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Komatsu WA450-6 WA480-6 Wheel Loader Shop Manual CEBM018601 – PDF DOWNLOAD
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Komatsu WA450-6 WA480-6 Wheel Loader Shop Manual
SERIAL NUMBERS:
WA450-6 A44001 and up
WA480-6 A38001 and up
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Description
Komatsu WA450-6 WA480-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA450-6 WA480-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA450-6, WA480-6
Serial Number: A44001 and up, A38001 and up
Book Code: CEBM018601
Language: English
Pages: 1623
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA450-6 WA480-6 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 gives the judgement standards when inspecting disassembled parts. It 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.
TESTING, ADJUSTING AND TROUBLESHOOTING:
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 charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
OTHER:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu WA450-6 WA480-6 Wheel Loader Shop Manual
COVER............................................................................................. 1 FOREWORD.......................................................................................... 2 CONTENTS...................................................................................... 2 SAFETY........................................................................................ 17 SAFETY NOTICE............................................................................. 17 IMPORTANT SAFETY NOTICE............................................................... 17 GENERAL PRECAUTIONS................................................................... 17 PREPARATIONS FOR WORK................................................................. 17 PRECAUTIONS DURING WORK............................................................... 17 GENERAL....................................................................................... 19 HOW TO READ THE SHOP MANUAL................................................................... 20 VOLUMES................................................................................... 20 DISTRIBUTION AND UPDATING................................................................. 20 FILING METHOD............................................................................. 20 REVISED EDITION MARK...................................................................... 20 REVISIONS................................................................................. 20 SYMBOLS................................................................................... 20 HOISTING INSTRUCTIONS......................................................................... 21 HOISTING.................................................................................. 21 WIRE ROPES................................................................................ 21 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................. 22 COATING MATERIALS............................................................................. 24 STANDARD TIGHTENING TORQUE.................................................................... 26 Standard Tightening Torque of Bolts and Nuts.............................................. 26 Tightening Torque of Hose Nuts............................................................ 27 Tightening Torque of Split Flange Bolts................................................... 27 Tightening Torque for Flared Nuts......................................................... 27 CONNECTING PUSH-PULL TYPE COUPLER............................................................. 28 CONVERSION TABLES............................................................................. 31 Method of Using the Conversion Table...................................................... 31 01 GENERAL........................................................................................ 37 MACHINE SPECIFICATIONS........................................................................ 38 WEIGHT TABLE.................................................................................. 41 FUEL, COOLANT AND LUBRICANTS.................................................................. 43 GENERAL ASSEMBLY DRAWING...................................................................... 44 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................... 45 SUPPORT, COOLING AND FAN SYSTEM............................................................... 52 Engine and Transmission Mounting.......................................................... 52 Cooling System............................................................................ 53 Specifications........................................................................ 53 Cooling Fan Pump.......................................................................... 54 Type: LPV30........................................................................... 54 Function.............................................................................. 56 Structure............................................................................. 56 Operation............................................................................. 57 Control of Delivery................................................................... 57 Servo Valve............................................................................... 58 Function.............................................................................. 59 Cooling Fan Motor......................................................................... 60 Type: LMF28........................................................................... 60 Specifications........................................................................ 60 Motor..................................................................................... 62 Function.............................................................................. 62 Principle of Operation................................................................ 62 Suction Valve............................................................................. 63 Function.............................................................................. 63 Operation............................................................................. 63 Operation of Reversible Valve......................................................... 64 Safety Valve.............................................................................. 65 Function.............................................................................. 65 Operation............................................................................. 65 POWER TRAIN SYSTEM............................................................................ 66 Drive Line Components..................................................................... 66 Outline............................................................................... 66 System Diagram............................................................................ 67 Outline............................................................................... 68 Drive Shaft System........................................................................ 69 Outline............................................................................... 69 Power Train Piping System................................................................. 70 Torque Converter.......................................................................... 71 Without Lockup Clutch................................................................. 71 Power Transmitting Route.............................................................. 73 Oil Flow.............................................................................. 73 With Lockup Clutch.................................................................... 74 Torque Flow............................................................................... 77 Lockup Clutch Disengaged.............................................................. 77 Lockup Clutch Engaged................................................................. 77 Oil Flow.............................................................................. 78 Transmission.............................................................................. 79 Outline............................................................................... 80 Transmission with Lockup Clutch....................................................... 82 F and R Clutch Packs...................................................................... 85 Without Lockup Clutch................................................................. 85 With Lockup Clutch.................................................................... 86 1st and 4th Clutch.................................................................... 87 2nd and 3rd Clutch.................................................................... 88 Operation of Clutch Pack.................................................................. 89 When Clutch is Engaged................................................................ 89 When Clutch is Disengaged............................................................. 89 Transmission Torque Flow Route............................................................ 90 Forward 1st Gear Speed................................................................ 90 Forward 2nd Gear Speed................................................................ 91 Forward 3rd Gear Speed................................................................ 92 Forward 4th Gear Speed................................................................ 93 Reverse 1st Gear Speed................................................................ 94 Flow Control Valve........................................................................ 95 Operation............................................................................. 95 Valve Assembly........................................................................ 96 ECMV Operation Table.................................................................. 97 Electronic Control Modulation Valve (ECMV)................................................ 98 ECMV for Gear Speed Clutch............................................................ 99 ECMV for Lockup Clutch................................................................ 102 Operation............................................................................. 103 Main and Torque Converter Relief Valve System............................................. 105 Outline............................................................................... 106 Operation............................................................................. 106 DRIVE AXLE SYSTEM............................................................................. 107 Front and Rear Axles...................................................................... 107 Front Axle (WA450-6).................................................................. 107 Front Axle (WA480-6).................................................................. 108 Rear Axle (WA450-6.................................................................... 109 Rear Axle (WA480-6)................................................................... 110 Differential.............................................................................. 111 Front Differential.................................................................... 111 Rear Differential..................................................................... 113 Outline............................................................................... 115 When Traveling in a Straight Line..................................................... 115 When Turning.......................................................................... 115 Limited Slip Differential (if equipped)................................................... 116 Axle Carrier.............................................................................. 117 WA450-6 and WA480-6 Front Carrier..................................................... 118 WA450-6 Rear.......................................................................... 119 WA480-6 Rear.......................................................................... 120 Limited Slip Differential Operation................................................... 121 Generation of Braking Torque by Right / Left Side Gears (5)........................... 121 When Traveling in a Straight Line..................................................... 121 When Machine is Turning............................................................... 122 Final Drives.............................................................................. 123 WA450-6............................................................................... 123 WA480-6............................................................................... 125 Outline............................................................................... 128 STEERING SYSTEM............................................................................... 129 Steering Piping Diagram................................................................... 129 Steering Column........................................................................... 130 Steering Pump............................................................................. 131 Type: LPV90........................................................................... 131 Pump Unit............................................................................. 132 Servo Valve........................................................................... 134 LS Valve.............................................................................. 138 PC Valve.............................................................................. 139 Steering Valve............................................................................ 143 Operation of Flow Amplifier........................................................... 145 Operation of Flow Control Spool....................................................... 147 Operation of Steering Valve........................................................... 150 Orbit-roll Valve.......................................................................... 157 Outline............................................................................... 158 Structure............................................................................. 158 Connection of Hand Pump and Sleeve.................................................... 159 Role of Centering Spring.............................................................. 160 Stop Valve................................................................................ 161 Steering Relief Valve (if equipped)....................................................... 162 Steering Cylinder......................................................................... 163 Emergency Steering Motor (if equipped).................................................... 165 Function.............................................................................. 165 Emergency Steering Pump (if equipped)..................................................... 166 Type: SBL (1) 21...................................................................... 166 SERVICE BRAKING SYSTEM........................................................................ 167 Brake Piping Diagram...................................................................... 167 Charge Valve.............................................................................. 168 Function.............................................................................. 169 Operation............................................................................. 170 Main Relief Valve (R1)................................................................ 172 PPC Relief Valve (R3)................................................................. 173 Sequence Valve (H1)................................................................... 173 Shuttle Valve (S1).................................................................... 173 Brake Valve............................................................................... 174 Outline............................................................................... 175 Operation............................................................................. 175 Accumulator for Brake..................................................................... 179 Between Charge Valve and Brake Valve.................................................. 179 Between Brake Valve and Brake Cylinder................................................ 180 Slack Adjuster............................................................................ 181 Outline............................................................................... 182 Operation............................................................................. 182 Brakes.................................................................................... 183 Front Brake........................................................................... 183 Rear Brake............................................................................ 185 Parking Brake System...................................................................... 188 Brake Control......................................................................... 188 Parking Brake......................................................................... 189 Parking Brake Solenoid Valve.......................................................... 191 Operation............................................................................. 192 Emergency Parking Brake Release Valve................................................. 193 UNDERCARRIAGE AND FRAME....................................................................... 194 Axle Mounting and Center Hinge Pin........................................................ 194 Outline............................................................................... 194 Tires..................................................................................... 198 Tire Structure and Characteristic Comparisons......................................... 198 HYDRAULIC SYSTEM.............................................................................. 199 Piping Diagram............................................................................ 199 Outline............................................................................... 201 Work Equipment Control Lever System....................................................... 202 Hydraulic Tank............................................................................ 203 Tank Vent System.......................................................................... 204 Specifications........................................................................ 204 Power Train Pump.......................................................................... 205 Type: SAL (4)125...................................................................... 205 Work Equipment Pump....................................................................... 206 Type: HPV95........................................................................... 206 Pump Unit............................................................................. 208 Pump Control Valve System................................................................. 211 LS Valve.............................................................................. 211 PC Valve.............................................................................. 216 PC-EPC Valve.......................................................................... 221 Work Equipment Control Valve.............................................................. 224 Sectional View of Valve (1 of 6)...................................................... 226 Sectional View of Valve (2 of 6)...................................................... 228 Sectional View of Valve (3 of 6)...................................................... 230 Sectional View of Valve (4 of 6)...................................................... 231 Sectional View of Valve (5 of 6)...................................................... 232 Sectional View of Valve (6 of 6)...................................................... 234 CLSS...................................................................................... 235 Outline of CLSS....................................................................... 235 Basic Principle....................................................................... 236 Pressure Compensation Control......................................................... 237 Function and Operation of Each Valve...................................................... 238 Main Hydraulic Circuit Diagram of Valves.............................................. 238 Pressure Compensation Valve............................................................... 240 When a Heavy Load is Applied to the Lift Arm.......................................... 240 During Compound Operation (Lift Arm Lower and Bucket Tilt)............................ 241 Shuttle Valve in the Pressure Compensation Valve...................................... 242 Area Ratio of Pressure Compensation Valve............................................. 243 Supply of LS Pressure..................................................................... 244 LS Shuttle Valve...................................................................... 244 LS Bypass Plug............................................................................ 245 ECSS Control Valve........................................................................ 246 Function.............................................................................. 246 Operation............................................................................. 246 Accumulator Pressure Relief Valve..................................................... 246 Restriction on Lift Arm Raise Stroke...................................................... 247 Function.............................................................................. 248 Operation............................................................................. 248 Accumulator Charge Valve.................................................................. 249 When Valve is in Neutral and (P) is Low............................................... 251 When Load Pressure (P) is High........................................................ 252 PPC Valve................................................................................. 253 Work Equipment PPC Valve.............................................................. 253 Operation in Neutral.................................................................. 255 Operations During Fine Control........................................................ 256 At Full Stroke........................................................................ 257 When Lift Arm is “Float”.............................................................. 257 When “Float” State of Lift Arm is Reset............................................... 257 Accumulator for PPC Circuit........................................................... 258 Accumulator for ECSS.................................................................. 258 WORK EQUIPMENT................................................................................ 259 Work Equipment Linkage.................................................................... 259 WA450-6............................................................................... 260 WA480-6............................................................................... 261 Bucket.................................................................................... 262 Bucket Positioner and Boom Kick-out....................................................... 263 Bucket Positioner..................................................................... 264 Boom Kick-out......................................................................... 264 Proximity Switch.......................................................................... 265 When Bucket is Tilted................................................................. 265 When Lift Arm is Raised............................................................... 268 Work Equipment Cylinders.................................................................. 271 Lift Cylinder......................................................................... 271 Bucket Cylinder....................................................................... 271 CAB ENVIRONMENT............................................................................... 272 Cab....................................................................................... 272 Air Conditioner........................................................................... 273 Air Conditioner Piping Diagram........................................................ 273 Refrigerant Circuit Diagram........................................................... 274 Air Conditioner Unit.................................................................. 276 Blower and Intake Unit................................................................ 279 Refrigerant Compressor................................................................ 281 Condenser............................................................................. 282 Receiver.............................................................................. 283 Air Conditioner Panel................................................................. 284 ELECTRICAL SYSTEM............................................................................. 288 Machine Monitor System.................................................................... 288 Outline............................................................................... 288 Operator Mode......................................................................... 288 Service Mode.......................................................................... 289 System Circuit Diagram................................................................ 290 Monitor Display Functions................................................................. 292 List of Items Displayed on Monitor.................................................... 293 Monitor Operational Switches.............................................................. 300 Setting the Machine Monitor System........................................................ 301 Character Display Function............................................................ 302 Operator Mode Function................................................................ 303 Service Mode Functions................................................................ 306 Input and Output Signals.............................................................. 311 Transmission Controller System............................................................ 316 Gear Shifting Control................................................................. 316 Transmission Controller Protection.................................................... 322 Engine Control Function............................................................... 324 Economy Operation Pilot Lamp Function................................................. 325 Cooling Fan Control Function.......................................................... 325 Fan Reverse Rotation Function......................................................... 328 Work Equipment Swash Plate Control.................................................... 331 Transmission Cut-off.................................................................. 333 ECSS Function......................................................................... 335 Electric Emergency Steering (if equipped)............................................. 337 System Circuit Diagram................................................................ 339 Transmission Controller................................................................... 341 Input and Output Signals.............................................................. 341 Electronic Transmission Control........................................................... 343 Function.............................................................................. 344 Combination Switch........................................................................ 345 Outline............................................................................... 345 Function.............................................................................. 345 Operation............................................................................. 346 Kickdown and Hold Switch.................................................................. 347 Function.............................................................................. 347 KOMTRAX Terminal System................................................................... 348 KOMTRAX Terminal...................................................................... 349 Outline............................................................................... 349 Engine Starting Circuit................................................................... 350 Function.............................................................................. 350 Operation............................................................................. 351 Engine Stopping Circuit................................................................... 352 Operation............................................................................. 352 Preheating Circuit........................................................................ 353 Outline............................................................................... 353 Operation............................................................................. 353 Engine Power Mode Selector Circuit........................................................ 354 Function.............................................................................. 354 Operation............................................................................. 354 Engine Output Derating.................................................................... 354 Automatic Warm-up......................................................................... 355 Parking Brake Circuit..................................................................... 355 Operation............................................................................. 355 When Starting Switch is Turned OFF.................................................... 355 When Starting Switch is Turned ON..................................................... 356 SENSORS................................................................................... 357 Speed Sensor.......................................................................... 357 Torque Converter Oil Temperature Sensor............................................... 358 Hydraulic Oil Temperature Sensor...................................................... 358 Transmission Oil Temperature Sensor................................................... 358 Brake Oil Temperature Sensor.......................................................... 358 Work Equipment Pump Oil Pressure Sensor............................................... 359 Steering Pump Oil Pressure Sensor..................................................... 359 Transmission Cut-off Oil Pressure Sensor.............................................. 360 Coolant Level Sensor.................................................................. 361 Fuel Level Sensor..................................................................... 362 Air Cleaner Clogging Sensor........................................................... 363 Accelerator Pedal Sensor.............................................................. 364 Boom Kick-out Proximity Switch........................................................ 365 Bucket Positioner Proximity Switch.................................................... 365 20 TESTING, ADJUSTING AND TROUBLESHOOTING......................................................... 367 STANDARD VALUE TABLE FOR ENGINE............................................................... 372 STANDARD VALUE TABLE FOR CHASSIS.............................................................. 373 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................. 382 ENGINE COMPONENTS............................................................................. 385 Exhaust Smoke............................................................................. 385 Exhaust Temperature....................................................................... 385 Valve Clearance........................................................................... 385 Compression Pressure...................................................................... 385 Crankcase Pressure........................................................................ 385 Engine Oil Pressure....................................................................... 385 Boost Pressure............................................................................ 385 Fuel Pressure............................................................................. 385 Engine Speed Sensor....................................................................... 385 Bleeding Air from Fuel System............................................................. 385 Engine Speed.............................................................................. 386 Low Idling and High Idling............................................................ 386 Measuring Torque Converter Stall Speed................................................ 386 Measuring Hydraulic Stall Speed....................................................... 387 Measuring Torque Converter Stall and Hydraulic Stall (Full Stall) Speed............... 387 TRANSMISSION SPEED SENSOR..................................................................... 388 REFRIGERANT COMPRESSOR BELT................................................................... 389 Testing................................................................................... 389 Adjusting................................................................................. 389 ALTERNATOR BELT TENSION....................................................................... 390 Testing................................................................................... 390 Adjusting................................................................................. 391 ADJUSTING DIRECTIONAL LEVER LENGTH............................................................ 392 ADJUSTING GEAR SHIFT LEVER LENGTH............................................................. 392 MEASURING DIRECTIONAL LEVER................................................................... 393 Special Tools Required.................................................................... 393 Operating Effort of Directional Lever..................................................... 393 Stroke of Directional Lever............................................................... 393 POWER TRAIN OIL PRESSURES..................................................................... 394 Special Tools Required.................................................................... 396 Oil Pressure Measuring Position and Gauges................................................ 396 Transmission Hydraulic Operating Pressures................................................ 397 Measuring Main Relief Pressure........................................................ 397 Measuring Torque Converter Relief Pressure (Inlet).................................... 398 Measuring Torque Converter Outlet Pressure............................................ 399 Measuring Lockup Clutch Pressure (Lockup Clutch Specification)........................ 400 Measuring F (Forward) Clutch Pressure................................................. 401 Measuring R (Reverse) Clutch Pressure................................................. 402 Measuring 1st Clutch Pressure......................................................... 403 Measuring 2nd Clutch Pressure......................................................... 404 Measuring 3rd Clutch Pressure......................................................... 405 Measuring 4th Clutch Pressure......................................................... 406 Measuring Lubrication Pressure........................................................ 407 Measuring Parking Brake Pressure...................................................... 408 Transmission Hydraulic Pressure Adjustments............................................... 409 Adjusting Transmission Main Relief Valve.............................................. 409 Flushing Transmission System.............................................................. 410 Torque Converter, Transmission and Hydraulic Circuit.................................. 410 If Transmission Valve Fails............................................................... 412 Moving Machine........................................................................ 412 Special Tools Required................................................................ 412 Check Axle Drive for Oil Leakage.......................................................... 414 Check Drive Shafts for Looseness, Play and Damage......................................... 414 STEERING SYSTEM............................................................................... 415 Steering Stop Valve....................................................................... 415 Testing............................................................................... 415 Adjusting............................................................................. 415 Steering Wheel............................................................................ 417 Special Tools Required................................................................ 417 Measuring Play in Steering Wheel...................................................... 417 Measuring Operating Effort of Steering Wheel.......................................... 417 Measuring Operating Time of Steering Wheel............................................ 418 Steering Oil Pressure..................................................................... 419 Special Tools Required................................................................ 419 Measuring................................................................................. 419 Steering Relief Pressure.............................................................. 419 Steering Pilot Circuit Pressure....................................................... 420 Adjusting................................................................................. 420 Steering Relief Pressure.............................................................. 420 Adjusting Steering Control Circuit Pressure........................................... 421 Bleeding Air from Steering Circuit.................................................... 421 Bleeding Air from Steering Pump....................................................... 421 Bleeding Air from Steering Cylinder Circuit........................................... 421 HYDRAULIC DRIVE FAN........................................................................... 422 Special Tools Required.................................................................... 422 Measuring Fan Speed....................................................................... 422 Tachometer Kit P1..................................................................... 423 Measuring Fan Drive Oil Pressure.......................................................... 423 Bleeding Air From Fan Circuit............................................................. 424 Special Tools Required................................................................ 424 Bleeding Air from Fan Pump............................................................ 424 Bleeding Air from Fan Motor Circuit................................................... 424 WHEEL BRAKE SYSTEM............................................................................ 426 Measuring Brake Pedal..................................................................... 426 Measuring Pressing Angle of Pedal..................................................... 426 Brake Pedal Linkage....................................................................... 427 Testing............................................................................... 427 Adjusting............................................................................. 427 Brake Performance......................................................................... 428 Accumulator Charge........................................................................ 429 Special Tools Required................................................................ 429 Measuring............................................................................. 429 Accumulator Charge Cut-out Pressure................................................... 429 Wheel Brake Oil Pressure.................................................................. 430 Special Tools Required................................................................ 430 Brake Test Kit........................................................................ 432 Wheel Brake Disc Wear..................................................................... 433 Special Tools Required................................................................ 433 Bleeding Air from Brake Circuit........................................................... 434 Releasing Residual Pressure in Brake Accumulator Circuit.............................. 435 PARKING BRAKE SYSTEM.......................................................................... 436 Parking Brake Performance................................................................. 436 Measuring Method...................................................................... 436 Parking Brake Oil Pressure................................................................ 437 Special Tools Required................................................................ 437 Parking Brake Disc Wear................................................................... 439 Manual Release Method for Parking Brake................................................... 440 WORK EQUIPMENT SYSTEM......................................................................... 441 Control Levers............................................................................ 441 Special Tools Required................................................................ 441 Operating Effort of Work Equipment Control Lever...................................... 441 Stroke of Work Equipment Control Lever................................................ 441 PPC Oil Pressure.......................................................................... 442 Special Tools Required................................................................ 442 Measuring PPC Pump Basic Pressure..................................................... 442 PPC Valve Output Pressure............................................................. 443 Adjusting............................................................................. 444 Hydraulic Pressure........................................................................ 445 Special Tools Required................................................................ 445 Combination of Actuator and Valve..................................................... 445 Preparation Work...................................................................... 445 Measuring Work Equipment Relief Pressure.............................................. 446 Measuring Unload Pressure............................................................. 446 Measuring Work Equipment LS Differential Pressure..................................... 447 Adjusting................................................................................. 448 Adjusting Work Equipment Relief Pressure.............................................. 448 Adjusting LS Differential Pressure.................................................... 448 Bleeding Air from Work Equipment Circuit.................................................. 449 From Work Equipment Pump (Piston Pump)................................................ 449 Bleeding Air from Hydraulic Cylinder.................................................. 449 Releasing Residual Pressure in Work Equipment Circuit..................................... 450 Between Hydraulic Cylinders and Control Valve......................................... 450 From ECSS (Travel Damper) Circuit..................................................... 450 Bucket Positioners........................................................................ 452 Testing............................................................................... 452 Adjusting............................................................................. 452 Adjusting Mounting Position (Stopping Position)....................................... 452 Boom Kickout.......................................................................... 453 Proximity Switch Operation Pilot Lamp................................................. 454 ELECTRICAL SYSTEM TROUBLESHOOTING............................................................. 455 Procedure for Testing Diodes.............................................................. 455 When Using Digital-Type Circuit Tester................................................ 455 When Using Analog-Type Circuit Tester................................................. 455 Preparation for Troubleshooting Electrical System......................................... 456 Machine Monitor....................................................................... 456 Transmission Controller............................................................... 457 Work Equipment Controller (if equipped)............................................... 458 KOMTRAX Controller.................................................................... 458 Ambient Pressure Sensor (AMBAIR PRESSURE)............................................. 459 Engine NE Speed Sensor (CRANK SENSOR)................................................. 459 Engine BKUP Speed Sensor (CAM SENSOR)................................................. 459 Engine Oil Pressure Switch (OIL PRESSURE SWITCH)...................................... 459 Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)............................. 459 Supply Pump IMV Solenoid (FUEL REGULATOR)............................................. 459 Common Rail Pressure Sensor (FUEL RAIL PRESS)......................................... 460 Engine Coolant Temperature Sensor (COOLANT TEMP)...................................... 460 KOMTRAX TERMINAL SYSTEM OPERATION............................................................. 461 KOMTRAX Terminal Installed at Plant....................................................... 461 KOMTRAX Terminal Retrofitted.............................................................. 461 Station Opening Check in Machine Side................................................. 461 Application for the Start of Use...................................................... 464 KOMTRAX Terminal Lamps.................................................................... 465 Check Antennas........................................................................ 466 Check Terminal Led Displays........................................................... 466 MACHINE MONITOR SYSTEM........................................................................ 468 Machine Monitor........................................................................... 468 Adjusting Replaced, Reassembled or Added Sensor, Controller, etc. with Machine Monitor.... 469 Items to be Set When Sensor or Controller is Replaced, Reassembled or Added........... 469 Adjustment for User's Needs........................................................... 470 Special Functions of Machine Monitor (EMMS)............................................... 471 Normal and Special Functions of Machine Monitor....................................... 471 Functions and Flow of Service Mode........................................................ 472 Operator Mode............................................................................. 475 Service Meter/Clock Display Function.................................................. 475 Load Meter Function (if Equipped)..................................................... 475 Odometer Display Function............................................................. 475 Maintenance Monitoring Function....................................................... 476 Telephone Number Input Function....................................................... 476 Language Selection Function........................................................... 476 Monitor Brightness Adjustment Function................................................ 476 Time Adjustment Function.............................................................. 477 Travel Speed/Engine Speed Display Selecting Function.................................. 478 Travel Speed/Engine Speed Display/Non-Display Selecting Function...................... 478 Action Code Display Function.......................................................... 478 Action Codes and Actions Alerted to Operator.............................................. 479 Failure Code Display Function............................................................. 479 Service Mode.............................................................................. 480 Electrical System Fault History Display Function (ELECTRIC FAULT)......................... 481 Mechanical System Fault History Display Function (MACHINE FAULT).......................... 483 Real-time Monitoring Function (REAL-TIME MONITOR)..................................... 484 REAL-TIME MONITORING CODE TABLES.............................................................. 487 Monitor Panel Display (1)................................................................. 487 Monitor Panel Display (2)................................................................. 489 MON Mode.................................................................................. 491 Transmission Display (1).................................................................. 493 Transmission Display (1).................................................................. 494 Transmission Display (2).................................................................. 495 Transmission Display (2).................................................................. 496 Transmission Display (3).................................................................. 497 Transmission Display (3).................................................................. 498 TM Mode................................................................................... 499 Engine Display............................................................................ 501 MONITOR USAGE................................................................................. 503 Cylinder Cut-out Function................................................................. 503 No Injection Cranking Function........................................................ 504 Adjustment Function (Tuning).............................................................. 506 Adjustment Functions.................................................................. 506 Preparations for Transmission ECMV Current Adjustment................................. 506 Confirmation of Transmission Oil Temperature Control.................................. 507 Adjustment of Transmission ECMV Current............................................... 508 Codes for Abnormal End................................................................ 511 Setting of Transmission Initial Learning.............................................. 511 Reset of Initial Learning............................................................. 511 Preparations for Transmission Initial Learning........................................ 512 Implementation of Transmission Initial Learning....................................... 513 Confirmation of Completion of Transmission Initial Learning........................... 514 Adjustment of Transmission L Mode Shift Point Function................................ 514 Clearing an Adjusted Shift Point...................................................... 514 Adjusting a Shift Point............................................................... 515 Gear Shift Pattern Change Procedure................................................... 516 Adjustments Not Used.................................................................. 516 Adjustment of Fan Automatic Reverse Operation Interval (if equipped).................. 517 Adjustment of Fan Automatic Reverse Operation Continuance (if equipped)............... 519 Maintenance Monitoring Function........................................................... 521 Changing Maintenance Interval Time.................................................... 521 List of Maintenance Items............................................................. 521 Selection Between Enabling or Disabling Timer by Item................................. 523 Changing Set Default Value............................................................ 524 Selection Between Timer Stop for All Items and Enable by Item......................... 525 Operating Information Display Function.................................................... 527 Fuel Consumption Ratio and Average Fuel Consumption Screen............................ 527 Cumulative Fuel Consumption and Travel Distance....................................... 527 Cumulative Fuel Consumption and Elapsed Time.......................................... 528 Loaded Volume and Loading Frequency Screen............................................ 528 Deleting Display Data................................................................. 528 Setting Gain Correction............................................................... 528 Optional Select Function.................................................................. 530 Optional Component Setting Table...................................................... 530 Change or Settlement of “BOOM TYPE OPTION SELECT”..................................... 533 Option Setting/Not Setting Selection.................................................. 533 Setting Tire Deflection Option........................................................ 533 Storing Option Selection.............................................................. 534 Machine Serial Number Input Function.................................................. 534 Machine Model Select Function (MACHINE)................................................... 534 Implementing the Model Change......................................................... 535 Storing Model Change.................................................................. 535 Initialize Function................................................................... 536 PM-CLINIC INSPECTION TABLES................................................................... 537 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................... 544 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................... 546 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..................................................... 547 Precautions When Handling Electrical Equipment............................................ 547 Handling Electronic Control Unit.......................................................... 552 Points to Remember When Troubleshooting Electrical Circuits............................... 553 ELECTRIC WIRE CODE............................................................................ 554 Classification by Thickness............................................................... 554 Classification by Color and Code.......................................................... 554 How to Read Electric Wire Code............................................................ 555 Points to Remember When Handling Hydraulic Equipment...................................... 557 CHECKS BEFORE TROUBLESHOOTING................................................................. 559 Categories and Method of Using Troubleshooting Charts..................................... 560 Troubleshooting Individual Electrical Circuits............................................ 561 Chart Use............................................................................. 563 Chart Tips............................................................................ 563 Troubleshooting Individual Hydraulic Circuits............................................. 564 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................... 566 T-ADAPTER TABLE............................................................................... 591 MODE CHART.................................................................................... 595 INFORMATION CONTAINED IN TESTING PROCEDURES................................................... 603 FAILURE CODE CHART............................................................................ 605 TABLE OF FUSE BOX AND SLOW BLOW FUSES......................................................... 615 VIEW OF FUSE LOCATIONS.................................................................... 617 FAILURE CODE.................................................................................. 618 1500L0 Torqflow Transmission - Double Engagement Detected................................. 618 15SAL1 ECMV F Clutch...................................................................... 619 When Command Current is Off, Fill Signal is On........................................ 619 15SALH ECMV F Clutch...................................................................... 621 When Command Current is On, Fill Signal is Off........................................ 621 15SBL1 ECMV R Clutch...................................................................... 623 When Command Current is Off, Fill Signal is On........................................ 623 15SBLH ECMV R Clutch...................................................................... 625 When Command Current is On, Fill Signal is Off........................................ 625 15SEL1 ECMV 1st Clutch.................................................................... 627 When Command Current is Off, Fill Signal is On........................................ 627 15SELH ECMV 1st Clutch.................................................................... 629 When Command Current is On, Fill Signal is Off........................................ 629 15SFL1 ECMV 2nd Clutch.................................................................... 631 When Command Current is Off, Fill Signal is On........................................ 631 15SFLH ECMV 2nd Clutch.................................................................... 633 When Command Current is On, Fill Signal is Off........................................ 633 15SGL1 ECMV 3rd Clutch.................................................................... 635 When Command Current is Off, Fill Signal is On........................................ 635 15SGLH ECMV 3rd Clutch.................................................................... 637 When Command Current is On, Fill Signal is Off........................................ 637 15SHL1 ECMV 4th Clutch.................................................................... 639 When Command Current is Off, Fill Signal is On........................................ 639 15SHLH ECMV 4th Clutch.................................................................... 641 When Command Current is On, Fill Signal is Off........................................ 641 2F00MA Parking Brake Malfunction.......................................................... 643 2G43ZG Accumulator Oil Pressure Low....................................................... 645 44K0L4 Bucket Positioner On/Off Signals Incorrect......................................... 647 AA1ANX Air Cleaner Clogged Indication..................................................... 650 AB00L6 Alternator Signal Incorrect with Operating State of Engine......................... 652 AB00MA Alternator Malfunction............................................................. 654 B@BAZG Engine Power and Speed Derated by Low Oil Pressure................................. 656 B@BAZK Engine Oil Level Low Level......................................................... 658 B@BCNS Engine Coolant Overheating......................................................... 660 B@BCZK Coolant Level Low.................................................................. 662 B@C7NS Brake Oil Overheating.............................................................. 664 b@CENS Torque Converter Oil Overheating................................................... 666 B@CENS Torque Converter Oil Overheating................................................... 668 B@HANS Hydraulic Oil Overheating.......................................................... 670 CA111 Abnormality in Engine Controller.................................................... 672 CA115 Engine Ne or Bkup Speed Sensor Error................................................ 675 CA122 Charge Pressure Sensor Failure...................................................... 676 CA123 Charge Pressure Sensor Failure...................................................... 678 CA131 Throttle Sensor High Failure........................................................ 679 CA132 Throttle Sensor Low Failure......................................................... 681 CA135 Engine Oil Pressure Sensor High Error............................................... 683 CA141 Engine Oil Pressure Sensor High Error............................................... 685 CA144 Coolant Sensor High Failure......................................................... 686 CA145 Coolant Sensor Low Failure.......................................................... 688 CA153 Charge Temperature Sensor High Failure.............................................. 690 CA154 Charge Temperature Sensor Low Failure............................................... 692 CA187 Sensor Power Supply 2 Low Error..................................................... 694 CA221 Atmospheric Pressure Sensor High Failure............................................ 695 CA222 Atmospheric Pressure Sensor Low Failure............................................. 697 CA227 Sensor Power Supply 2 High Failure.................................................. 698 CA234 Engine Overspeed Detected........................................................... 701 CA238 Ne Speed Sensor Power Supply Error.................................................. 702 CA263 Fuel Temperature Sensor High Failure................................................ 704 CA265 Fuel Temperature Sensor Low Failure................................................. 706 CA271 PCV1 Short Circuit Detected......................................................... 707 CA272 PCV1 Open Circuit Detected.......................................................... 709 CA273 PCV2 Short Circuit Detected......................................................... 711 CA274 PCV2 Open Circuit Detected.......................................................... 713 CA322 Injector #1 (L/B#1) Has an Open/Short............................................... 715 CA323 Injector #5 (L/B#5) Has an Open/Short............................................... 717 CA324 Injector #3 (L/B#3) Has an Open/Short............................................... 719 CA325 Injector #6 (L/B#6) Has an Open/Short............................................... 721 CA331 Injector #2 (L/B#2) Has an Open/Short............................................... 723 CA332 Injector #4 (L/B#4) Has an Open/Short............................................... 725 CA342 Calibration Code Inconsistency...................................................... 727 CA351 Injectors Drive Circuit Error....................................................... 728 CA352 Sensor Power Supply 1 Low Failure................................................... 731 CA386 Sensor Power Supply 1 High Failure.................................................. 732 CA431 Idle Validation Switch Error........................................................ 734 CA432 Idle Validation Switch Action Error................................................. 736 CA435 Engine Oil Pressure Switch Error.................................................... 739 CA441 Low Battery Voltage Error........................................................... 741 CA442 High Battery Voltage Error.......................................................... 744 CA449 Common Rail Pressure High Error 2................................................... 746 CA451 Common Rail Pressure Sensor High Error.............................................. 747 CA452 Common Rail Pressure Sensor Low Error............................................... 749 CA553 Common Rail Pressure High Error 1................................................... 750 CA554 Common Rail Pressure Sensor In-range Error.......................................... 751 CA559 Supply Pump Pressure Very Low Error................................................. 752 Check Sheet For No-pressure Feed...................................................... 753 WA450-6 Specifications................................................................ 754 WA480-6 Specifications................................................................ 755 CA689 Ne Speed Sensor Error............................................................... 756 CA731 Engine Bkup Speed Sensor Phase Error................................................ 758 CA757 All Continuous Data Loss Error...................................................... 758 CA778 Engine Bkup Speed Sensor Error...................................................... 759 CA1228 EGR Valve Servo Error 1............................................................ 761 CA1625 EGR Valve Servo Error 2............................................................ 762 CA1633 KOMNET Data Link Time Out Error.................................................... 763 CA2185 Throttle Sensor Supply Voltage High Failure........................................ 765 CA2186 Throttle Sensor Supply Voltage Low Failure......................................... 767 CA2249 Supply Pump Pressure Very Low Error................................................ 769 CA2271 EGR Valve Lift Sensor High Error................................................... 770 CA2272 EGR Valve Lift Sensor Low Error.................................................... 772 CA2351 EGR Valve Solenoid Showing Short Circuit Error..................................... 773 CA2352 EGR Valve Solenoid Showing Open Circuit Error...................................... 775 CA2555 Intake Heater Relay Open Error..................................................... 776 CA2556 Intake Heater Relay Short Error.................................................... 778 D150KA Emergency Steering Relay Open...................................................... 780 D150KB Emergency Steering Relay Shorted................................................... 782 D150KY Emergency Steering Relay Shorted with Power Supply................................. 784 D160KA Backup Lamp Relay Open............................................................. 786 D160KB Backup Lamp Relay Shorted.......................................................... 788 D191KA Joystick Steering Neutral Safety Relay: Disconnection.............................. 790 D191KB Joystick Steering Neutral Safety Relay Shorted..................................... 792 D191KY Joystick Steering Neutral Safety Relay Shorted..................................... 794 D192KA ECSS Solenoid Open................................................................. 796 D192KB ECSS Solenoid Shorted.............................................................. 798 D192KY ECSS Solenoid Power Supply Error................................................... 800 D193KA Joystick Steering Solenoid Cut Relay Shorted....................................... 802 D193KB Joystick Steering Solenoid Cut Relay Shorted....................................... 804 D193KY Joystick Steering Solenoid Cut Relay Shorted....................................... 806 D5ZHKA Terminal C Signal Open............................................................. 809 D5ZHKB Terminal C Signal Shorted.......................................................... 813 D5ZHKZ Terminal C Signal: Disconnection or Short Circuit.................................. 817 D5ZHL6 Terminal C Signal Does Not Match Engine Running or Stopped......................... 821 DA80L4 Auto Grease Controller On/Off Signals Disagree..................................... 825 DAF3KK Machine Monitor Low Voltage Input.................................................. 828 DAF5KP Machine Monitor Low Output Voltage................................................. 830 DAFRKR CAN Communication with Machine Monitor Defective................................... 833 DAQ0KK Transmission Controller Low Voltage Source......................................... 835 DAQ0KT Transmission Controller Defective.................................................. 837 DAQ2KK Transmission Controller Low Voltage Source Input................................... 838 DAQ9KQ Transmission Controller Model Selection Disagreement............................... 840 DAQRKR CAN Communication with Transmission Controller Abnormal............................ 841 DAQRMA Transmission Controller Option Setting Malfunction................................. 844 DB2RKR CAN Communication with Engine Controller Abnormal.................................. 845 DB90KK Work Equipment Controller Low Voltage Source....................................... 848 DB90KT Work Equipment Controller Malfunction.............................................. 850 DB92KK Work Equipment Controller Low Voltage Input Source................................. 851 DB95KX Work Equipment Power Supply Output, Out of Range................................... 853 DB99KQ Work Equipment Controller Model Selection Disagreement............................. 857 DB9RKR CAN Communication with Work Equipment Controller Abnormal.......................... 858 DB9RMA Work Equipment Controller Option Setting Malfunction............................... 861 DB9RMC Communication with Transmission Controller Defective............................... 864 DD15LD n Switch (Panel Switch 1) is Defective............................................. 867 DD16LD ‡ Switch (Panel Switch 2) is Defective............................................. 869 DD17LD < Switch (Panel Switch 3) is Defective............................................. 871 DD18LD > Switch (Panel Switch 4) is Defective............................................. 873 DD1ALD Remote Positioner Set Switch is Defective.......................................... 875 DD1BLD Remote Positioner Set Switch is Defective.......................................... 877 DD1CLD Load Meter Subtotal Switch Defective............................................... 879 DD1FLD Load Meter Mode Selector Switch (A/B) is Defective................................. 881 DD1GLD Load Meter Mode Selector Switch (+/-) is Defective................................. 883 DD1HLD Load Meter Display Selector Switch is Defective.................................... 885 DD1NLD Fan Reverse Selector Switch is Defective........................................... 887 DD1NL4 Fan Reverse Selector Switch is Defective........................................... 890 DDB6L4 Parking Brake Switch On/Off Signals Disagree....................................... 893 DDD1LD Remote Bucket Positioner Switch is Defective....................................... 896 DDE5MA Emergency Steering Drive Switch Malfunction........................................ 899 DDK3KA Right FNR Switch Showing Open...................................................... 901 DDK4KA FNR Switch Showing Open............................................................ 904 DDK5L4 Joystick Steering Shift-up Switch On/Off Signal Error.............................. 907 DDK6KA FNR Switch Showing Open............................................................ 909 DDK6KB FNR Switch Showing a Short......................................................... 912 DDS5KA Steering Pressure Switch Signal: Disconnected...................................... 915 DDS5KB Steering Pressure Switch Signal: Short Circuit..................................... 917 DDT0L4 Shift Mode Selector Switch On/Off Signals Incorrect................................ 919 DDT4LD Transmission Cut-off Switch is Defective........................................... 922 DDW9LD Kick-down Switch Defective......................................................... 924 DDWLLD Hold Switch Defective.............................................................. 926 DDY0LD Load Meter Cancel Switch Defective................................................. 928 DF10KA Transmission Shift Lever Switch Open............................................... 930 DF10KB Transmission Shift Lever Switch Shorted............................................ 933 DGF1KA Transmission Oil Temperature Sensor Showing Open................................... 936 DGF1KB Transmission Oil Temperature Sensor Showing a Short................................ 938 DGH2KX Hydraulic Oil Temperature Sensor Out of Range...................................... 940 DGR2KA Rear Brake Oil Temperature Sensor Open............................................. 942 DGR2KX Rear Brake Oil Temperature Sensor Shorted.......................................... 944 DGT1KX Torque Converter Oil Temperature Sensor Out of Range............................... 946 DH21KA Loader Pump Pressure Sensor: Disconnection......................................... 948 DH21KB Loader Pump Pressure Sensor: Power Supply Line Short............................... 950 DHPCKX Lift Arm Cylinder Bottom Pressure Sensor Out of Range.............................. 952 DHPDKX Lift Arm Cylinder Head Pressure Sensor Out of Range................................ 954 DHT1KX Transmission Cut-off Pressure Sensor Out of Range.................................. 956 DHT8KA Steering Pump Pressure Sensor Open................................................. 958 DHT8KB Steering Pump Pressure Sensor Short Circuit........................................ 960 DK59KA Lift Arm Epc Lever Showing Open.................................................... 962 DK59KY Lift Arm EPC Lever Showing a Short................................................. 965 DK59L8 Lift Arm EPC Lever Showing Incorrect Signals....................................... 968 DK5AKA Lift Arm Epc Lever Showing Open.................................................... 971 DK5AKY Lift Arm EPC Lever Shorted......................................................... 974 DK5BKA Bucket EPC Lever Showing Open...................................................... 977 DK5BKY Bucket EPC Lever System Shorted.................................................... 980 DK5BL8 Bucket EPC Lever Showing Incorrect Signals......................................... 983 DK5CKA Bucket EPC Lever System Open....................................................... 986 DK5CKY Bucket EPC Lever System Shorted.................................................... 989 DK5DKA 3-Spool Attachment EPC Lever System Showing Open................................... 992 DK5DKY 3-Spool Attachment EPC Lever System Showing a Short................................ 995 DK5DL8 3-Spool EPC Lever Showing Incorrect Signals........................................ 998 DK5EKA 3-Spool Attachment EPC Lever System Showing Open...................................1001 DK5EKY 3-Spool Attachment EPC Lever System Showing Short..................................1004 DK5FKA Joystick Steering EPC Lever System Showing Open....................................1007 DK5FKY Joystick Steering EPC Lever System Showing a Short.................................1010 DK5GKA Joystick Steering EPC Lever System Showing an Open.................................1013 DK5GKY Joystick Steering EPC Lever System Showing a Short.................................1016 DK5FL8 Joystick Steering EPC Lever System Incorrect Signals...............................1019 DKA0KA Lift Arm Angle Sensor System Showing an Open.......................................1022 DKA0KY Lift Arm Angle Sensor System Showing a Short.......................................1025 DKA0L0 Lift Arm Angle Sensor System Double Meshing........................................1028 DLT3KA Transmission Speed Sensor Open.....................................................1031 DLT3LC Transmission Speed Sensor Out of Range.............................................1033 DT20KB Transmission Cut-off Indicator Lamp Shorted........................................1035 DUM1KB Remote Positioner Raise Set Indicator Shorted......................................1037 DUM2KB Remote Positioner Raise Set Indicator Shorted......................................1039 DV00KB Alarm Buzzer Shorted...............................................................1041 DW4PKA Lift Arm Raise EPC Solenoid Showing Open...........................................1043 DW4PKB Lift Arm Raise EPC Solenoid Showing a Short Circuit................................1045 DW4PKY Lift Arm Raise EPC Solenoid Showing a Short Circuit................................1047 DW4QKA Lift Arm Lower EPC Solenoid Showing an Open........................................1049 DW4QKB Lift Arm Lower EPC Solenoid Showing a Short........................................1051 DW4QKY Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line..................1053 DW4RKA Bucket Tilt EPC Solenoid Showing an Open...........................................1055 DW4RKB Bucket Tilt EPC Solenoid Showing a Short...........................................1057 DW4RKY Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line.....................1059 DW4SKA Bucket Dump EPC Solenoid Showing an Open...........................................1061 DW4SKB Bucket Dump EPC Solenoid Showing a Short...........................................1063 DW4SKY Bucket Dump EPC Solenoid Showing a Short...........................................1065 DW7BKA Fan Reverse Solenoid Open..........................................................1067 DW7BKB Fan Reverse Solenoid Shorted.......................................................1069 DW7BKY Fan Reverse Solenoid Shorted.......................................................1071 DW7DKA Hydraulic Fan Neutral Solenoid Showing Open........................................1073 DW7DKB Hydraulic Fan Neutral Solenoid Shorted.............................................1074 DW7DKY Hydraulic Fan Neutral Solenoid Showing Open........................................1075 DWM1KA Work Equipment Neutral Lock Solenoid Showing Open..................................1076 DWM1KB Work Equipment Neutral Lock Solenoid Shorted.......................................1079 DWM1KY Work Equipment Neutral Lock Solenoid Shorted.......................................1082 DWN6KA Lift Arm Raise Magnetic Detent Solenoid Showing Open...............................1085 DWN6KB Lift Arm Raise Magnetic Detent Solenoid is Shorted.................................1087 DWN6KY Lift Arm Raise Magnetic Detent Solenoid is Shorted.................................1089 DWN7KA Lift Arm Float Magnetic Detent Solenoid Showing Open...............................1091 DWN7KB Lift Arm Float Magnetic Detent Solenoid Showing Short..............................1093 DWN7KY Lift Arm Float Magnetic Detent Solenoid Showing Short..............................1095 DWN8KA Bucket Magnetic Detent Solenoid Showing Open.......................................1097 DWN8KB Bucket Magnetic Detent Solenoid Shorted............................................1099 DWN8KY Bucket Magnetic Detent Solenoid Shorted............................................1101 DX16KA Fan Pump EPC Solenoid Open.........................................................1103 DX16KB Fan Pump EPC Solenoid Shorted......................................................1105 DX16KY Fan Pump EPC Solenoid Shorted......................................................1107 DXH1KA Lock-up ECMV Solenoid Open.........................................................1109 DXH1KB Lock-up ECMV Solenoid Shorted......................................................1111 DXH1KY Lock-up ECMV Solenoid Shorted......................................................1113 DXH4KA 1st Clutch ECMV Solenoid Open......................................................1115 DXH4KB 1st Clutch ECMV Solenoid Shorted...................................................1117 DXH4KY 1st Clutch ECMV Solenoid Shorted...................................................1119 DXH5KA 2nd Clutch ECMV Solenoid Open......................................................1121 DXH5KB 2nd Clutch ECMV Solenoid Shorted...................................................1123 DXH5KY 2nd Clutch ECMV Solenoid Shorted...................................................1125 DXH6KA 3rd Clutch ECMV Solenoid Open......................................................1127 DXH6KB 3rd Clutch ECMV Solenoid Shorted...................................................1129 DXH6KY 3rd Clutch ECMV Solenoid Shorted...................................................1131 DXH7KA Reverse (R) Clutch ECMV Solenoid Open..............................................1133 DXH7KB Reverse (R) Clutch ECMV Solenoid Shorted...........................................1135 DXH7KY Reverse (R) Clutch ECMV Solenoid Shorted...........................................1137 DXH8KA Forward (F) Clutch ECMV Solenoid Open..............................................1139 DXH8KB Forward (F) Clutch ECMV Solenoid Shorted...........................................1141 DXH8KY Forward (F) Clutch ECMV Solenoid Shorted...........................................1143 DXHHKA 4th Clutch ECMV Solenoid Open......................................................1145 DXHHKB 4th Clutch ECMV Solenoid Shorted...................................................1147 DXHHKY 4th Clutch ECMV Solenoid Shorted...................................................1149 DXHJKA 3-Spool Valve Extend EPC Solenoid Showing an Open..................................1151 DXHJKB 3-Spool Valve Extend EPC Solenoid Showing a Short..................................1153 DXHJKY 3-Spool Valve Extend EPC Solenoid Showing a Short..................................1155 DXHKKA 3-Spool Valve Retract EPC Solenoid Showing an Open.................................1157 DXHKKB 3-Spool Valve Extend EPC Solenoid Showing a Short..................................1159 DXHKKY 3-Spool Valve Extend EPC Solenoid Showing a Short..................................1161 DXHLKA Joystick Steering Right EPC Solenoid Showing Open..................................1163 DXHLKB Joystick Steering Right EPC Solenoid Shorted.......................................1166 DXHLKY Joystick Steering Right EPC Solenoid Shorted.......................................1169 DXHMKA Joystick Steering Left EPC Solenoid Showing Open...................................1172 DXHMKB Joystick Steering Left EPC Solenoid Shorted........................................1175 DXHMKY Joystick Steering Left EPC Solenoid Showing Open...................................1178 DY30MA Motor-driven Emergency Steering Pump Failure (During Operation of Machine).........1181 DY30MC Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)..........1184 DY30ME Emergency Steering: Operating for More Than One Minute.............................1187 E-MODE (ELECTRICAL SYSTEM)....................................................................1192 Information Contained in Testing Procedures...............................................1192 Table of Fuse Box and Slow Blow Fuses.....................................................1194 View of Fuse Locations....................................................................1196 E-1 Engine Will Not Crank.................................................................1197 E-2 Front Wiper Does Not Operate..........................................................1203 Rear Wiper Does Not Operate...............................................................1206 E-3 Windshield Washer Does Not Operate....................................................1208 E-4 Head, Clearance, License and Tail Lamps Do Not Operate Correctly......................1211 Head Lamps (High or Low Beams) Do Not Operate Correctly...............................1213 Head Lamp Low Beams Do Not Operate Correctly..........................................1216 Head Lamp High Beams Do Not Operate Correctly.........................................1219 Clearance Lamps Do Not Operate Correctly..............................................1222 E-5 Work Lamps Do Not Operate Correctly...................................................1224 Front Work Lamps......................................................................1224 Rear Work Lamps.......................................................................1226 E-6 Hazard Lamps Do Not Operate Correctly.................................................1228 Directional Lamps Do Not Operate Correctly............................................1231 Directional Lamps Work and Hazard Lamps Do Not Work.......................................1234 E-7 Rear Brake Lamps Do Not Operate Correctly.............................................1237 E-8 Backup Lamps Do Not Operate Correctly.................................................1239 E-9 Backup Alarm Does Not Operate Correctly...............................................1241 E-10 Horns Do Not Operate Correctly.......................................................1243 E-11 Alarm Buzzer Does Not Operate Correctly..............................................1245 E-12 Air Conditioner Does Not Operate or Stop.............................................1247 E-13 KOMTRAX System Does Not Operate Correctly............................................1250 S-MODE ENGINE SYSTEM..........................................................................1253 H-MODE HYDRAULIC AND MECHANICAL SYSTEM........................................................1256 Method of Using Troubleshooting Chart.....................................................1256 Failure Code and Cause Table..............................................................1260 H-1 The Machine Does Not Start............................................................1264 Defective Clutch and ECMV (Check by Failure Code).....................................1265 H-2 Torque Converter Lockup Will Not Switch Off (if equipped).............................1266 H-3 Torque Converter Lockup Will Not Switch On (if equipped)..............................1267 H-4 Slow Travel Speed, Weak Thrust Force and Uphill Travel and Gear Does Not Shift........1268 Defective Clutch and ECMV (Check by Failure Code).....................................1269 H-5 Strong Jerks Occur When Shifting Gears................................................1270 Defective Clutch and ECMV (Check by Failure Code).....................................1271 H-6 Extreme Time Lag Between Shifting Gears...............................................1272 Defective Clutch and ECMV (Check by Failure Code).....................................1273 H-7 Torque Converter Oil Temperature is High..............................................1274 H-8 Steering Does Not Turn................................................................1275 H-9 Steering Does Not Turn (Joystick Steering)............................................1276 H-10 Steering Response is Poor............................................................1277 H-11 Steering Response is Poor (Joystick Steering)........................................1278 H-12 Steering Feels Stiff.................................................................1279 H-13 Shaking or Jerking Occurs When Turning the Machine...................................1280 H-14 Shaking or Jerking Occurs When Turning the Machine (Joystick Steering)...............1281 H-15 Wheel Brakes Do Not Work Properly....................................................1282 H-16 Wheel Brakes Do Not Release Properly.................................................1283 H-17 The Parking Brake Does Not Work Properly.............................................1284 H-18 The Parking Brake Does Not Release Properly..........................................1285 H-19 Lift Arm Does Not Rise...............................................................1286 H-20 Lift Arm Speed is Slow or Power is Insufficient......................................1287 H-21 When Rising, Lift Arm Moves Slowly at Specific Heights...............................1288 H-22 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)............................1288 H-23 Hydraulic Drifts of the Lift Arm are Large...........................................1288 H-24 The Lift Arm Wobbles During Operation................................................1288 H-25 Bucket Does Not Tilt Back............................................................1289 H-25 Bucket Speed is Low or Tilt Back Force is Weak.......................................1290 H-27 The Bucket Operates Slowly in The Midst of Tilting Back..............................1291 H-28 The Bucket Cylinder Cannot Hold Down the Bucket......................................1291 H-29 Hydraulic Drift of The Bucket is Large...............................................1291 H-30 Bucket Wobbles During Travel Loaded (Work Equipment Valve is Set at “Hold”)..........1291 H-31 Work Equipment Levers Move Hard......................................................1292 H-32 During Operation, Engine Speed Lowers or Engine Stalls...............................1293 H-33 Strong Jerk is Felt When Work Equipment Starts and Stops.............................1293 H-34 When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves...........1293 H-35 ECSS Does Not Operate, or Pitching and Bouncing Occur................................1294 30 DISASSEBMLY AND ASSEMBLY.......................................................................1295 HOW TO READ THIS MANUAL.......................................................................1299 Removal and Installation of Assemblies....................................................1299 Disassembly and Assembly of Assemblies....................................................1301 COATING MATERIALS LIST........................................................................1303 SPECIAL TOOLS LIST............................................................................1306 SCHEMATIC DRAWINGS OF SPECIAL TOOLS...........................................................1310 CONNECTOR REPAIR PROCEDURES...................................................................1321 Stripping Insulation......................................................................1321 Wire Inspection...........................................................................1321 Contact Terminal Removal (HD30 Type)......................................................1322 Crimping Contact Terminal (HD30 Type).....................................................1323 Insertion Of Contact Terminal (HD30 Type).................................................1324 Contact Terminal Removal (DT Type)........................................................1325 Crimping Contact Terminal (DT Type).......................................................1326 Insertion Of Contact Terminal (DT Type)...................................................1327 ENGINE........................................................................................1328 Alternator................................................................................1328 Engine Front Seal.........................................................................1328 Engine Rear Seal..........................................................................1328 Starting Motor............................................................................1328 Thermostat................................................................................1328 Turbocharger..............................................................................1328 Water Pump................................................................................1328 ENGINE AND COOLING SYSTEM.....................................................................1329 Engine....................................................................................1329 Removal...............................................................................1329 Installation..........................................................................1333 Engine Hood...............................................................................1335 Removal...............................................................................1335 Installation..........................................................................1338 Radiator..................................................................................1339 Removal...............................................................................1339 Installation..........................................................................1342 Aftercooler...............................................................................1343 Removal...............................................................................1343 Installation..........................................................................1344 Oil Cooler................................................................................1345 Removal...............................................................................1345 Installation..........................................................................1346 Cooling Fan and Drive Motor...............................................................1347 Removal...............................................................................1347 Installation..........................................................................1350 Fuel Supply Pump..........................................................................1351 Special Tools.........................................................................1351 Removal...............................................................................1351 Installation..........................................................................1354 Fuel Injector.............................................................................1358 Removal...............................................................................1358 Installation..........................................................................1361 Cylinder Head.............................................................................1364 Removal...............................................................................1364 Installation..........................................................................1372 Fuel Tank.................................................................................1378 Removal...............................................................................1378 Installation..........................................................................1381 POWER TRAIN...................................................................................1382 Torque Converter and Transmission.........................................................1382 Removal...............................................................................1382 Installation..........................................................................1388 Torque Converter - Standard Specifications................................................1390 Special Tools.........................................................................1390 Disassembly...........................................................................1390 Assembly..............................................................................1392 Torque Converter - Lockup Specifications..................................................1395 Special Tools.........................................................................1395 Disassembly...........................................................................1395 Assembly..............................................................................1398 Transmission..............................................................................1403 Special Tools.........................................................................1403 Disassembly...........................................................................1403 Assembly..............................................................................1411 Transmission Clutch Pack..................................................................1421 Special Tools.........................................................................1421 Disassembly...........................................................................1421 Assembly..............................................................................1428 Parking Brake.............................................................................1443 Special Tools.........................................................................1443 Disassembly...........................................................................1443 Assembly..............................................................................1446 Front Axle................................................................................1453 Removal...............................................................................1453 Installation..........................................................................1454 Rear Axle.................................................................................1455 Removal...............................................................................1455 Installation..........................................................................1461 Axle Housing..............................................................................1463 Special Tools.........................................................................1463 Disassembly...........................................................................1463 Assembly..............................................................................1467 Differential..............................................................................1474 Special Tools.........................................................................1474 Disassembly...........................................................................1474 Assembly..............................................................................1482 UNDERCARRIAGE AND FRAME.......................................................................1498 Center Hinge Pin..........................................................................1498 Special Tools.........................................................................1498 Removal...............................................................................1498 Installation..........................................................................1503 Counterweight.............................................................................1508 Removal...............................................................................1508 Installation..........................................................................1510 HYDRAULIC SYSTEM..............................................................................1511 Steering Demand Valve.....................................................................1511 Removal...............................................................................1511 Installation..........................................................................1514 Work Equipment Valve......................................................................1515 Removal...............................................................................1515 Installation..........................................................................1518 Brake Charge Valve........................................................................1519 Removal...............................................................................1519 Installation..........................................................................1519 Hydraulic Tank............................................................................1520 Removal...............................................................................1520 Installation..........................................................................1522 Steering and Power Train Pump.............................................................1523 Removal...............................................................................1523 Installation..........................................................................1524 Work Equipment and Cooling Fan Pump.......................................................1525 Removal...............................................................................1525 Installation..........................................................................1526 WORK EQUIPMENT................................................................................1528 Work Equipment............................................................................1528 Removal...............................................................................1528 Installation..........................................................................1531 CAB AND ITS ATTACHMENTS.......................................................................1533 Operator's Cab and Floor Frame............................................................1533 Special Tools.........................................................................1533 Removal...............................................................................1533 Installation..........................................................................1537 Operator's Cab Glass (Stuck Glass)........................................................1538 Special Tools.........................................................................1538 Removal...............................................................................1538 Installation..........................................................................1539 Operator’s Seat...........................................................................1547 Disassembly...........................................................................1547 Assembly..............................................................................1554 ELECTRICAL SYSTEM.............................................................................1560 Air Conditioner Unit......................................................................1560 Special Tools.........................................................................1560 Removal...............................................................................1560 Installation..........................................................................1565 Engine Controller.........................................................................1566 Removal...............................................................................1566 Installation..........................................................................1566 Transmission Controller...................................................................1567 Removal...............................................................................1567 Installation..........................................................................1567 KOMTRAX Controller........................................................................1568 Removal...............................................................................1568 Installation..........................................................................1568 90 DIAGRAMS AND SCHEMATICS........................................................................1569 ELECTRICAL SCHEMATICS.........................................................................1571 IN CAB SWITCHES (VIEW 1 OF 47)............................................................1571 IN CAB SWITCHES AND CONNECTORS (VIEW 2 OF 47).............................................1572 CAB HARNESS (VIEW 3 OF 47)................................................................1573 TO MONITOR PANEL AND CONTROLLERS (VIEW 4 OF 47)...........................................1574 THROTTLE PEDAL, PPC AND KICK-OUT SWITCHES (VIEW 5 OF 47)..................................1575 MONITOR PANEL AND OPTIONAL LOAD METER (VIEW 6 OF 47)......................................1576 TRANSNISSION AND FAN PUMP CONTROLLER HARNESS (VIEW 7 OF 47)...............................1577 LAMP SWITCHES AND MODE SELECTOR (VIEW 8 OF 47)............................................1578 SWITCH AND CONTROLER HARNESS (VIEW 9 OF 47)...............................................1579 SYSTEM SWITCHES AND HARNESS (VIEW 10 OF 47)...............................................1580 MODE SWITCHES AND HARNESS (VIEW 11 OF 47).................................................1581 KOMTRAX SYSTEM (VIEW 12 OF 47)............................................................1582 DASH PANEL SWITCHES AND HARNESS (VIEW 13 OF 47)...........................................1583 CAB REAR HARNESS (VIEW 14 OF 47)..........................................................1584 GROUND DRIVEN STEERING AND FAN SWITCH (VIEW 15 OF 47).....................................1585 TO REAR HARNESS (VIEW 16 OF 47)...........................................................1586 TO REAR HARNESS (VIEW 17 OF 47)...........................................................1587 MAIN HARNESS (VIEW 18 OF 47)..............................................................1588 FUSES AND HARNESS (VIEW 19 OF 47).........................................................1589 SYSTEM HARNESS (VIEW 20 OF 47)............................................................1590 FUSE BOX AND HARNESS (VIEW 21 OF 47)......................................................1591 SYSTEM HARNESS (VIEW 22 OF 47)............................................................1592 RELAY SYSTEM (VIEW 23 OF 47)..............................................................1593 RELAY SYETEM (VIEW 24 OF 47)..............................................................1594 TO FRONT HARNESS (VIEW 25 OF 47)..........................................................1595 ENGINE HARNESS (VIEW 26 OF 47)............................................................1596 ENGINE CONTROL MODULE (VIEW 27 OF 47).....................................................1597 LAMPS AND SWITCH IN HARNESS (VIEW 28 OF 47)...............................................1598 ENGINE SENSORS (VIEW 29 OF 47)............................................................1599 MACHINE LIGHTING SYSTEM AND SWITCHES (VIEW 30 OF 47)......................................1600 FUSES AND GROUND DRIVEN STEERING (VIEW 31 OF 47)..........................................1601 SOLENOID AND SWITCH SYSTEMS (VIEW 32 OF 47)...............................................1602 IN CAB CONTROL SYSTEMS (VIEW 33 OF 47)....................................................1603 AIR CONDITIONING SYSTEM (VIEW 34 OF 47)...................................................1604 AIR CONDITIONING SYSTEM (VIEW 35 OF 47)...................................................1605 TO FLOOR HARNESS (VIEW 36 OF 47)..........................................................1606 ENGINE SYSTEM (VIEW 37 OF 47).............................................................1607 ENGINE CONTROL MODULE (VIEW 38 OF 47).....................................................1608 SWITCHES, RELAYS AND LAMPS (VIEW 39 OF 47)................................................1609 CONNECTING HARNESS VIEW (VIEW 40 OF 47)...................................................1610 ENGINE ACCESSORIES (VIEW 41 OF 47)........................................................1611 ENGINE CONTROL MODULE (VIEW 42 OF 47).....................................................1612 GROUND DRIVEN STEERING (VIEW 43 OF 47)....................................................1613 FRONT HARNESS AND LOAD METER (VIEW 44 OF 47)..............................................1614 FUSES (VIEW 45 OF 47).....................................................................1615 ENGINE CONTROL MODULE HARNESS (VIEW 46 OF 47).............................................1616 ENGINE FUEL INJECTORS (VIEW 47 OF 47).....................................................1617 HYDRAULIC CIRCUIT DIAGRAM.....................................................................1618 POWER TRAIN HYDRAULIC CIRCURIT DIAGRAM........................................................1619 WITH LOCKUP CLUTCH........................................................................1619 WITHOUT LOCKUP CLUTCH.....................................................................1620 CONNECTOR LIST AND STEREOGRAM.................................................................1621 CHASSIS (VIEW 1 OF 3).....................................................................1621 ENGINE AND TRANSMISSION (VIEW 2 OF 3).....................................................1622 OPERATOR'S COMPARTMENT (VIEW 3 OF 3)......................................................1623
KOMATSU WA450-6 WA480-6 WHEEL LOADER SHOP MANUAL CEBM018601 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
