Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual PDF

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Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024419 – PDF DOWNLOAD

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Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024419 – PDF DOWNLOAD 

Language : English
Pages : 1316
Downloadable : Yes
File Type : PDF

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Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024419 – PDF DOWNLOAD 

MACHINE MODEL     SERIAL NUMBER
WA470-5                      70001 and up
WA480-5                      80001 and up

COVER 1
CONTENTS 2
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 35
LIST OF LUBRICANT AND COOLANT 37
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 39
RADIATOR, OIL COOLER 40
ENGINE MOUNT, TRANSMISSION MOUNT 41
POWER TRAIN 42
POWER TRAIN SYSTEM DIAGRAM 43
DRIVE SHAFT 46
TORQUE CONVERTER,TRANSMISSION PIPING 47
TORQUE CONVERTER 48
TRANSMISSION 58
TRANSMISSION CONTROL VALVE 76
AXLE 94
DIFFERENTIAL 98
FINAL DRIVE 110
AXLE MOUNTING,CENTER HINGE PIN 116
STEERING PIPING 120
STEERING COLUMN, ORBIT-ROLL 121
STEERING VALVE 122
ORBIT-ROLL VALVE 138
STOP VALVE 142
STEERING PUMP, SWITCH PUMP 144
EMERGENCY STEERING PUMP (IF EQUIPPED) 146
EMERGENCY STEERING MOTOR (IF EQUIPPED) 147
STEERING CYLINDER 148
JOYSTICK STEERING LEVER (IF EQUIPPED) 150
STEERING LEVER (IF EQUIPPED) 152
STEERING SWITCH VALVE (IF EQUIPPED) 154
BRAKE PIPING 156
BRAKE VALVE 158
CHARGE VALVE 166
ACCUMULATOR (FOR BRAKE) 170
SLACK ADJUSTER 172
BRAKE 174
PARKING BRAKE CONTROL 180
PARKING BRAKE 182
PARKING BRAKE SOLENOID VALVE 184
PARKING BRAKE EMERGENCY RELEASE VALVE 186
HYDRAULIC PIPING 188
WORK EQUIPMENT CONTROL LEVER 192
HYDRAULIC TANK 194
TORQUE CONVERTER CHARGING,WORK EQUIPMENT,AND PPC PUMPS 196
PPC RELIEF VALVE 198
ECSS VALVE (IF EQUIPPED) 200
WORK EQUIPMENT CONTROL VALVE 202
PPC VALVE 222
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) 228
WORK EQUIPMENT CONTROL EPC VALVE (IF EQUIPPED) 234
SHUT OFF VALVE (IF EQUIPPED) 237
COOLING FAN MOTOR 238
COOLING FAN MOTOR DRIVE PUMP 244
WORK EQUIPMENT LINKAGE 252
BUCKET 254
BUCKET POSITIONER, BOOM KICK-OUT 256
WORK EQUIPMENT CYLINDER 262
CAB 264
AIR CONDITIONER (IF EQUIPPED) 265
MACHINE MONITORING SYSTEM 266
MACHINE MONITOR 274
TRANSMISSION CONTROL SYSTEM 344
TRANSMISSION CONTROLLER 372
WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED) 374
WORK EQUIPMENT CONTROLLER (IF EQUIPPED) 390
ELECTRIC TRANSMISSION CONTROL 392
KICK DOWN, HOLD SWITCH 396
ENGINE STARTING CIRCUIT 398
ENGINE STOP CIRCUIT 400
PARKING BRAKE CIRCUIT 402
SENSORS 406
20 TESTING AND ADJUSTING 417
STANDARD VALUE TABLE 418
STAND ARD VALUE TABLE FOR ENGINE 418
STANDARD VALUE TABLE FOR CHASSIS 419
TESTING AND ADJUSTING 427
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 428
MEASURING ENGINE SPEED 430
MEASURING EXHAUST COLOR 432
MEASURING EXHAUST TEMPERATURE 433
ADJUSTING VALVE CLEARANCE 434
MEASURING COMPRESSION PRESSURE 436
MEASURING BLOW-BY PRESSURE 438
MEASURING ENGINE OIL PRESSURE 439
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 440
MEASURING FUEL PRESSURE 440
TESTING LEAKAGE THROUGH PRESSURE LIMITER AND RETURN RATE FROM INJECTOR 442
HANDLING EQUIPMENT IN FUEL SYSTEM 446
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 446
BLEEDING AIR FROM FUEL CIRCUIT 447
REDUCED CYLINDER MODE OPERATION FOR ENGINE 449
CHECKING FOR LEAKAGE IN FUEL SYSTEM 451
ADJUSTING ACCELERATOR PEDAL POTENTIOMETER 452
ADJUSTING ACCELERATOR PEDAL MICROSWITCH 453
ADJUSTING TRANSMISSION SPEED SENSOR 454
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE 455
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 459
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 460
TESTING AND ADJUSTING STEERING CONTROL 462
TESTING AND ADJUSTING STEERING OIL PRESSURE 463
TESTING HYDRAULIC FAN 465
MEASURING BRAKE OIL PRESSURE 466
TESTING WEAR OF WHEEL BRAKE DISC 468
BLEEDING AIR FROM BRAKE CIRCUIT 469
TESTING WEAR OF PARKING BRAKE DISC 470
MANUAL RELEASE METHOD FOR PARKING BRAKE 471
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 472
TESTING AND ADJUSTING PPC OIL PRESSURE 474
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 476
TESTING AND ADJUSTING BUCKET POSITIONER 478
TESTING AND ADJUSTING LIFT ARM KICK-OUT 479
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP 480
ADJUSTING MACHINE MONITOR 481
TESTING AND ADJUSTING LOAD METER 484
BLEEDING AIR 488
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 489
RELEASING REMAINING PRESSURE IN ECSS DAMPER CIRCUIT 489
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT 490
INDICATOR LAMPS OF KOMTRAX TERMINAL 491
PM-CLINIC INSPECTION TABLE 497
TROUBLESHOOTING 499
POINTS TO REMEMBER WHEN TROUBLESHOOTING 500
SEQUENCE OF EVENTS IN TROUBLESHOOTING 501
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 502
CHECKS BEFORE TROUBLESHOOTING 510
SPECIAL FUNCTIONS OF MACHINE MONITOR 512
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS 549
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 558
T-ADAPTER TABLE 581
CONNECTOR TYPES AND INSTALLATION POSITIONS 585
CONNECTORS LAYOUT DRAWING 594
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE) 603
ENGINE CONTROL SYSTEM DIAGRAM 604
FAILURE CODE [A000N1] (ENGINE OVERRUN (N1)) IS DISPLAYED 606
FAILURE CODE [AD00L2] (COMMON RAIL IS HIGHER THAN MAXIMUM SET VALUE) IS DISPLAYED 607
FAILURE CODE [AD00MA] (FUNCTION OF COMMON RAIL IS DEFECTIVE) IS DISPLAYED 608
FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP CANNOT BE CONTROLLED) IS DISPLAYED 609
FAILURE CODE [AD10MA] (FUNCTION OF FUEL SUPPLY PUMP IS DEFECTIVE) IS DISPLAYED 613
FAILURE CODE [AD10MB] (FUNCTION OF FUEL SUPPLY PUMP IS LOWERED) IS DISPLAYED 614
FAILURE CODE [AD11KA] (DISCONNECTION IN FUEL SUPPLY PUMP PVC1 SYSTEM) IS DISPLAYED 615
FAILURE CODE [AD11KB] (SHORT CIRCUIT IN FUEL SUPPLY PUMP PVC1 SYSTEM) IS DISPLAYED 616
FAILURE CODE [AD51KA] (DISCONNECTION IS FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED 617
FAILURE CODE [AD51KB] (SHORT CIRCUIT IN FUEL SUPPLY PUMP PVC2 SYSTEM) IS DISPLAYED 618
FAILURE CODE [ADA1KA] (DISCONNECTION IN NO 1 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED) 619
FAILURE CODE [ADAZKB] (SHORT CIRCUIT IN NO 1,2,3 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 620
FAILURE CODE [ADB1KA] (DISCONNECTION IN NO 2 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 622
FAILURE CODE [ADC1KA] (DISCONNECTION IN NO 3 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 623
FAILURE CODE [ADD1KA] (DISCONNECTION IN NO 4 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 624
FAILURE CODE [ADDZKB] (SHORT CIRCUIT IN NO 4,5,6 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 626
FAILURE CODE [ADE1KA] (DISCONNECTION IN NO 5 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 628
FAILURE CODE [ADF1KA] (DISCONNECTION IN NO 6 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 629
FAILURE CODE [D182KZ] (DISCONNECTION OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL) ID DISPLAYED 630
FAILURE CODE [D1D0KB] (SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY OF ENGINE CONTROLLER POWER SUPPLY (SW) CIRCUIT) IS DISPLAYED 632
FAILURE CODE [DB20KT] (TROUBLE IN CONTROLLER) IS DISPLAYED 634
FAILURE CODE [DB22KK] (TROUBLE IN POWER SUPPLY OF ENGINE CONTROLLER LOAD POWER SUPPLY (SW) 1) IS DISPLAYED 636
FAILURE CODE [DB29KQ] (NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER CONNECTING WIRING HARNESS) IS DISPLAYED 638
FAILURE CODE [DB2AMA] (FUNCTION OF Q ADJUSTMENT SWITCH OF ENGINE CONTROLLER IS DEFECTIVE) IS DISPLAYED 640
FAILURE CODE [DD11KB] (TROUBLE IN INPUT OF STARTING SWITCH C (IGN C)) IS DISPLAYED 642
FAILURE CODE [DGE3L6] (TROUBLE IN WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM) IS DISPLAYED 644
FAILURE CODE [DGE4KX] (TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM) ID DISPLAYED 645
FAILURE CODE [DH30KX] (TROUBLE IN BOOST PRESSURE SENSOR SYSTEM) ID DISPLAYED 646
FAILURE CODE [DH40KX] (TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED 647
FAILURE CODE [DK10KX] (TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM) IS DISPLAYED 648
FAILURE CODE [DLE3LC] (TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM) IS DISPLAYED 649
FAILURE CODE [DLH1LC] (TROUBLE IN ENGINE G SPEED SYSTEM) IS DISPLAYED 650
TROUBLESHOOTING CODE [ENG-1] (ENGINE DOED NOT START) IS DISPLAYED 651
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE) 657
TRANSMISSION CONTROL SYSTEM DIAGRAM 660
FAILURE CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED 663
FAILURE CODE [15SAL1] (F_ECMV F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 664
FAILURE CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 665
FAILURE CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 666
FAILURE CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 667
FAILURE CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 668
FAILURE CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 669
FAILURE CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 670
FAILURE CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 671
FAILURE CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 672
FAILURE CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 673
FAILURE CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 674
FAILURE CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 675
FAILURE CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 676
FAILURE CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 677
FAILURE CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED 678
FAILURE CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED 680
FAILURE CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 681
FAILURE CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 682
FAILURE CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 683
FAILURE CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 684
FAILURE CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 686
FAILURE CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 688
FAILURE CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 690
FAILURE CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 691
FAILURE CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED 692
FAILURE CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED 693
FAILURE CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED 694
FAILURE CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED 696
FAILURE CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH OR MULTI FUNCTION MONO LEVER FNR SWITCH SIGNAL INPUT) IS DISPLAYED 698
FAILURE CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED 700
FAILURE CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED 702
FAILURE CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED 704
FAILURE CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED 705
FAILURE CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED 706
FAILURE CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED 708
FAILURE CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED 709
FAILURE CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED 712
FAILURE CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED 714
FAILURE CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED 716
FAILURE CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED 718
FAILURE CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED 719
FAILURE CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 720
FAILURE CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED 721
FAILURE CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED 722
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED 723
FAILURE CODE [DLT3KA] (SPEED SENSOR SYSTEM DISCONTINUITY (TRANSMISSION REVOLUTION SENSOR FAILURE)) IS DISPLAYED 724
FAILURE CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED 725
FAILURE CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 726
FAILURE CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 727
FAILURE CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED 728
FAILURE CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED 729
FAILURE CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 730
FAILURE CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 731
FAILURE CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 732
FAILURE CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 733
FAILURE CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 734
FAILURE CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 735
FAILURE CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 736
FAILURE CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 737
FAILURE CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 738
FAILURE CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 739
FAILURE CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 740
FAILURE CODE [DXH7KB] (3RD_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 741
FAILURE CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 742
FAILURE CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 743
FAILURE CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 744
FAILURE CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 745
FAILURE CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE)) 746
FAILURE CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE)) 748
TROUBLESHOOTING CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM 750
TROUBLESHOOTING CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING (NO HOLD CONTROL PERFORMED BY PRESSING HOLD SWITCH) 752
TROUBLESHOOTING CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE (NO LOCK-UP PERFORMED OR NO LOCK-UP CANCELLATION PERFORMED) 754
TROUBLESHOOTING CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE 756
TROUBLESHOOTING CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE 758
TROUBLESHOOTING CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT 760
TROUBLESHOOTING CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING 761
TROUBLESHOOTING CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING 762
TROUBLESHOOTING CODE [TM-9-a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT) 763
TROUBLESHOOTING CODE [TM-9-b] (FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE) 764
TROUBLESHOOTING CODE [TM-10] (STARTING SWITCH “C” (IGN_C) SIGNAL SYSTEM FAILURE) 766
TROUBLESHOOTING CODE [TM-11] (JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE) 768
TROUBLESHOOTING CODE [TM-12] (ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT) 770
TROUBLESHOOTING CODE [TM-13] (TRAVEL DAMPER NO/OFF SWITCH DISCONTINUITY OR GROUND FAULT) 771
TROUBLESHOOTING CODE [TM-14] (HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY) 772
TROUBLESHOOTING CODE [TM-15] (MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 774
TROUBLESHOOTING CODE [TM-16] (TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 775
TROUBLESHOOTING CODE [TM-17] (SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 776
TROUBLESHOOTING CODE [TM-18] (BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 777
TROUBLESHOOTING CODE [TM-19] (NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING) 778
TROUBLESHOOTING CODE [TM-20] (F ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 779
TROUBLESHOOTING CODE [TM-21] (R ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 780
TROUBLESHOOTING CODE [TM-22] (1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 781
TROUBLESHOOTING CODE [TM-23] (2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 782
TROUBLESHOOTING CODE [TM-24] (3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 783
TROUBLESHOOTING CODE [TM-25] (4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 784
TROUBLESHOOTING CODE [TM-26] (LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 785
TROUBLESHOOTING CODE [TM-27] (FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING) 786
TROUBLESHOOTING CODE [TM-28] (FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING) 787
TROUBLESHOOTING CODE [TM-29] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE) 788
TROUBLESHOOTING CODE [TM-30] (ECSS SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT) 789
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE) 791
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 794
FAILURE CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED 797
FAILURE CODE [D193KB] (DEFECTIVE JOYSTICK SOLENOID CUT RELAY SYSTEM (GROUND FAULT)) IS DISPLAYED 798
FAILURE CODE [DB90KK] (LOWERING VOLTAGE OF WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED 799
FAILURE CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 800
FAILURE CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 802
FAILURE CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED 804
FAILURE CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED 805
FAILURE CODE [DFAOKM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED 806
FAILURE CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 807
FAILURE CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED 808
FAILURE CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 809
FAILURE CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED 810
FAILURE CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 811
FAILURE CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 812
FAILURE CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIUCUIT SHORTED)) IS DISPLAYED 813
FAILURE CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB CIRCUIT)) IS DISPLAYED 814
FAILURE CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 815
FAILURE CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB CIRCUIT)) IS DISPLAYED 816
FAILURE CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 817
FAILURE CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED 818
FAILURE CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB CIRCUIT)) IS DISPLAYED 819
FAILURE CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 820
FAILURE CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB CIRCUIT)) IS DISPLAYED 821
FAILURE CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 822
FAILURE CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED 823
FAILURE CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM) IS DISPLAYED 824
FAILURE CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB CIRCUITS)) IS DISPLAYED 825
FAILURE CODE [DK5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB CIRCUIT)) IS DISPLAYED 826
FAILURE CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 827
FAILURE CODE [DKAOKA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (OUTSIDE OF SIGNAL VOLTAGE AREA: DISCONNECTION OR GROUND FAULT)) IS DISPLAYED 828
FAILURE CODE [DKAOKY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED 829
FAILURE CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 830
FAILURE CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED 831
FAILURE CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED 832
FAILURE CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED 833
FAILURE CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED 834
FAILURE CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 835
FAILURE CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED 836
FAILURE CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 837
FAILURE CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED 838
FAILURE CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 839
FAILURE CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 840
FAILURE CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 841
FAILURE CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 842
FAILURE CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 843
FAILURE CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 844
FAILURE CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 845
FAILURE CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 846
FAILURE CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 847
FAILURE CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 848
FAILURE CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED 849
FAILURE CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 850
FAILURE CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 851
FAILURE CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 852
FAILURE CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 853
FAILURE CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 854
FAILURE CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 855
FAILURE CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 856
FAILURE CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 857
TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM 858
TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM 859
TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM 860
TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM 862
TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM 864
TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM 866
TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SYSTEM 868
TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARDWARE SELECTION SWITCH SYSTEM 869
TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFTWARE SELECTION SWITCH SYSTEM 870
TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM 872
TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM 874
TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM 875
TROUBLESHOOTING CODE [WRK-13] SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM 876
TROUBLESHOOTING CODE [WRK-14] SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM 877
TROUBLESHOOTING CODE [WRK-15] SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM 878
TROUBLESHOOTING CODE [WRK-16] SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM 879
TROUBLESHOOTING CODE [WRK-17] SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM 880
TROUBLESHOOTING CODE [WRK-18] SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM 881
TROUBLESHOOTING CODE [WRK-19] SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM 882
TROUBLESHOOTING CODE [WRK-20] SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM 883
TROUBLESHOOTING CODE [WRK-21] SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM 884
TROUBLESHOOTING CODE [WRK-22] SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM 885
TROUBLESHOOTING CODE [WRK-23] SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM 886
TROUBLESHOOTING CODE [WRK-24] SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM 887
TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER,LIFT ARM KICK-OUT AND FLOATING MAINTENANCE FUNCTION 888
TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION 890
TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION 892
TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING MAINTENANCE AND CANCELLATION 894
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) 897
MONITOR SYSTEM DIAGRAM 900
FAILURE CODE [2F00MA] DEFECTIVE PARKING BRAKE SYSTEM 904
FAILURE CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW 906
FAILURE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW 907
FAILURE CODE [AA1ANX] AIR CLEANER 1 CLOGGED 908
FAILURE CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED 910
FAILURE CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED,DETECTION FAILURE) 911
FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE LOW 912
FAILURE CODE [B@BAZK] ENGINE OIL LEVEL LOW 913
FAILURE CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING 914
FAILURE CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL 915
FAILURE CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING 916
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING 917
FAILURE CODE [D5ZHL6] STARTING SWITCH C (IGN”C”) INPUT FAILURE 918
FAILURE CODE [DA80L4] AUTO GREASE INPUT FAILURE 919
FAILURE CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF 920
FAILURE CODE [DAF5KP] 5-V POWER SUPPLY OUTPUT FAILURE 922
FAILURE CODE [DAF6KP] 24-V POWER SUPPLY OUTPUT FAILURE 924
FAILURE CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION 926
FAILURE CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION 927
FAILURE CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) SELECTION 928
FAILURE CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 929
FAILURE CODE [DB2SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER) 930
FAILURE CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 932
FAILURE CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SW1) INPUT ERROR 933
FAILURE CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SW2) INPUT ERROR 934
FAILURE CODE [DD17LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [＜](PANEL SW3) INPUT ERROR 935
FAILURE CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [＞](PANEL SW4) INPUT ERROR 936
FAILURE CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE (*) 938
FAILURE CODE [DDS5L6] DECREASED STEERING OIL PRESSURE 940
FAILURE CODE [DDY0LD] CANCEL SWITCH FAILURE (*) 942
FAILURE CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE 943
FAILURE CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE 944
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE 945
FAILURE CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE 946
FAILURE CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE (*) 948
FAILURE CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE (*) 950
FAILURE CODE [DKA0KX] BOOM ANGLE SENSOR FAILURE (*) 951
FAILURE CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM 952
FAILURE CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE 954
TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT) 956
TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT) 958
TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT) 959
TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 960
TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 962
TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON 963
TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 964
TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON 965
TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON AFTER THE ENGINE STARTS, THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE 966
TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON AFTER THE ENGINE STARTS, THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE 967
TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 968
TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1) 969
TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◇] (PANEL SW2) 970
TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3) 971
TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4) 972
TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH 973
TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH 974
TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT) 975
TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR 976
TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION IN ALARM BUZZER OUTPUT SYSTEM, OR GROUND FAULT) 977
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 979
H-1 THE MACHINE DOES NOT START 980
H-2 THE LOCK UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS)(WHEN THE LOCK-UP CLUTCH IS PROVIDED) 982
H-3a THE TRAVEl SPEED IS SLOW,THE THRUSTING FORCE IS WEAK,THE UPHILL TRAVELING POWER IS WEAK,AND THE GEAR IS NOT SHIFTED 983
H-3b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LOT IN(WHEN THE LOCK-UP CLUTCH IS PROVIDED 985
H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 986
H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 988
H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH 990
H-7 THE STEERING WHEEL DOES NOT TURN 991
H-8 THE STEERING WHEEL IS HEAVY 992
H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED 993
H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING 993
H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT 993
H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL 994
H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED 995
H-14 THE BRAKE IS NOT RELEASED OR DRAGGED 996
H-15 THE LIFT ARM DOES NOT RISE 997
H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 998
H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT 999
H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR) 999
H-19 HYDRAULIC DRIFTS OF THE LIFE ARM OCCUR OFTEN 999
H-20 THE LIFT ARM WOBBLES DURING OPERATION 999
H-21 WHEN THE CONTROL LOVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY 1000
H-22 THE BUCKET DOES NOT TILT BACK 1001
H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT 1002
H-24 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK 1003
H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 1003
H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN 1003
H-27 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 1004
H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY 1004
H-29 THE CONTROL LOVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 1005
H-30 ECSS DOES NOT WORK,AND THERE IS PITCHING AND BOUNCING 1006
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 1007
ELECTRICAL SYSTEM DIAGRAM 1008
TROUBLESHOOTING CODE [E-1-a] (THE FRONT WIPER DOES NOT FUNCTION) 1009
TROUBLESHOOTING CODE [E-1-b] (THE REAR WIPER DOES NOT FUNCTION) 1012
TROUBLESHOOTING CODE [E-1-c] (THE SIDE WIPER DOES NOT FUNCTION)(IF EQUIPPED) 1013
TROUBLESHOOTING CODE [E-2] (THE WIND WASHER DOES NOT FUNCTION) 1014
TROUBLESHOOTING CODE [E-3-a] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON) 1017
TROUBLESHOOTING CODE [E-3-b] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION) 1020
TROUBLESHOOTING CODE [E-3-c] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP) 1022
TROUBLESHOOTING CODE [E-3-d] (THE TURN SIGNAL DOES NOT BLINK) 1023
TROUBLESHOOTING CODE [E-4] (THE HORN DOES NOT SOUND) 1025
TROUBLESHOOTING CODE [E-5] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP) 1027
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 1031
POINTS TO REMEMBER WHEN TROUBLESHOOTING 1032
METHOD OF USING TROUBLESHOOTING CHARTS 1033
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 1037
S-2 ENGINE DOES NOT START 1038
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 1041
S-4 ENGINE STOPS DURING OPERATIONS 1042
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 1043
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 1044
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 1045
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 1046
S-9 OIL BECOMES CONTAMINATED QUICKLY 1047
S-10 FUEL CONSUMPTION IS EXCESSIVE 1048
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN) 1049
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 1050
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL) 1051
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1052
S-15 ABNORMAL NOISE IS MADE 1053
S-16 VIBRATION IS EXCESSIVE 1054
30 DISASSEMBLY AND ASSEMBLY 1055
HOW TO READ THIS MANUAL 1058
PRECAUTIONS WHEN PERFORMING OPERATION 1061
SPECIAL TOOL LIST 1064
SKETCHES OF SPECIAL TOOLS 1069
FUEL SUPPLY PUMP ASSEMBLY 1084
SPECIAL TOOLS 1084
REMOVAL 1084
INSTALLATION 1086
FUEL INJECTOR ASSEMBLY 1089
REMOVAL 1089
INSTALLATION 1091
NOZZLE TIP 1093
SPECIAL TOOL 1093
REMOVAL 1093
INSTALLATION 1094
CYLINDER HEAD ASSEMBLY 1096
SPECIAL TOOL 1096
REMOVAL 1096
INSTALLATION 1100
RADIATOR ASSEMBLY 1103
REMOVAL 1103
INSTALLATION 1104
AIR AFTERCOOLER ASSEMBLY 1105
REMOVAL 1105
INSTALLATION 1105
COOLONG FAN DRIVE MOTOR 1106
REMOVAL 1106
INSTALLATION 1106
ENGINE ASSEMBLY 1107
REMOVAL 1107
INSTALLATION 1111
STEERING, SWITCH PUMP, COOLING FAN DRIVE PUMP ASSEMBLY 1112
REMOVAL 1112
INSTALLATION 1113
TORQUE CONVERTER CHARGE, WORK EQUIPMENT AND PPC PUMP ASSEMBLY 1114
REMOVAL 1114
INSTALLATION 1114
TORQUE CONVERTER, TRANSMISSION ASSEMBLY 1115
REMOVAL 1115
INSTALLATION 1118
TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATIONS) 1120
SPECIAL TOOLS 1120
DISASSEMBLY 1120
ASSEMBLY 1121
TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATIONS) 1124
SPECIAL TOOLS 1124
DISASSEMBLY 1124
ASSEMBLY 1126
TRANSMISSION ASSEMBLY 1131
SPECIAL TOOLS 1131
DISASSEMBLY 1131
ASSEMBLY 1137
TRANSMISSION CLUTCH PACK ASSEMBLY 1147
SPECIAL TOOLS 1147
DISASSEMBLY 1147
ASSEMBLY 1153
PARKING BRAKE ASSEMBLY 1166
SPECIAL TOOLS 1166
DISASSEMBLY 1166
ASSEMBLY 1168
FRONT AXLE ASSEMBLY 1174
DISASSEMBLY 1174
ASSEMBLY 1175
REAR AXLE ASSEMBLY 1176
REMOVAL 1176
INTALLATION 1178
AXLE HOUSING ASSEMBLY 1180
SPECIAL TOOLS 1180
DISASSEMBLY 1180
ASSEMBLY 1183
DIFFERENTIAL ASSEMBLY 1190
SPECIAL TOOLS 1190
DISASSEMBLY 1190
ASSEMBLY 1197
CENTER HINGE PIN 1212
SPECIAL TOOLS 1212
REMOVAL 1212
INSTALLATION 1216
STEERING VALVE ASSEMBLY 1220
REMOVAL 1220
INSTALLATION 1221
STEERING VALVE OIL SEAL 1222
REMOVAL 1222
INSTALLATION 1223
ECSS ASSEMBLY 1224
REMOVAL 1224
INSTALLATION 1224
PARKING BRAKE DISC 1225
SPECIAL TOOLS 1225
REMOVAL 1225
INSTALLATION 1227
HYDRAULIC TANK 1228
REMOVAL 1228
INSTALLATION 1229
WORK EQUIPMENT VALVE ASSEMBLY 1230
REMOVAL 1230
INSTALLATION 1231
HYDRAULIC CYLINDER ASSEMBLY 1232
SPECIAL TOOLS 1232
DISASSEMBLY 1232
ASSWMBLY 1235
WORK EQUIPMENT ASSEMBLY 1240
REMOVAL 1240
INSTALLATION 1242
COUNTERWEIGHT 1245
REMOVAL 1245
INSTALLATION 1245
FUEL TANK ASSEMBLY 1246
REMOVAL 1246
INSTALLATION 1246
CAB ASSEMBLY 1247
REMOVAL 1247
INSTALLATION 1249
CAB, FLOOR FRAME ASSEMBLY 1250
REMOVAL 1250
INSTALLATION 1253
OPERATOR’S CAB GLASS (STUCK GLASS) 1254
SPECIAL TOOLS 1254
REMOVAL 1254
INSTALLATION 1255
AIR CONDITIONER UNIT ASSEMBLY 1262
REMOVAL 1262
INSTALLATION 1264
AIR CONDITIONER COMPRESSOR ASSEMBLY 1265
SPECIAL TOOLS 1265
REMOVAL 1265
INSTALLATION 1265
OPERATOR’S SEAT ASSEMBLY 1266
DISASSEMBLY 1266
ASSEMBLY 1271
90 OTHERS 1275
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1277
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER) 1279
POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH) 1281
POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH) 1283
BRAKE OIL CIRCUIT DIAGRAM 1285
ELECTRICAL CIRCUIT DIAGRAM(1/8)(1/4) 1287
ELECTRICAL CIRCUIT DIAGRAM(1/8)(2/4) 1289
ELECTRICAL CIRCUIT DIAGRAM(1/8)(3/4) 1291
ELECTRICAL CIRCUIT DIAGRAM(1/8)(4/4) 1293
ELECTRICAL CIRCUIT DIAGRAM(2/8)(1/4) 1295
ELECTRICAL CIRCUIT DIAGRAM(2/8)(2/4) 1297
ELECTRICAL CIRCUIT DIAGRAM(2/8)(3/4) 1299
ELECTRICAL CIRCUIT DIAGRAM(2/8)(4/4) 1301
ELECTRICAL CIRCUIT DIAGRAM(3/8) 1303
ELECTRICAL CIRCUIT DIAGRAM(4/8) 1305
ELECTRICAL CIRCUIT DIAGRAM(5/8) 1307
ELECTRICAL CIRCUIT DIAGRAM(6/8) 1309
ELECTRICAL CIRCUIT DIAGRAM(7/8) 1311
ELECTRICAL CIRCUIT DIAGRAM(8/8) 1313
AXLE OIL TEMPERATURE GAUGE ELECTRICAL CIRCUIT DIAGRAM 1315

DESCRIPTION:

Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024419 – PDF DOWNLOAD 

MACHINE MODEL     SERIAL NUMBER
WA470-5                      70001 and up
WA480-5                      80001 and up

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 29/12/24