannot Hold Down the Bucket 1590
H-29 1590
Hydraulic Drifts of the Bucket Are Large 1590
H-30 1591
Bucket Wobbles During Travel with Load 1591
H-31 1592
Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy 1592
H-32 1593
During Operation of Machine, Engine Speed Drops Drastically or Engine Stalls 1593
H-33 1593
Large Shocks When Work Equipment Starts and Stops 1593
H-34 1593
When Work Equipment Circuit is Relieved Individually, Other Work Equipment Moves 1593
H-35 1594
ECSS Does Not Operate – Pitching and Bouncing Occur 1594
TROUBLESHOOTING: S-MODE 1595
Troubleshooting Engine 1595
Using Troubleshooting Charts 1595
S-1 1598
Engine Does Not Start Easily 1598
S-2 1600
Engine Does Not Start 1600
S-3 1604
Engine Does Not Pick Up Smoothly 1604
S-4 1606
Engine Stops During Operation 1606
S-5 1608
Engine Does Not Rotate Smoothly 1608
S-6 1610
Engine Lacks Output (or Lacks Power) 1610
S-7 1612
Exhaust Smoke is Black (Incomplete Combustion) 1612
S-8 1614
Oil Consumption is Excessive (or Exhaust Smoke is Blue) 1614
S-9 1615
Engine Oil Becomes Contaminated Quickly 1615
S-10 1616
Fuel Consumption is Excessive 1616
S-11 1617
Coolant Contains Oil (Blows Back or Reduces) 1617
S-12 1618
Oil Pressure Drops 1618
S-13 1619
Oil Level Rises (Water, Fuel in Oil) 1619
S-14 1620
Coolant Temperature Rises Too High (Overheating) 1620
S-15 1622
Abnormal Noise is Made 1622
S-16 1624
Vibration is Excessive 1624
50 DISASSEMBLY AND ASSEMBLY 1625
HOW TO READ THIS MANUAL 1628
Removal and Installation of Assemblies 1628
Disassembly and Assembly of Assemblies 1630
COATING MATERIALS LIST 1632
SPECIAL TOOLS LIST 1636
SKETCHES OF SPECIAL TOOLS 1641
CONNECTOR REPAIR PROCEDURES 1654
Stripping Insulation 1654
Wire Inspection 1654
Contact Terminal Removal (HD30 Type) 1655
Crimping Contact Terminal (HD30 Type) 1656
Insertion Of Contact Terminal (HD30 Type) 1657
Contact Terminal Removal (DT Type) 1658
Crimping Contact Terminal (DT Type) 1659
Insertion Of Contact Terminal (DT Type) 1660
ENGINE AND COOLING SYSTEM 1661
Cylinder Head 1661
Removal 1661
Installation 1671
Engine Hood and Radiator Guard 1678
Removal 1678
Installation 1680
Radiator 1681
Removal 1681
Installation 1683
Air Aftercooler 1684
Removal 1684
Installation 1685
Hydraulic Oil Cooler 1686
Removal 1686
Installation 1686
Engine 1687
Removal 1687
Installation 1693
Front Seal 1694
Removal 1694
Installation 1695
Rear Oil Seal 1697
Removal 1697
Installation 1698
Cooling Fan and Fan Motor 1702
Removal 1702
Installation 1706
FUEL SUPPLY SYSTEM 1707
Fuel Supply Pump 1707
Removal 1707
Installation 1709
Fuel Injector 1710
Removal 1710
Installation 1715
Fuel Tank 1720
Removal 1720
Installation 1722
POWER TRAIN 1723
Torque Converter and Transmission Assembly 1723
Removal 1723
Installation 1729
Torque Converter (Standard Specification) 1730
Disassembly 1730
Assembly 1732
Torque Converter (Lockup Specification) 1735
Disassembly 1735
Assembly 1738
Transmission 1743
Disassembly 1743
Assembly 1751
Transmission Clutch Pack 1761
Forward and Reverse Clutch Packs: Disassembly 1761
1st and 4th Clutch Pack: Disassembly 1764
2nd and 3rd Clutch Pack: Disassembly 1767
Forward and Reverse Clutch Packs: Assembly 1770
1st and 4th Clutch Pack: Assembly 1774
2nd and 3rd Clutch Pack: Assembly 1778
Parking Brake 1782
Disassembly 1782
Assembly 1785
Front Axle 1791
Removal 1791
Installation 1792
Rear Axle 1793
Removal 1793
Installation 1796
Axle Housing 1798
Disassembly 1798
Assembly 1803
Differential 1810
Disassembly 1810
Assembly 1819
STEERING SYSTEM 1835
Steering Demand Valve 1835
Removal 1835
Installation 1837
BRAKE SYSTEM 1838
Parking Brake Disc and Plate 1838
Removal 1838
Installation 1841
UNDERCARRIAGE AND FRAME 1842
Center Hinge Pin 1842
Removal 1842
Installation 1848
Counterweight 1853
Removal 1853
Installation 1855
HYDRAULIC SYSTEM 1856
Work Equipment Control Valve 1856
Removal 1856
Installation 1859
Power Train Pump and Work Equipment Pump Assembly 1860
Removal 1860
Installation 1861
Steering Pump and Cooling Fan Pump Assembly 1862
Removal 1862
Installation 1863
Hydraulic Tank 1864
Removal 1864
Installation 1866
WORK EQUIPMENT 1867
Work Equipment Assembly 1867
Removal 1867
Installation 1871
Hydraulic Cylinder 1873
Disassembly 1873
Assembly 1878
CAB AND ATTACHMENTS 1883
Cab and Floor Frame 1883
Removal 1883
Installation 1887
Cab Glass (Stuck Glass) 1888
Removal 1888
Installation 1889
Operator Seat Assembly (Standard Specification) (ISRING HAUSEN) 1897
Disassembly 1897
Assembly 1904
Operator Seat Assembly (GRAMMER) 1910
Upper Seat 1910
Suspension 1918
AIR CONDITIONER UNIT ASSEMBLY 1946
Removal 1946
Installation 1951
ELECTRICAL SYSTEM 1952
Engine Controller Assembly 1952
Removal 1952
Installation 1952
KOMTRAX Terminal Assembly 1953
Removal 1953
Installation 1953
90 DIAGRAMS AND SCHEMATICS 1955
HYDRAULIC SYSTEM 1957
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1957
Without Lockup Clutch – Without Bypass Solenoid Valve 1957
Without Lockup Clutch – With Bypass Solenoid Valve (if equipped) 1958
With Lockup Clutch – Without Bypass Solenoid Valve 1959
With Lockup Clutch – With Bypass Solenoid Valve (if equipped) 1960
AUTOMATIC GREASING CIRCUIT DIAGRAM 1961
HYDRAULIC CIRCUIT DIAGRAM 1963
ELECTRICAL SYSTEM 1964
ELECTRICAL CIRCUIT DIAGRAM (1/10) 1964
ELECTRICAL CIRCUIT DIAGRAM (2/10) 1965
ELECTRICAL CIRCUIT DIAGRAM (3/10) 1966
ELECTRICAL CIRCUIT DIAGRAM (4/10) 1967
ELECTRICAL CIRCUIT DIAGRAM (5/10) 1968
ELECTRICAL CIRCUIT DIAGRAM (6/10) 1969
ELECTRICAL CIRCUIT DIAGRAM (7/10) 1970
ELECTRICAL CIRCUIT DIAGRAM (8/10) 1971
ELECTRICAL CIRCUIT DIAGRAM (9/10) 1972
ELECTRICAL CIRCUIT DIAGRAM (10/10) 1973
WORK EQUIPMENT CONTROLLER SYSTEM 1974
CONNECTOR LIST AND STEROGRAM 1975

S.V 12/12/24