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Komatsu WA430-6 Wheel Loader Shop Manual SN WA430-6 A41001 and up – PDF DOWNLOAD
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Komatsu WA430-6 Wheel Loader Shop Manual
SERIAL NUMBERS : WA430-6 A41001 and UP
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Description
Komatsu WA430-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA430-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA430-6
Serial Number: A41001 and up
Book Code: CEBM019402
Language: English
Pages: 1975
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA430-6 Wheel Loader Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
OTHERS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu WA430-6 Wheel Loader Shop Manual
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
KOMATSU WA430-6 WHEEL LOADER SHOP MANUAL SN WA430-6 A41001 AND UP – PDF DOWNLOAD:
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1 review for Komatsu WA430-6 Wheel Loader Shop Manual SN WA430-6 A41001 and up – PDF DOWNLOAD
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Fletcher Danny –
A little confusing on how to download.