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Komatsu WA470-5H, WA480-5H Wheel Loader Shop Manual – PDF DOWNLOA
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Komatsu WA470-5H, WA480-5H Wheel Loader Shop Manual
MODEL SERIAL NUMBER
WA470-5H WA470H50051 AND UP
WA480-5H WA480H50051 AND UP
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Description
Komatsu WA470-5H, WA480-5H Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA470-5H, WA480-5H Wheel Loader Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEBM180101
Total Pages : 1302
KOMATSU WA470-5H, WA480-5H WHEEL LOADER SHOP MANUAL – PDF DOWNLOA:
DESCRIPTION:
Komatsu WA470-5H, WA480-5H Wheel Loader Shop Manual
FOREWORD:
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 chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
TABLE OF CONTENTS:
Komatsu WA470-5H, WA480-5H Wheel Loader Shop Manual
WA470-5H / WA480-5H............................................................................................. 1 CONTENTS........................................................................................................ 3 SAFETY.......................................................................................................... 13 Safety...................................................................................................... 14 Safety notice........................................................................................... 14 General precautions..................................................................................... 14 Preparations for work................................................................................... 15 Precautions during work................................................................................. 15 General..................................................................................................... 17 General................................................................................................. 17 Structure and Function.................................................................................. 17 Testing, Adjusting and Troubleshooting.................................................................. 17 Disassembly and Assembly................................................................................ 17 Maintenance Standard.................................................................................... 17 How to read the shop manual................................................................................. 18 Volumes................................................................................................. 18 Filing method........................................................................................... 18 Revised edition mark.................................................................................... 18 Revisions............................................................................................... 18 Symbols................................................................................................. 19 Hoisting instructions....................................................................................... 20 Hoisting................................................................................................ 20 Coating materials........................................................................................... 22 Standard tightening torque.................................................................................. 24 Standard tightening torque of bolts and nuts............................................................ 24 Tightening torque of hose nuts.......................................................................... 25 Tightening torque of split flange bolts................................................................. 25 Tightening torque for flared nuts....................................................................... 25 Tightening torque for 102 engine series (bolts and nuts)................................................ 26 Tightening torque for 102 engine series (eye joints).................................................... 26 Tightening torque for 102 engine series (tapered screws)................................................ 26 Electric wire code.......................................................................................... 27 Classification by thickness............................................................................. 27 Classification by color and code........................................................................ 27 Conversion tables........................................................................................... 28 Method of using the conversion table.................................................................... 28 Temperature......................................................................................... 33 Units....................................................................................................... 34 GENERAL......................................................................................................... 35 General assembly drawing.................................................................................... 36 Specifications.............................................................................................. 37 Weight table................................................................................................ 41 List of lubricant and coolant............................................................................... 43 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD.................................................................... 45 Radiator, oil cooler........................................................................................ 46 Engine mount, transmission mount............................................................................ 47 Power train................................................................................................. 48 Power train system diagram.................................................................................. 49 Without torque converter lock-up clutch................................................................. 49 With torque converter lock-up clutch.................................................................... 50 Drive shaft (propeller shaft)............................................................................... 52 Torque converter, transmission piping....................................................................... 53 Torque converter............................................................................................ 54 Without lock-up clutch.................................................................................. 54 Path of power transmission.............................................................................. 57 With lock-up clutch..................................................................................... 58 Path of power transmission.............................................................................. 62 Transmission................................................................................................ 64 F-R clutch (without lock-up clutch)..................................................................... 71 F-R clutch (with lock-up clutch)........................................................................ 72 1st-4th clutch.......................................................................................... 73 2nd-3rd clutch.......................................................................................... 74 Operation of clutch..................................................................................... 75 Forward 1st............................................................................................. 76 Forward 2nd............................................................................................. 77 Forward 3rd............................................................................................. 78 Forward 4th............................................................................................. 79 Reverse 1st............................................................................................. 80 Transmission control valve.................................................................................. 82 Without lock-up clutch.................................................................................. 82 With lock-up clutch..................................................................................... 84 ECMV (Electronic Control Modulation Valve).............................................................. 86 ECMV for speed clutch................................................................................... 87 ECMV for lock-up clutch................................................................................. 90 Main relief, torque converter relief valve.............................................................. 92 Flow valve.......................................................................................... 94 Axle........................................................................................................ 96 Front axle – WA470-5.................................................................................... 96 Front axle – WA480-5.................................................................................... 97 Rear axle – WA470-5..................................................................................... 98 Rear axle – WA480-5..................................................................................... 99 Differential................................................................................................ 100 Anti-slip differential.................................................................................. 100 Operation of anti-slip differential................................................................. 104 Front differential...................................................................................... 106 Rear differential....................................................................................... 108 Final drive................................................................................................. 112 WA470-5................................................................................................. 112 WA480-5................................................................................................. 113 Axle mounting, center hinge pin............................................................................. 118 Steering piping............................................................................................. 122 Steering column, orbit-roll................................................................................. 123 Steering valve.............................................................................................. 124 Overload relief valve................................................................................... 126 Function............................................................................................ 126 Operation........................................................................................... 126 Steering relief valve................................................................................... 128 Function............................................................................................ 128 Operation of steering relief valve.................................................................. 129 Operation of demand valve........................................................................... 130 Flow AMP............................................................................................ 133 Operation of steering valve......................................................................... 136 Orbit-roll valve............................................................................................ 140 Connection between hand pump and sleeve................................................................. 142 Stop valve.................................................................................................. 144 Steering pump, switch pump.................................................................................. 146 Emergency steering pump (op)................................................................................ 148 Emergency steering motor (op)............................................................................... 149 Steering cylinder........................................................................................... 150 Joystick steering lever (op)................................................................................ 152 Steering lever (op)......................................................................................... 154 (For joystick steering lever)........................................................................... 154 Steering switch valve (op).................................................................................. 156 (For joystick steering lever)........................................................................... 156 Brake piping................................................................................................ 158 Brake valve................................................................................................. 160 Brake valve (left)...................................................................................... 160 Brake valve (right)..................................................................................... 162 Outline............................................................................................. 164 Operation........................................................................................... 164 Charge valve................................................................................................ 168 Accumulator (for brake)..................................................................................... 172 Slack adjuster.............................................................................................. 174 Outline................................................................................................. 175 Operation............................................................................................... 175 Brake....................................................................................................... 176 Front................................................................................................... 176 Outline............................................................................................. 177 Rear.................................................................................................... 178 Outline............................................................................................. 179 Outline............................................................................................. 180 Parking brake control....................................................................................... 182 Parking brake............................................................................................... 184 Outline................................................................................................. 184 Parking brake solenoid valve................................................................................ 186 Operation............................................................................................... 187 Parking brake emergency release valve....................................................................... 188 Outline................................................................................................. 188 Hydraulic piping............................................................................................ 190 Outline................................................................................................. 192 Work equipment control lever................................................................................ 194 For PPC valve........................................................................................... 194 For EPC valve (op)...................................................................................... 195 Hydraulic tank.............................................................................................. 196 Breather................................................................................................ 197 Torque converter charging, work equipment, and PPC pumps.................................................... 198 Outline................................................................................................. 198 PPC relief valve............................................................................................ 200 Outline................................................................................................. 200 Operation............................................................................................... 201 Travel damper valve (op).................................................................................... 202 Work equipment control valve................................................................................ 204 PPC valve................................................................................................... 224 Work equipment control epc valve (op)....................................................................... 230 Shut off valve (op)......................................................................................... 233 Cooling fan motor........................................................................................... 234 Model: LMF28............................................................................................ 234 Cooling fan motor drive pump................................................................................ 240 Model: LPV30............................................................................................ 240 Servo valve................................................................................................. 245 Safety valve................................................................................................ 247 Work equipment linkage...................................................................................... 248 Bucket...................................................................................................... 250 Bucket positioner, lift arm kick-out........................................................................ 251 Bucket positioner....................................................................................... 252 Lift arm kick-out....................................................................................... 253 Operation of proximity switch........................................................................... 254 Work equipment cylinder..................................................................................... 258 Lift arm cylinder....................................................................................... 258 Bucket cylinder......................................................................................... 258 Cab (op).................................................................................................... 260 Air conditioner (op)........................................................................................ 261 Air conditioner piping.................................................................................. 261 Machine monitoring system................................................................................... 262 Outline................................................................................................. 262 Individual circuit diagrams of the machine monitor...................................................... 264 Starting and lighting functions..................................................................... 264 Load meter.......................................................................................... 264 Sensing functions....................................................................................... 265 Power supply and network................................................................................ 266 Machine monitor............................................................................................. 270 Load meter specifications (option)...................................................................... 271 Table of monitor indication items....................................................................... 272 Setting of the machine monitor.......................................................................... 277 Service mode functions.............................................................................. 281 Items related to the fault history of electric system.............................................. 285 Items related to the fault history of machine system............................................... 287 Items related to maintenance monitor................................................................ 289 Engine cylinders cut-out function................................................................... 292 Real-time monitoring function....................................................................... 294 Real-time monitoring items.......................................................................... 297 Machine setting..................................................................................... 307 Setting necessary for option mounting............................................................... 310 Optional device setting for machine monitor......................................................... 311 Transmission control system................................................................................. 332 System diagram.......................................................................................... 332 Control Function.................................................................................... 333 Electric circuit diagram (std)...................................................................... 352 Electric circuit diagram (op)....................................................................... 354 Transmission controller..................................................................................... 356 Work equipment control system (op).......................................................................... 358 System diagram.......................................................................................... 358 Electric circuit diagram (op)........................................................................... 372 Work equipment controller................................................................................... 374 Electric transmission control............................................................................... 376 Functions............................................................................................... 377 Combination switch...................................................................................... 378 Overview................................................................................................ 378 Functions........................................................................................... 378 Operation........................................................................................... 379 Kick down, hold switch...................................................................................... 380 Functions............................................................................................... 380 Engine starting circuit..................................................................................... 382 Function................................................................................................ 382 Operation............................................................................................... 383 Engine stop circuit......................................................................................... 384 Operation............................................................................................... 384 Parking brake circuit....................................................................................... 386 Operation............................................................................................... 386 Turn signal, hazard lamp circuit............................................................................ 390 Operation............................................................................................... 390 Backup lamp, stop lamp circuit.............................................................................. 392 Operation............................................................................................... 392 Small lamp, head lamp circuit............................................................................... 394 Operation............................................................................................... 394 Working lamp circuit........................................................................................ 395 Operation............................................................................................... 395 Horn circuit................................................................................................ 396 Operation............................................................................................... 396 Windshield wiper/window washer circuit (If equipped with cab)............................................... 398 Sensors..................................................................................................... 400 Engine speed sensor..................................................................................... 400 Speed sensor........................................................................................ 400 Engine oil pressure sensor.............................................................................. 401 Engine oil level sensor................................................................................. 401 Engine water temperature sensor......................................................................... 402 Torque converter oil temperature sensor................................................................. 402 Hydraulic oil temperature sensor........................................................................ 402 Transmission oil temperature sensor..................................................................... 402 Brake oil temperature sensor............................................................................ 402 Transmission cut-off pressure sensor.................................................................... 403 Radiator water level sensor............................................................................. 404 Fuel level sensor....................................................................................... 405 Lift arm angle sensor (op).............................................................................. 406 Air cleaner clogging sensor............................................................................. 407 Pressure sensor for load meter (op)..................................................................... 408 Battery liquid sensor (op).............................................................................. 409 Relay................................................................................................... 410 Standard value table for engine............................................................................. 412 Standard value table for chassis............................................................................ 413 TESTING AND ADJUSTING........................................................................................... 411 Measuring engine speed...................................................................................... 422 Measuring exhaust color..................................................................................... 424 Measuring exhaust temperature............................................................................... 425 Adjusting valve clearance................................................................................... 426 Measuring compression pressure.............................................................................. 428 Measuring blow-by pressure.................................................................................. 430 Measuring engine oil pressure............................................................................... 431 Measuring air supply pressure (boost pressure).............................................................. 432 Measuring fuel pressure..................................................................................... 432 Adjusting engine speed sensor............................................................................... 433 Handling equipment in fuel system........................................................................... 434 Releasing remaining pressure in fuel system................................................................. 434 Bleeding air from fuel circuit.............................................................................. 435 Reduced cylinder mode operation for engine.................................................................. 436 Checking for leakage in fuel system......................................................................... 437 Adjusting accelerator pedal potentiometer................................................................... 438 Adjusting accelerator pedal microswitch..................................................................... 439 Adjusting transmission speed sensor......................................................................... 440 Testing and adjusting power train oil pressure.............................................................. 441 Flushing torque converter, transmission hydraulic circuit................................................... 445 Moving machine when transmission valve fails................................................................ 446 Testing and adjusting steering control...................................................................... 448 Testing and adjusting steering oil pressure................................................................. 449 Measuring brake oil pressure................................................................................ 452 Testing wear of wheel brake disc............................................................................ 454 Bleeding air from brake circuit............................................................................. 455 Testing wear of parking brake disc.......................................................................... 456 Manual release method for parking brake..................................................................... 457 Testing and adjusting accumulator charge pressure........................................................... 458 Testing and adjusting ppc oil pressure...................................................................... 460 Testing and adjusting work equipment hydraulic pressure..................................................... 462 Testing and adjusting bucket positioner..................................................................... 464 Testing and adjusting lift arm kick-out..................................................................... 465 Checking proximity switch actuation pilot lamp.............................................................. 466 Adjusting machine monitor................................................................................... 467 Testing and adjusting load meter............................................................................ 470 Bleeding air................................................................................................ 471 Releasing remaining pressure in hydraulic circuit........................................................... 472 Releasing remaining pressure in travel damper circuit....................................................... 472 Handling controller high-voltage circuit.................................................................... 473 TESTING AND ADJUSTING........................................................................................... 421 Points to remember when troubleshooting..................................................................... 476 Sequence of events in troubleshooting....................................................................... 477 Precautions when carrying out maintenance................................................................... 478 Checks before troubleshooting............................................................................... 486 Equipment for troubleshooting electrical system............................................................. 487 Special functions of machine monitor........................................................................ 488 Flow of modes and functions................................................................................. 489 Categories, procedure, and method of using troubleshooting charts.......................................... 525 Connection table for connector pin numbers.................................................................. 530 TROUBLESHOOTING................................................................................................. 475 Connector types and installation positions.................................................................. 545 Connectors layout drawing................................................................................... 554 Engine control system diagram............................................................................... 560 Error code [A000N1]......................................................................................... 562 Error code [AD00L2]......................................................................................... 563 Error code [AD00MA]......................................................................................... 564 Error code [AD10L3]......................................................................................... 565 Error code [AD10MA]......................................................................................... 567 Error code [AD10MB]......................................................................................... 568 Error code [AD11KA]......................................................................................... 569 Error code [AD11KB]......................................................................................... 570 Error code [AD51KA]......................................................................................... 571 Error code [AD51KB]......................................................................................... 572 Error code [ADA1KA]......................................................................................... 573 Error code [ADAZKB]......................................................................................... 574 Error code [ADB1KA]......................................................................................... 576 Error code [ADC1KA]......................................................................................... 577 Error code [ADD1KA]......................................................................................... 578 Error code [ADDZKB]......................................................................................... 580 Error code [ADE1KA]......................................................................................... 582 Error code [ADF1KA]......................................................................................... 583 Error code [D182KZ]......................................................................................... 584 Error code [D1D0KB]......................................................................................... 586 Error code [DB20KT]......................................................................................... 588 Error code [AB20KT]......................................................................................... 590 Error code [DB22KK]......................................................................................... 592 Error code [DB29KQ]......................................................................................... 594 Error code [DB2AMA]......................................................................................... 596 Error code [DD11KB]......................................................................................... 597 Error code [DGE3L6]......................................................................................... 598 Error code [DGE4KX]......................................................................................... 599 Error code [DH30KX]......................................................................................... 600 Error code [DH40KX]......................................................................................... 601 Error code [DK10KX]......................................................................................... 602 Error code [DLE3LC]......................................................................................... 603 Error code [DLH1LC]......................................................................................... 604 Error code [ENG-1].......................................................................................... 605 TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE)............................................................ 543 Connector types and installation positions.................................................................. 614 Connector layout drawing.................................................................................... 622 Transmission control system diagram......................................................................... 628 Error code [1500L1]......................................................................................... 631 Error code [15SAL1]......................................................................................... 632 Error code [15SALH]......................................................................................... 633 Error code [15SBL1]......................................................................................... 634 Error code [15SBLH]......................................................................................... 635 Error code [15SEL1]......................................................................................... 636 Error code [15SELH]......................................................................................... 637 Error code [15SFL1]......................................................................................... 638 Error code [15SFLH]......................................................................................... 639 Error code [15SGL1]......................................................................................... 640 Error code [15SGLH]......................................................................................... 641 Error code [15SHL1]......................................................................................... 642 Error code [15SHLH]......................................................................................... 643 Error code [15SJL1]......................................................................................... 644 Error code [15SJLH]......................................................................................... 645 Error code [989F00]......................................................................................... 646 Error code [989G00]......................................................................................... 647 Error code [B@C7NS]......................................................................................... 648 Error code [D150KA]......................................................................................... 649 Error code [D150KB]......................................................................................... 650 Error code [D160KA]......................................................................................... 651 Error code [D160KB]......................................................................................... 652 Error code [D191KA]......................................................................................... 654 Error code [D191KB]......................................................................................... 656 Error code [D192KA]......................................................................................... 658 Error code [D192KB]......................................................................................... 659 Error code [DAQ0KK]......................................................................................... 660 Error code [DAQ2KK]......................................................................................... 661 Error code [DAQ9KQ]......................................................................................... 662 Error code [DDK3KA]......................................................................................... 664 Error code [DDK3KB]......................................................................................... 666 Error code [DDK6KA]......................................................................................... 668 Error code [DDK6KB]......................................................................................... 670 Error code [DDS5KA]......................................................................................... 672 Error code [DDS5KB]......................................................................................... 673 Error code [DDT0L4]......................................................................................... 674 Error code [DDT4LD]......................................................................................... 676 Error code [DDW9LD]......................................................................................... 677 Error code [DDWLLD]......................................................................................... 678 Error code [DF10KA]......................................................................................... 680 Error code [DF10KB]......................................................................................... 682 Error code [DGF1KX]......................................................................................... 684 Error code [DGR2KA]......................................................................................... 685 Error code [DGR2KB]......................................................................................... 686 Error code [DHT1KX]......................................................................................... 687 Error code [DLE2KA]......................................................................................... 688 Error code [DLE2LC]......................................................................................... 689 Error code [DLT3KA]......................................................................................... 690 Error code [DT20KB]......................................................................................... 691 Error code [DW7BKA]......................................................................................... 692 Error code [DW7BKB]......................................................................................... 693 Error code [DW7CKA]......................................................................................... 694 Error code [DW7CKB]......................................................................................... 695 Error code [DX16KA]......................................................................................... 696 Error code [DX16KB]......................................................................................... 697 Error code [DXH1KA]......................................................................................... 698 Error code [DXH1KB]......................................................................................... 699 Error code [DXH4KA]......................................................................................... 700 Error code [DXH4KB]......................................................................................... 701 Error code [DXH5KA]......................................................................................... 702 Error code [DXH5KB]......................................................................................... 703 Error code [DXH6KA]......................................................................................... 704 Error code [DXH6KB]......................................................................................... 705 Error code [DXH7KA]......................................................................................... 706 Error code [DXH7KB]......................................................................................... 707 Error code [DXH8KA]......................................................................................... 708 Error code [DXH8KB]......................................................................................... 709 Error code [DXHHKA]......................................................................................... 710 Error code [DXHHKB]......................................................................................... 711 Error code [DY30MA]......................................................................................... 712 Error code [DY30MC]......................................................................................... 714 Action code [TM-1].......................................................................................... 716 Action code [TM-2].......................................................................................... 717 Action code [TM-3].......................................................................................... 718 Action code [TM-4].......................................................................................... 720 Action code [TM-5].......................................................................................... 722 Action code [TM-6].......................................................................................... 724 Action code [TM-7].......................................................................................... 725 Action code [TM-8].......................................................................................... 726 Action code [TM-9].......................................................................................... 727 Action code [TM-10-A]....................................................................................... 728 Action code [TM-10-B]....................................................................................... 730 Action code [TM-11]......................................................................................... 732 Action code [TM-12]......................................................................................... 734 Action code [TM-13]......................................................................................... 735 Action code [TM-14]......................................................................................... 736 Action code [TM-15]......................................................................................... 738 Action code [TM-16]......................................................................................... 740 Action code [TM-17]......................................................................................... 741 Action code [TM-18]......................................................................................... 742 Action code [TM-19]......................................................................................... 743 Action code [TM-20]......................................................................................... 744 Action code [TM-21]......................................................................................... 745 Action code [TM-22]......................................................................................... 746 Action code [TM-23]......................................................................................... 747 Action code [TM-24]......................................................................................... 748 Action code [TM-25]......................................................................................... 749 Action code [TM-26]......................................................................................... 750 Action code [TM-27]......................................................................................... 751 Action code [TM-28]......................................................................................... 752 Action code [TM-29]......................................................................................... 753 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)....................................................... 611 Connector types and installation positions.................................................................. 757 Connector layout drawing.................................................................................... 766 Work equipment control system diagram....................................................................... 772 Error code [D193KA]......................................................................................... 775 Error code [D193KB]......................................................................................... 776 Error code [DB90KK]......................................................................................... 777 Error code [DB92KK]......................................................................................... 778 Error code [DB95KX]......................................................................................... 780 Error code [DD1ALD]......................................................................................... 782 Error code [DD1BLD]......................................................................................... 783 Error code [DFAOKM]......................................................................................... 784 Error code [DK59KA]......................................................................................... 785 Error code [DK59KY]......................................................................................... 786 Error code [DK59L8]......................................................................................... 787 Error code [DK5AKA]......................................................................................... 788 Error code [DK5AKY]......................................................................................... 789 Error code [DK5BKA]......................................................................................... 790 Error code [DK5BKY]......................................................................................... 791 Error code [DK5BL8]......................................................................................... 792 Error code [DK5CKA]......................................................................................... 793 Error code [DK5CKY]......................................................................................... 794 Error code [DK5DKA]......................................................................................... 795 Error code [DK5DKY]......................................................................................... 796 Error code [DK5DL8]......................................................................................... 797 Error code [DK5EKA]......................................................................................... 798 Error code [DK5EKY]......................................................................................... 799 Error code [DK5FKA]......................................................................................... 800 Error code [DK5FKY]......................................................................................... 801 Error code [DK5FKM]......................................................................................... 802 Error code [DK5FL8]......................................................................................... 803 Error code [DK5GKA]......................................................................................... 804 Error code [DK5GKY]......................................................................................... 805 Error code [DKAOKA]......................................................................................... 806 Error code [DKAOKY]......................................................................................... 807 Error code [DLE2LC]......................................................................................... 808 Error code [DLT3LC]......................................................................................... 809 Error code [DUM1KA]......................................................................................... 810 Error code [DUM1KB]......................................................................................... 811 Error code [DW4PKA]......................................................................................... 812 Error code [DW4PKB]......................................................................................... 813 Error code [DW4QKA]......................................................................................... 814 Error code [DW4QKB]......................................................................................... 815 Error code [DW4RKA]......................................................................................... 816 Error code [DW4RKB]......................................................................................... 817 Error code [DW4SKA]......................................................................................... 818 Error code [DW4SKB]......................................................................................... 819 Error code [DWM1KA]......................................................................................... 820 Error code [DWM1KB]......................................................................................... 821 Error code [DWN6KA]......................................................................................... 822 Error code [DWN6KB]......................................................................................... 823 Error code [DWN7KA]......................................................................................... 824 Error code [DWN7KB]......................................................................................... 825 Error code [DWN8KA]......................................................................................... 826 Error code [DWN8KB]......................................................................................... 827 Error code [DXHJKA]......................................................................................... 828 Error code [DXHJKB]......................................................................................... 829 Error code [DXHKKA]......................................................................................... 830 Error code [DXHKKB]......................................................................................... 831 Error code [DXHLKA]......................................................................................... 832 Error code [DXHLKB]......................................................................................... 833 Error code [DXHMKA]......................................................................................... 834 Error code [DXHMKB]......................................................................................... 835 Action code [WRK-1]......................................................................................... 836 Action code [WRK-2]......................................................................................... 837 Action code [WRK-3]......................................................................................... 838 Action code [WRK-4]......................................................................................... 840 Action code [WRK-5]......................................................................................... 842 Action code [WRK-6]......................................................................................... 844 Action code [WRK-7]......................................................................................... 846 Action code [WRK-8]......................................................................................... 847 Action code [WRK-9]......................................................................................... 848 Action code [WRK-10]........................................................................................ 850 Action code [WRK-11]........................................................................................ 852 Action code [WRK-12]........................................................................................ 853 Action code [WRK-13]........................................................................................ 854 Action code [WRK-14]........................................................................................ 855 Action code [WRK-15]........................................................................................ 856 Action code [WRK-16]........................................................................................ 857 Action code [WRK-17]........................................................................................ 858 Action code [WRK-18]........................................................................................ 859 Action code [WRK-19]........................................................................................ 860 Action code [WRK-20]........................................................................................ 861 Action code [WRK-21]........................................................................................ 862 Action code [WRK-22]........................................................................................ 863 Action code [WRK-23]........................................................................................ 864 Action code [WRK-24]........................................................................................ 865 Action code [WRK-25]........................................................................................ 866 Action code [WRK-26]........................................................................................ 868 Action code [WRK-27]........................................................................................ 870 Action code [WRK-28]........................................................................................ 872 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WORK MODE).................................................. 755 Connector types and installation positions.................................................................. 877 Connector layout drawing.................................................................................... 884 Monitor system diagram...................................................................................... 890 Error code [2F00KM]......................................................................................... 894 Error code [2G42ZG]......................................................................................... 896 Error code [2G43ZG]......................................................................................... 897 Error code [AA1ANX]......................................................................................... 898 Error code [AB00L6]......................................................................................... 900 Error code [AB00MA]......................................................................................... 901 Error code [B@BAZG]......................................................................................... 902 Error code [B@BAZK]......................................................................................... 903 Error code [B@BCNS]......................................................................................... 904 Error code [B@BCZK]......................................................................................... 905 Error code [B@HANS]......................................................................................... 906 Error code [B@CENS]......................................................................................... 907 Error code [D5ZHL6]......................................................................................... 908 Error code [DA80L4]......................................................................................... 909 Error code [DAF3KK]......................................................................................... 910 Error code [DAF5KP]......................................................................................... 912 Error code [DAF6KP]......................................................................................... 914 Error code [DAFBKM]......................................................................................... 916 Error code [DAFSKQ]......................................................................................... 917 Error code [DAQSKR]......................................................................................... 918 Error code [DBQSKR]......................................................................................... 919 Error code [DB9SKR]......................................................................................... 920 Error code [DD15LD]......................................................................................... 921 Error code [DD16LD]......................................................................................... 922 Error code [DD17LD]......................................................................................... 923 Error code [DD18LD]......................................................................................... 924 Error code [DD1CLD]......................................................................................... 925 Error code [DDK3KM]......................................................................................... 926 Error code [DDK4KM]......................................................................................... 927 Error code [DDK6KM]......................................................................................... 928 Error code [DDS5L6]......................................................................................... 929 Error code [DDY0LD]......................................................................................... 930 Error code [DGE2KX]......................................................................................... 931 Error code [DGH2KX]......................................................................................... 932 Error code [DGT1KX]......................................................................................... 933 Error code [DHE4L6]......................................................................................... 934 Error code [DHPCKX]......................................................................................... 936 Error code [DHPDKX]......................................................................................... 938 Error Code [DKA0KX]......................................................................................... 939 Error code [DV00KB]......................................................................................... 940 Error code [DY30ME]......................................................................................... 942 Action code [MON-1]......................................................................................... 944 Action code [MON-2]......................................................................................... 946 Action code [MON-3]......................................................................................... 947 Action code [MON-4]......................................................................................... 948 Action code [MON-5]......................................................................................... 950 Action code [MON-6]......................................................................................... 951 Action code [MON-7]......................................................................................... 952 Action code [MON-8]......................................................................................... 953 Action code [MON-9]......................................................................................... 954 Action code [MON-10]........................................................................................ 955 Action code [MON-11]........................................................................................ 956 Action code [MON-12]........................................................................................ 957 Action code [MON-13]........................................................................................ 958 Action code [MON-14]........................................................................................ 959 Action code [MON-15]........................................................................................ 960 Action code [MON-16]........................................................................................ 961 Action code [MON-17]........................................................................................ 962 Action code [MON-18]........................................................................................ 963 Action code [MON-19]........................................................................................ 964 Action code [MON-20]........................................................................................ 965 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE).................................................................... 875 H-1......................................................................................................... 968 The machine does not start.............................................................................. 968 H-2......................................................................................................... 970 The lock-up clutch is not released (The engine stops) (When the lock-up clutch is provided)............. 970 H-3 – a..................................................................................................... 971 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and th....... 971 H-3 – b..................................................................................................... 973 The torque converter lock-up clutch is not let in (When the lock-up clutch is provided)................. 973 H-4......................................................................................................... 974 Shocks are large at the times of starting and shifting gear............................................. 974 H-5......................................................................................................... 976 Time lag is large at the times of starting and shifting gear............................................ 976 H-6......................................................................................................... 978 The torque converter oil temperature is high............................................................ 978 H-7......................................................................................................... 979 The steering wheel does not turn........................................................................ 979 H-8......................................................................................................... 980 The steering wheel is heavy............................................................................. 980 H-9......................................................................................................... 981 The steering wheel fluctuates or is strongly shocked.................................................... 981 H-10........................................................................................................ 981 The steering wheel fluctuates or is strongly shocked.................................................... 981 H-11........................................................................................................ 981 The right and left swing radii are different............................................................ 981 H-12........................................................................................................ 982 The brake does not work or does not work well........................................................... 982 H-13........................................................................................................ 983 The brake is not released or is dragged................................................................. 983 H-14........................................................................................................ 984 The brake is not released or dragged.................................................................... 984 H-15........................................................................................................ 985 The boom does not rise.................................................................................. 985 H-16........................................................................................................ 986 The boom moves slowly or the boom rising force is insufficient.......................................... 986 H-17........................................................................................................ 987 When rising, the boom comes to move slowly at specific height........................................... 987 H-18........................................................................................................ 987 The boom cylinder cannot hold down the bucket (The bucket rises in the air)............................. 987 H-19........................................................................................................ 987 Hydraulic drifts of the boom occur often................................................................ 987 H-20........................................................................................................ 987 The boom wobbles during operation....................................................................... 987 H-21........................................................................................................ 988 When the control lever is switched from "HOLD" to "RAISE," the boom falls temporarily................... 988 H-22........................................................................................................ 989 The bucket does not tilt back........................................................................... 989 H-23........................................................................................................ 990 The bucket moves slowly or the tilting-back force is insufficient....................................... 990 H-24........................................................................................................ 991 The bucket comes to operate slowly in he midst of tilting-back.......................................... 991 H-25........................................................................................................ 991 The bucket cylinder cannot hold down the bucket......................................................... 991 H-26........................................................................................................ 991 Hydraulic drifts of the bucket occur often.............................................................. 991 H-27........................................................................................................ 992 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD")................. 992 H-28........................................................................................................ 992 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily.................. 992 H-29........................................................................................................ 993 The control levers of boom and bucket do not move smoothly and heavy.................................... 993 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)........................................................ 967 Connector types and installation positions.................................................................. 997 Connector layout drawing....................................................................................1006 Monitor system diagram......................................................................................1012 Action code [E-1]...........................................................................................1014 Action code [E-2]...........................................................................................1016 Action code [E-3]...........................................................................................1018 Action code [E-4]...........................................................................................1020 Action code [E-5-A].........................................................................................1021 Action code [E-5-B].........................................................................................1024 Action code [E-5-C].........................................................................................1025 Action code [E-6]...........................................................................................1026 Action code [E-7-A].........................................................................................1029 Action code [E-7-B].........................................................................................1032 Action code [E-7-C].........................................................................................1034 Action code [E-7-D].........................................................................................1035 Action code [E-8]...........................................................................................1037 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................... 995 DISASSEMBLY AND ASSEMBLY........................................................................................1043 Method of using manual......................................................................................1045 Precautions when carrying out operation.....................................................................1046 Fuel supply pump assembly...................................................................................1050 Special tools...........................................................................................1050 Removal.................................................................................................1050 Installation............................................................................................1052 Schematic drawings of special tools.....................................................................1054 A1 Remover..........................................................................................1054 A1 Block............................................................................................1055 A1 Bolt.............................................................................................1055 Nozzle holder assembly......................................................................................1056 Removal.................................................................................................1056 Installation............................................................................................1059 Nozzle tip..................................................................................................1061 Special tool............................................................................................1061 Removal.................................................................................................1061 Installation............................................................................................1063 Schematic drawing of special tool.......................................................................1064 A3 Wrench...........................................................................................1064 Cylinder head assembly......................................................................................1065 Special tool............................................................................................1065 Removal.................................................................................................1065 Installation............................................................................................1071 Radiator assembly...........................................................................................1074 Removal.................................................................................................1074 Installation............................................................................................1076 Air aftercooler assembly....................................................................................1077 Removal.................................................................................................1077 Installation............................................................................................1077 Cooling fan drive motor.....................................................................................1078 Removal.................................................................................................1078 Installation............................................................................................1078 Engine assembly.............................................................................................1079 Removal.................................................................................................1079 Installation............................................................................................1085 Steering, switch pump, cooling fan drive pump assembly.....................................................1086 Removal.................................................................................................1086 Installation............................................................................................1087 Torque converter charge, work equipment and PPC pump assembly...............................................1088 Removal.................................................................................................1088 installation............................................................................................1088 Torque converter, transmission assembly....................................................................1089 Removal.................................................................................................1089 Installation............................................................................................1094 Torque converter assembly (standard specifications).........................................................1095 Special tools...........................................................................................1095 Disassembly.............................................................................................1095 Assembly................................................................................................1098 Torque converter assembly (lock-up specifications)..........................................................1101 Special tools...........................................................................................1101 Disassembly.............................................................................................1101 Assembly................................................................................................1104 Transmission assembly.......................................................................................1109 Special tools...........................................................................................1109 Disassembly.............................................................................................1109 Assembly................................................................................................1118 Schematics of special tools.................................................................................1128 C1 Bracket..............................................................................................1128 C6, C7 Pushing tools....................................................................................1128 C7 Spacer...............................................................................................1129 C11 Lifting tool........................................................................................1129 C11 Lifting tool........................................................................................1130 Transmission clutch pack assembly...........................................................................1131 Special tools...........................................................................................1131 Disassembly.............................................................................................1131 Disassembly of forward-reverse clutch packs.........................................................1131 Disassembly of 1st • 4th speed clutch packs.........................................................1134 Disassembly of 2nd • 3rd clutch packs...............................................................1137 Assembly................................................................................................1140 Assembly of forward-reverse clutch packs............................................................1140 Assembly of 1st • 4th clutch packs..................................................................1144 Assembly of 2nd • 3rd clutch packs..................................................................1149 Schematic diagram of special tool.......................................................................1154 C2 Push tool........................................................................................1154 Parking brake assembly......................................................................................1155 Special tools...........................................................................................1155 Disassembly.............................................................................................1155 Assembly................................................................................................1159 Schematic drawing of special tools..........................................................................1165 C4, C5 Push tool........................................................................................1165 C5 Spacer...............................................................................................1165 C8 Push tool............................................................................................1166 C9 Push tool............................................................................................1166 C10 Push tool...........................................................................................1167 C13 Bracket.............................................................................................1167 Front axle assembly.........................................................................................1168 Disassembly.............................................................................................1168 Assembly................................................................................................1170 Rear axle assembly..........................................................................................1171 Removal.................................................................................................1171 Installation............................................................................................1174 Axle housing assembly.......................................................................................1176 Special tools...........................................................................................1176 Disassembly.............................................................................................1176 Assembly................................................................................................1181 Schematic drawing of special tools..........................................................................1187 D7 Pushing tool.........................................................................................1187 D7 Spacer...............................................................................................1187 D7 Pushing tool.........................................................................................1188 D9 Support..............................................................................................1188 D9 Support..............................................................................................1189 Differential assembly.......................................................................................1190 Special tools...........................................................................................1190 Disassembly.............................................................................................1190 Assembly................................................................................................1196 Schematic drawing of special tools..........................................................................1208 D1 Plate................................................................................................1208 D2, D3 Push tool........................................................................................1208 D3 Spacer...............................................................................................1209 D4 Push tool............................................................................................1209 D5 Push tool............................................................................................1210 Center hinge pin............................................................................................1211 Special tools...........................................................................................1211 Removal.................................................................................................1211 Installation............................................................................................1217 Steering valve assembly.....................................................................................1221 Removal.................................................................................................1221 Installation............................................................................................1222 Travel damper assembly......................................................................................1223 Removal.................................................................................................1223 Installation............................................................................................1223 Parking brake disc..........................................................................................1224 Special tools...........................................................................................1224 Removal.................................................................................................1224 Installation............................................................................................1226 Schematic drawing of special tools..........................................................................1227 C13 Bracket.............................................................................................1227 Hydraulic tank..............................................................................................1228 Removal.................................................................................................1228 Installation............................................................................................1229 Work equipment valve assembly...............................................................................1230 Removal.................................................................................................1230 Installation............................................................................................1231 Hydraulic cylinder assembly (steering, lift, and bucket cylinder assemblies)................................1232 Special tools...........................................................................................1232 Disassembly.............................................................................................1233 Assembly................................................................................................1237 Work equipment assembly.....................................................................................1242 Removal.................................................................................................1242 Installation............................................................................................1245 Counterweight...............................................................................................1248 Removal.................................................................................................1248 Installation............................................................................................1249 Fuel tank assembly..........................................................................................1250 Removal.................................................................................................1250 Installation............................................................................................1251 Cab assembly................................................................................................1252 Removal.................................................................................................1252 Installation............................................................................................1254 Cab, floor frame assembly...................................................................................1255 Removal.................................................................................................1255 Installation............................................................................................1259 Air conditioner unit assembly...............................................................................1260 Removal.................................................................................................1260 Installation............................................................................................1263 Air conditioner compressor assembly.........................................................................1264 Special tools...........................................................................................1264 Removal.................................................................................................1264 Installation............................................................................................1265 APPENDIX........................................................................................................1267 Power train oil circuit diagram.............................................................................1271 Power train oil circuit diagram.............................................................................1273 Brake oil circuit diagram...................................................................................1275
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