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Komatsu WA470-6 WA480-6 WHEEL LOADER Service Repair Manual – PDF Download
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- komatsu WA470-6 WA480-6 WHEEL LOADER Service Repair Manual
- PUBLICATION NUMBER:CEBM007102
- SERIAL NUMBERS:
WA470-6 A45001 to A45999
WA480-6 A47001 to A47999
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Description
Komatsu WA470-6 WA480-6 WHEEL LOADER Service Repair Manual
Screenshot of the Manual:
KOMATSU WA470-6 WA480-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
Komatsu WA470-6 WA480-6 WHEEL LOADER Service Repair Manual
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine
Table of Contents:
Komatsu WA470-6 WA480-6 WHEEL LOADER Service Repair Manual
FOREWORD.................................................................................................................................. 2 CONTENTS.............................................................................................................................. 2 SAFETY................................................................................................................................ 33 Safety Notice..................................................................................................................... 33 IMPORTANT SAFETY NOTICE....................................................................................................... 33 General Precautions........................................................................................................... 33 Preparations For Work......................................................................................................... 33 Precautions During Work....................................................................................................... 33 GENERAL............................................................................................................................... 35 HOW TO READ THE SHOP MANUAL........................................................................................................... 36 Volumes........................................................................................................................... 36 Distribution And Updating......................................................................................................... 36 Filing Method..................................................................................................................... 36 Revised Edition Mark.............................................................................................................. 36 Revisions......................................................................................................................... 36 Symbols........................................................................................................................... 36 HOISTING INSTRUCTIONS................................................................................................................. 37 Hoisting.......................................................................................................................... 37 Wire Ropes........................................................................................................................ 37 MAINTENANCE STANDARD TERMINOLOGY...................................................................................................... 38 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.................................................................................. 40 PUSH PULL COUPLER..................................................................................................................... 49 Type 1............................................................................................................................ 49 Disconnection................................................................................................................. 49 Connection.................................................................................................................... 49 Type 2............................................................................................................................ 50 Disconnection................................................................................................................. 50 Connection.................................................................................................................... 50 Type 3............................................................................................................................ 51 Disconnection................................................................................................................. 51 Connection.................................................................................................................... 51 HANDLING OF CONNECTORS NEWLY USED FOR ENGINES......................................................................................... 52 COATING MATERIALS..................................................................................................................... 56 STANDARD TIGHTENING TORQUE............................................................................................................ 59 Standard Tightening Torque Of Bolts And Nuts...................................................................................... 59 Tightening Torque Of Hose Nuts.................................................................................................... 60 Tightening Torque Of Split Flange Bolts........................................................................................... 60 Tightening Torque For Flared Nuts................................................................................................. 60 Table Of Tightening Torques For O-ring Boss Piping Joints......................................................................... 61 Table Of Tightening Torques For O-ring Boss Plugs................................................................................. 61 Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type)............................................................ 61 ELECTRIC WIRE CODE.................................................................................................................... 62 Classification By Thickness....................................................................................................... 62 Classification By Color And Code.................................................................................................. 62 CONVERSION TABLES..................................................................................................................... 63 Method Of Using The Conversion Table.............................................................................................. 63 01 GENERAL................................................................................................................................ 69 SPECIFICATIONS........................................................................................................................ 70 Dimension Drawing................................................................................................................. 70 Specification Tables.............................................................................................................. 72 WEIGHT TABLE.......................................................................................................................... 76 TABLE OF FUEL, COOLANT AND LUBRICANTS................................................................................................. 78 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD........................................................................................... 81 ENGINE AND COOLING SYSTEM............................................................................................................. 86 Engine and Transmission Mounting.................................................................................................. 86 Cooling System.................................................................................................................... 88 Cooling Fan Pump.................................................................................................................. 90 Operation..................................................................................................................... 94 Servo Valve................................................................................................................... 95 Cooling Fan Motor................................................................................................................. 98 Hydraulic Motor................................................................................................................... 100 Suction Valve................................................................................................................. 101 Operation of Reversible Valve................................................................................................. 102 Safety Valve.................................................................................................................. 103 POWER TRAIN........................................................................................................................... 104 System Diagram.................................................................................................................... 105 Drive Shaft....................................................................................................................... 107 Power Train Piping Diagram........................................................................................................ 108 Torque Converter.................................................................................................................. 110 Transmission...................................................................................................................... 118 Transmission control valve........................................................................................................ 138 Left valve assembly........................................................................................................... 138 Right valve assembly.......................................................................................................... 139 ECMV.............................................................................................................................. 141 MAIN AND TORQUE CONVERTER RELIEF VALVES............................................................................................... 152 AXLE.................................................................................................................................. 154 Front axle........................................................................................................................ 154 WA470-6....................................................................................................................... 154 WA480-6....................................................................................................................... 155 Rear axle......................................................................................................................... 156 WA470-6....................................................................................................................... 156 WA480-6....................................................................................................................... 157 DIFFERENTIAL.......................................................................................................................... 158 Front Differential................................................................................................................ 158 Rear Differential................................................................................................................. 160 LIMITED SLIP DIFFERENTIAL............................................................................................................. 163 FINAL DRIVE........................................................................................................................... 170 STEERING SYSTEM....................................................................................................................... 175 Steering System Layout Drawing.................................................................................................... 175 Steering Column................................................................................................................... 176 Steering Pump..................................................................................................................... 178 Pump Unit..................................................................................................................... 180 Steering Valve.................................................................................................................... 189 Orbit-roll Valve.................................................................................................................. 202 Stop Valve........................................................................................................................ 210 Steering Relief Valve............................................................................................................. 211 Steering Cylinder................................................................................................................. 212 Emergency steering motor.......................................................................................................... 214 Emergency Steering Pump........................................................................................................... 215 Joystick Steering Lever Linkage................................................................................................... 216 Electrical Steering Lever......................................................................................................... 217 Joystick EPC Valve................................................................................................................ 218 BRAKE SYSTEM.......................................................................................................................... 219 Brake Component Layout Drawing.................................................................................................... 219 Charge Valve...................................................................................................................... 220 Brake Valve....................................................................................................................... 226 Accumulator (for brake)........................................................................................................... 231 Slack Adjuster.................................................................................................................... 232 Brake............................................................................................................................. 234 Front Brake................................................................................................................... 234 Rear Brake.................................................................................................................... 236 Parking Brake Control............................................................................................................. 239 Parking Brake..................................................................................................................... 240 Parking Brake Solenoid Valve...................................................................................................... 242 Emergency Parking Brake Release Valve............................................................................................. 244 UNDERCARRIAGE and FRAME............................................................................................................... 245 Axle Mount and Center Hinge Pin................................................................................................... 245 Tires............................................................................................................................. 249 HYDRAULIC SYSTEM...................................................................................................................... 250 Hydraulic Component Layout Drawing................................................................................................ 250 Work Equipment Control Lever Linkage.............................................................................................. 253 Multi-Function Mono-lever Type................................................................................................ 254 Hydraulic Tank.................................................................................................................... 255 Breather...................................................................................................................... 256 Power Train Pump.................................................................................................................. 257 Work Equipment Pump............................................................................................................... 258 Sectional View................................................................................................................ 260 LS Valve...................................................................................................................... 264 PC Valve...................................................................................................................... 269 PC-EPC Valve.................................................................................................................. 274 Work Equipment Control Valve...................................................................................................... 278 CLSS.............................................................................................................................. 288 Basic principle............................................................................................................... 289 Function and Operation of Each Valve.............................................................................................. 292 Pressure Compensation Valve (Installed to cylinder head side of lift arm valve)............................................... 292 Shuttle valve in the pressure compensation valve.............................................................................. 294 Supply of LS Pressure......................................................................................................... 296 LS Bypass Plug................................................................................................................ 297 ECSS Control Valve............................................................................................................ 298 Accumulator Charge Valve.......................................................................................................... 301 PPC Valve......................................................................................................................... 305 Work Equipment PPC Valve...................................................................................................... 305 Service PPC Valve (If equipped)............................................................................................... 310 Accumulator (for PPC circuit)..................................................................................................... 312 Accumulator (for power train circuit)............................................................................................. 313 Accumulator (for ECSS) (If equipped).............................................................................................. 314 Work Equipment PPC Cut-off Solenoid Valve (If equipped)........................................................................... 315 WORK EQUIPMENT........................................................................................................................ 318 Work Equipment Linkage............................................................................................................ 318 Bucket Positioner And Boom Kick-out............................................................................................... 323 Work Equipment Cylinder........................................................................................................... 331 Lift Cylinder................................................................................................................. 331 Bucket Cylinder............................................................................................................... 331 CAB AND ITS ATTACHMENTS............................................................................................................... 333 Cab............................................................................................................................... 333 Air Conditioner................................................................................................................... 334 Air Conditioner Piping Diagram................................................................................................ 334 Refrigerant Circuit Diagram................................................................................................... 336 Air Conditioner Unit.......................................................................................................... 338 Blower and Intake Unit........................................................................................................ 342 Compressor.................................................................................................................... 344 Condenser..................................................................................................................... 345 Receiver...................................................................................................................... 346 Air conditioner panel......................................................................................................... 347 ELECTRICAL SYSTEM..................................................................................................................... 352 Machine Monitor System............................................................................................................ 352 System Circuit Diagram........................................................................................................ 354 Machine Monitor................................................................................................................... 356 Transmission Controller System.................................................................................................... 388 Transmission Controller Gear Shifting Control Function........................................................................ 388 System Circuit Diagram........................................................................................................ 424 Transmission Controller........................................................................................................... 426 Work Equipment Controller System.................................................................................................. 428 System Circuit Diagram........................................................................................................ 430 Work Equipment Controller..................................................................................................... 432 Electric Transmission Control..................................................................................................... 434 Combination Switch............................................................................................................ 436 Kickdown Switch and Hold Switch................................................................................................... 438 Load Meter Cancel Switch and Load Meter Subtotal Switch....................................................................... 438 Multi-function Knob............................................................................................................... 439 Joystick Steering Knob............................................................................................................ 440 KOMTRAX System.................................................................................................................... 441 KOMTRAX Terminal.............................................................................................................. 442 Engine Starting Circuit........................................................................................................... 443 Engine Stopping Circuit........................................................................................................... 445 Preheating Circuit................................................................................................................ 446 Engine Power Mode Selector Circuit................................................................................................ 447 Engine Output Derating Function................................................................................................... 448 Automatic Warm-up Function........................................................................................................ 448 Parking Brake Circuit............................................................................................................. 449 Sensor............................................................................................................................ 451 Transmission Input Speed Sensor............................................................................................... 451 Transmission Output Speed Sensor.............................................................................................. 451 Cooling Fan Speed Sensor...................................................................................................... 451 Torque Converter Oil Temperature Sensor....................................................................................... 452 Hydraulic Oil Temperature Sensor.............................................................................................. 452 Transmission Oil Temperature Sensor........................................................................................... 452 Brake Oil Temperature Sensor.................................................................................................. 452 Work Equipment Pump Oil Pressure Sensor....................................................................................... 453 Steering Pump Oil Pressure Sensor............................................................................................. 453 Lift Cylinder Head Oil Pressure Sensor (machines equipped with load meter).................................................... 453 Lift Cylinder Bottom Oil Pressure Sensor (machines equipped with load meter).................................................. 453 Transmission Cut-off Oil Pressure Sensor...................................................................................... 454 Coolant Level Sensor.......................................................................................................... 455 Fuel Level Sensor............................................................................................................. 456 Air Cleaner Clogging Sensor (machine equipped with KOMTRAX)................................................................... 457 Accelerator Pedal Sensor...................................................................................................... 458 Boom Kick-out Proximity Switch................................................................................................ 459 Bucket Positioner Proximity Switch............................................................................................ 459 Lift Arm Potentiometer (machines equipped with load meter).................................................................... 460 20 STANDARD VALUE TABLES.................................................................................................................. 461 STANDARD SERVICE VALUE TABLE.......................................................................................................... 462 Standard Service Value Table for Engine........................................................................................... 462 Standard Value Table For Chassis.................................................................................................. 463 Machine Posture and Procedure for Performance Measurement......................................................................... 469 30 TESTING AND ADJUSTING.................................................................................................................. 471 TOOLS................................................................................................................................. 475 Tools For Testing, Adjusting, And Troubleshooting................................................................................. 475 ENGINE COMPONENTS..................................................................................................................... 481 Engine Speed...................................................................................................................... 481 Exhaust Gas Color................................................................................................................. 483 Exhaust Temperature............................................................................................................... 485 Valve Clearance................................................................................................................... 487 Compression Pressure.............................................................................................................. 489 Blow-by Pressure.................................................................................................................. 491 Engine Oil Pressure............................................................................................................... 492 EGR Valve Drive Pressure.......................................................................................................... 493 Intake Air (Boost) Pressure....................................................................................................... 495 FUEL SYSTEM........................................................................................................................... 497 Handling Fuel System Equipment.................................................................................................... 497 Releasing Residual Pressure In Fuel System........................................................................................ 497 Fuel Pressure..................................................................................................................... 498 Fuel Return and Leak Amount....................................................................................................... 500 Bleeding Air From Fuel Circuit.................................................................................................... 503 Fuel Circuit for Leakage.......................................................................................................... 505 Reduced Cylinder Mode Operation................................................................................................... 506 No Injection Cranking Operation................................................................................................... 506 Handling of Controller Voltage Circuit............................................................................................ 506 EXHAUST SYSTEM AND PIPING............................................................................................................. 507 Check Muffler and Muffler Stack for Looseness and Damage.......................................................................... 507 Check Muffler Function............................................................................................................ 507 Check Installed Condition of Cylinder Head and Manifolds.......................................................................... 507 Check Engine Piping for Damage and Looseness...................................................................................... 507 BELTS................................................................................................................................. 508 Air Conditioner Compressor Belt................................................................................................... 508 Testing....................................................................................................................... 508 Adjusting..................................................................................................................... 508 Adjusting Alternator Belt......................................................................................................... 509 Testing....................................................................................................................... 509 Adjusting..................................................................................................................... 509 TRANSMISSION SPEED SENSOR............................................................................................................. 510 DIRECTIONAL LEVER..................................................................................................................... 511 Adjusting Directional Lever Length................................................................................................ 511 Adjusting Gear Shift Lever Length................................................................................................. 511 FNR AND GEAR SHIFT LEVERS............................................................................................................. 512 Testing FNR Lever and Gear Shift Lever............................................................................................ 512 POWER TRAIN OIL PRESSURE.............................................................................................................. 513 Testing and Adjusting Power Train Oil Pressure.................................................................................... 513 Measurement................................................................................................................... 516 Adjustment.................................................................................................................... 527 FLUSHING TRANSMISSION SYSTEM.......................................................................................................... 528 Torque Converter and Transmission Hydraulic Circuit............................................................................... 528 TRANSMISSION VALVE FAILS.............................................................................................................. 529 Moving Machine When Transmission Valve Is Broken.................................................................................. 529 AXLE DRIVE AND DRIVE SHAFTS........................................................................................................... 532 Check of Axle Final Drive for Oil Leakage......................................................................................... 532 Check of Drive Shafts for Looseness, Play and Damage.............................................................................. 532 STEERING SYSTEM....................................................................................................................... 533 Steering Stop Valve............................................................................................................... 533 Testing....................................................................................................................... 533 Adjusting..................................................................................................................... 533 Steering Wheel.................................................................................................................... 535 Steering Oil Pressure............................................................................................................. 537 Adjusting..................................................................................................................... 539 Bleeding Air From Steering Circuit................................................................................................ 540 HYDRAULIC FAN......................................................................................................................... 541 Hydraulic Drive Fan............................................................................................................... 541 Testing....................................................................................................................... 541 Hydraulic Fan Speed Sensor........................................................................................................ 543 Adjustment.................................................................................................................... 543 Bleeding Air From Hydraulic Drive Fan Circuit..................................................................................... 545 BRAKE SYSTEM.......................................................................................................................... 547 Brake Pedal....................................................................................................................... 547 Testing....................................................................................................................... 547 Brake Pedal Linkage............................................................................................................... 548 Testing....................................................................................................................... 548 Adjusting..................................................................................................................... 548 Brake Performance................................................................................................................. 549 Testing....................................................................................................................... 549 Accumulator Charge Pressure....................................................................................................... 550 Testing....................................................................................................................... 550 Adjusting..................................................................................................................... 551 Wheel Brake Oil Pressure.......................................................................................................... 552 Testing....................................................................................................................... 552 Check Wear of Wheel Brake Disc.................................................................................................... 555 Bleed Air From Wheel Brake Circuit................................................................................................ 556 Release Residual Pressure in Brake Accumulator Circuit............................................................................ 557 Parking Brake Performance......................................................................................................... 557 Test.......................................................................................................................... 557 Parking Brake Oil Pressure........................................................................................................ 558 Testing....................................................................................................................... 558 Wear Of Parking Brake Disc........................................................................................................ 560 Testing....................................................................................................................... 560 Manual Release for Parking Brake.................................................................................................. 562 WORK EQUIPMENT........................................................................................................................ 563 Work Equipment Control Lever...................................................................................................... 563 Testing....................................................................................................................... 563 Work Equipment PPC Oil Pressure................................................................................................... 564 Measuring..................................................................................................................... 564 Adjusting..................................................................................................................... 567 Work Equipment Oil Pressure....................................................................................................... 568 Testing....................................................................................................................... 568 Adjusting..................................................................................................................... 572 Bleeding Air From Work Equipment Circuit.......................................................................................... 573 Releasing Residual Pressure in Work Equipment Circuit............................................................................. 574 ACCUMULATOR........................................................................................................................... 576 Nitrogen Gas Accumulator Pressure of ECSS......................................................................................... 576 Testing....................................................................................................................... 577 Charging Accumulator.......................................................................................................... 579 Brake Accumulator Nitrogen Gas Pressure........................................................................................... 583 Testing....................................................................................................................... 584 Charging Accumulator.......................................................................................................... 586 BUCKET POSITIONER..................................................................................................................... 589 Testing........................................................................................................................... 589 Adjusting......................................................................................................................... 589 BOOM KICK-OUT......................................................................................................................... 591 Testing........................................................................................................................... 591 Adjusting......................................................................................................................... 591 PROXIMITY SWITCH OPERATION PILOT LAMP................................................................................................. 592 ELECTRICAL SYSTEM..................................................................................................................... 593 Diode Testing Procedure........................................................................................................... 593 Electrical System Troubleshooting................................................................................................. 594 Preparation................................................................................................................... 594 KOMTRAX SYSTEM........................................................................................................................ 599 How to Start KOMTRAX Terminal Operations.......................................................................................... 599 Station Opening Check in Machine Side......................................................................................... 600 Application for the Start of Use.............................................................................................. 603 Indicator Lamps of KOMTRAX Terminal............................................................................................... 604 MACHINE MONITOR SYSTEM................................................................................................................ 607 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor............................................ 607 Special functions of machine monitor (EMMS)....................................................................................... 610 Normal functions and special functions of machine monitor..................................................................... 610 Functions and flow of the service mode............................................................................................ 611 Operator mode..................................................................................................................... 614 Service Meter/clock Display Function (1)...................................................................................... 614 Load Meter Function (if equipped) (2)......................................................................................... 614 Odometer Display Function (3)................................................................................................. 614 Maintenance Monitoring Function (4)........................................................................................... 614 Telephone Number Input Function (5)........................................................................................... 615 Language Selection Function (6)............................................................................................... 615 Monitor Brightness Adjustment Function (7).................................................................................... 615 Time Adjustment Function (8).................................................................................................. 616 Travel Speed/Engine Speed Display Selecting Function (9)...................................................................... 616 Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)......................................................... 616 Action Code Display Function (11)............................................................................................. 616 Failure Code Display Function (12)............................................................................................ 617 Service mode...................................................................................................................... 618 Procedure For Switching To Service Mode And Screen Display (1)................................................................ 618 Electrical System Fault History Display Function (ELECTRIC FAULT) (2)......................................................... 619 Mechanical System Fault History Display Function (MACHINE FAULT) (3).......................................................... 621 Real-Time Monitoring Function (REAL-TIME MONITOR) (4)......................................................................... 622 Engine Cylinder Cutout Function (CYLINDER CUT- OUT) (5)....................................................................... 644 No Injection Cranking Function (6)............................................................................................ 645 Adjustment Function (TUNING) (7).............................................................................................. 646 Maintenance Monitoring Function (8)........................................................................................... 663 Operating Information Display Function (9).................................................................................... 669 OPTIONAL SELECT Function (10)................................................................................................. 671 Machine Serial Number Input Function (11)..................................................................................... 675 Machine Model Select Function (MACHINE) (12).................................................................................. 675 Initialize Function (13)...................................................................................................... 676 PM-CLINIC INSPECTION TABLE............................................................................................................ 677 WA470-6 S/N A45001 to A45999...................................................................................................... 677 WA480-6 S/N A47001 to A47999...................................................................................................... 680 40 TROUBLESHOOTING........................................................................................................................ 683 FAILURE CODE TABLE.................................................................................................................... 697 Fuse Locations.................................................................................................................... 709 Locations and Numbers of Fuse Boxes and Slow Blow Fuse............................................................................ 711 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................... 712 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................. 714 Testing Before Troubleshooting.................................................................................................... 715 CLASSIFICATION AND TROUBLESHOOTING PROCEDURES......................................................................................... 716 MODE CHART............................................................................................................................ 717 Information Contained in Troubleshooting Table.................................................................................... 720 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................ 722 X-Type Connectors................................................................................................................. 722 SWP-Type Connectors............................................................................................................... 724 M-Type Connectors................................................................................................................. 726 S-Type Connectors................................................................................................................. 728 MIC-Type Connectors............................................................................................................... 730 AMP040-Type Connectors............................................................................................................ 732 AMP070-Type Connectors............................................................................................................ 734 AMP Connector..................................................................................................................... 736 L-Type Connector.................................................................................................................. 736 PA-Type Connector................................................................................................................. 737 Bendix (MS) Connector............................................................................................................. 737 KES1 (Automobile) Connectors...................................................................................................... 738 F-Type Connector.................................................................................................................. 739 HD30 Series Connectors............................................................................................................ 741 DT Series Connectors.............................................................................................................. 747 DTM Series Connectors............................................................................................................. 749 DTHD Series Connectors............................................................................................................ 749 DTP Series Connectors............................................................................................................. 750 DRC26 Series Connectors........................................................................................................... 751 DRC12, 16 Series Connectors....................................................................................................... 753 AMP Connectors for Pump Controller (CH700)........................................................................................ 754 BOSCH Connectors for Engine....................................................................................................... 755 SUMITOMO Connectors for Engine.................................................................................................... 756 CANNON Connector for Engine....................................................................................................... 757 AMP Connectors for Engine......................................................................................................... 758 FRAMATOME Connectors for Engine................................................................................................... 759 PACKARD Connectors for Engine..................................................................................................... 761 DT Series Connectors for Engine................................................................................................... 762 T-BRANCH BOX and T-BRANCH ADAPTER TABLE............................................................................................... 763 FAILURE CODES......................................................................................................................... 768 1500L0............................................................................................................................ 769 TORQFLOW Transmission: Double Meshing......................................................................................... 769 15SAL1............................................................................................................................ 770 ECMV F Clutch: When Command Current is OFF, Fill Signal is ON................................................................. 770 15SALH............................................................................................................................ 772 ECMV F Clutch: When Command Current is ON, Fill Signal is OFF................................................................. 772 15SBL1............................................................................................................................ 774 ECMV R Clutch: When Command Current is OFF, Fill Signal is ON................................................................. 774 15SBLH............................................................................................................................ 776 ECMV R Clutch: When Command Current is ON, Fill Signal is OFF................................................................. 776 15SEL1............................................................................................................................ 778 ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 778 15SELH............................................................................................................................ 780 ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 780 15SFL1............................................................................................................................ 782 ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON............................................................... 782 15SFLH............................................................................................................................ 784 ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 784 15SGL1............................................................................................................................ 786 ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 786 15GLH............................................................................................................................. 788 ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 788 15SHL1............................................................................................................................ 790 ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 790 15SHLH............................................................................................................................ 792 ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 792 2F00MA............................................................................................................................ 794 Parking Brake: Malfunction.................................................................................................... 794 2G43ZG............................................................................................................................ 796 Accumulator: Low Oil Pressure................................................................................................. 796 44K0L4............................................................................................................................ 798 Bucket Positioner: ON/OFF Signals Disagree.................................................................................... 798 AA1ANX............................................................................................................................ 802 Air Cleaner: Clogging......................................................................................................... 802 AB00L6............................................................................................................................ 804 Alternator: Signal Disagrees with Operating State of Engine................................................................... 804 AB00MA............................................................................................................................ 806 Alternator: Malfunction....................................................................................................... 806 B@BAZG............................................................................................................................ 808 Engine: Rotation Derating by Low Engine Oil Pressure.......................................................................... 808 B@BAZK............................................................................................................................ 810 Engine Oil: Low Level......................................................................................................... 810 B@BCNS............................................................................................................................ 812 Coolant: Overheating.......................................................................................................... 812 B@BCZK............................................................................................................................ 814 Engine Coolant: Low Level..................................................................................................... 814 B@C7NS............................................................................................................................ 816 Brake Oil: Overheating........................................................................................................ 816 b@CENS............................................................................................................................ 818 Torque Converter Oil: Overheating............................................................................................. 818 B@CENS............................................................................................................................ 820 Torque Converter Oil: Overheating............................................................................................. 820 B@HANS............................................................................................................................ 822 Hydraulic Oil: Overheating.................................................................................................... 822 CA111............................................................................................................................. 824 Abnormality in Engine Controller.............................................................................................. 824 CA115............................................................................................................................. 827 Engine Ne or Bkup Speed Sensor Error.......................................................................................... 827 CA122............................................................................................................................. 828 Charge Pressure Sensor High Error............................................................................................. 828 CA123............................................................................................................................. 830 Charge Pressure Sensor Low Error.............................................................................................. 830 CA131............................................................................................................................. 832 Throttle Sensor High Error.................................................................................................... 832 CA132............................................................................................................................. 834 Throttle Sensor Low Error..................................................................................................... 834 CA135............................................................................................................................. 836 Engine Oil Pressure Sensor High Error......................................................................................... 836 CA141............................................................................................................................. 838 Engine Oil Pressure Sensor Low Error.......................................................................................... 838 CA144............................................................................................................................. 840 Coolant Sensor High Error..................................................................................................... 840 CA145............................................................................................................................. 842 Coolant Temperature Sensor Low Error.......................................................................................... 842 CA153............................................................................................................................. 844 Charge Temperature Sensor High Error.......................................................................................... 844 CA154............................................................................................................................. 846 Charge Temperature Sensor Low Error........................................................................................... 846 CA187............................................................................................................................. 848 Sensor Power Supply 2 Low Error............................................................................................... 848 CA221............................................................................................................................. 850 Atmospheric Pressure Sensor High Error........................................................................................ 850 CA222............................................................................................................................. 852 Atmospheric Pressure Sensor Low Error......................................................................................... 852 CA227............................................................................................................................. 853 Sensor Power Supply 2 High Error.............................................................................................. 853 CA234............................................................................................................................. 856 Engine Overspeed.............................................................................................................. 856 CA238............................................................................................................................. 858 NE Speed Sensor Power Supply Error............................................................................................ 858 CA263............................................................................................................................. 860 Fuel Temperature Sensor High Error............................................................................................ 860 CA265............................................................................................................................. 862 Fuel Temperature Sensor Low Error............................................................................................. 862 CA271............................................................................................................................. 864 PCV1 Short Circuit............................................................................................................ 864 CA272............................................................................................................................. 866 PCV1 Disconnection............................................................................................................ 866 CA273............................................................................................................................. 868 PCV2 Short Circuit............................................................................................................ 868 CA274............................................................................................................................. 870 PCV2 Disconnection............................................................................................................ 870 CA322............................................................................................................................. 872 Injector #1 Open/Short Error.................................................................................................. 872 CA323............................................................................................................................. 874 Injector #5 Open/Short Error.................................................................................................. 874 CA324............................................................................................................................. 876 Injector #3 Open/Short Error.................................................................................................. 876 CA325............................................................................................................................. 878 Injector #6 Open/Short Error.................................................................................................. 878 CA331............................................................................................................................. 880 Injector #2 Open/Short Error.................................................................................................. 880 CA332............................................................................................................................. 882 Injector #4 Open/Short Error.................................................................................................. 882 CA342............................................................................................................................. 884 Calibration Code Inconsistency................................................................................................ 884 CA351............................................................................................................................. 886 Injectors Drive Circuit Error................................................................................................. 886 CA352............................................................................................................................. 888 Sensor Power Supply 1 Low Error............................................................................................... 888 CA386............................................................................................................................. 890 Sensor Power Supply 1 High Error.............................................................................................. 890 CA431............................................................................................................................. 892 Idle Validation Switch Error.................................................................................................. 892 CA432............................................................................................................................. 894 Idle Validation Action Error.................................................................................................. 894 CA441............................................................................................................................. 896 Battery Voltage Low Error..................................................................................................... 896 CA442............................................................................................................................. 900 Battery Voltage High Error.................................................................................................... 900 CA449............................................................................................................................. 902 Common Rail Pressure High Error 2............................................................................................. 902 CA451............................................................................................................................. 904 Common Rail Pressure Sensor High Error........................................................................................ 904 CA452............................................................................................................................. 906 Common Rail Pressure Sensor Low Error......................................................................................... 906 CA553............................................................................................................................. 907 Common Rail Pressure High Error 1............................................................................................. 907 CA554............................................................................................................................. 908 Common Rail Pressure Sensor In-Range Error.................................................................................... 908 CA559............................................................................................................................. 909 Supply Pump Pressure Very Low Error........................................................................................... 909 CA689............................................................................................................................. 916 Engine Ne Speed Sensor Error.................................................................................................. 916 CA731............................................................................................................................. 918 Engine Bkup Speed Sensor Phase Error.......................................................................................... 918 CA757............................................................................................................................. 919 All Continuous Data Lost Error................................................................................................ 919 CA778............................................................................................................................. 920 Engine Bkup Speed Sensor Error................................................................................................ 920 CA1228............................................................................................................................ 922 EGR Valve Servo Error 1....................................................................................................... 922 CA1625............................................................................................................................ 923 EGR Valve Servo Error 2....................................................................................................... 923 CA1633............................................................................................................................ 924 KOMNET Datalink Timeout Error................................................................................................. 924 CA2185............................................................................................................................ 926 Throttle Sensor Supply Voltage High Error..................................................................................... 926 CA2186............................................................................................................................ 928 Throttle Sensor Power Supply Low Error........................................................................................ 928 CA2249............................................................................................................................ 930 Supply Pump Pressure Very Low Error 2......................................................................................... 930 CA2271............................................................................................................................ 931 EGR Valve Lift Sensor High Error.............................................................................................. 931 CA2272............................................................................................................................ 933 EGR Valve Lift Sensor Low Error............................................................................................... 933 CA2351............................................................................................................................ 934 EGR Valve Solenoid Operation Short Circuit.................................................................................... 934 CA2352............................................................................................................................ 936 EGR Valve Solenoid Operation Disconnect....................................................................................... 936 CA2555............................................................................................................................ 938 Intake Heater Relay Disconnection Error....................................................................................... 938 CA2556............................................................................................................................ 940 Intake Heater Relay Short Circuit Error....................................................................................... 940 D150KA............................................................................................................................ 942 Emergency Steering Relay: Disconnection....................................................................................... 942 D150KB............................................................................................................................ 944 Emergency Steering Relay: Short Circuit....................................................................................... 944 D150KY............................................................................................................................ 946 Emergency Steering Relay: Short Circuit With Power Supply Line................................................................ 946 D160KA............................................................................................................................ 948 Backup Lamp Relay Output: Disconnection....................................................................................... 948 D160KB............................................................................................................................ 950 Backup Lamp Relay Output: Short Circuit....................................................................................... 950 D191KA............................................................................................................................ 952 Joystick Steering Neutral Safety Relay: Disconnection......................................................................... 952 D191KB............................................................................................................................ 954 Joystick Steering Neutral Safety Relay: Short Circuit......................................................................... 954 D191KY............................................................................................................................ 956 Joystick Steering Neutral Safety Relay: Short Circuit With Power Supply Line.................................................. 956 D192KA............................................................................................................................ 958 ECSS Solenoid: Disconnection.................................................................................................. 958 D192KB............................................................................................................................ 960 ECSS Solenoid: Short Circuit.................................................................................................. 960 D192KY............................................................................................................................ 962 ECSS Solenoid: Short Circuit With Power Supply Line........................................................................... 962 D193KA............................................................................................................................ 964 Joystick Steering Solenoid Cut-Off Relay: Disconnection....................................................................... 964 D193KB............................................................................................................................ 966 Joystick steering solenoid cut-off relay: Short circuit....................................................................... 966 D193KY............................................................................................................................ 968 Joystick Steering Solenoid Cut-Off Relay: Short Circuit With Power Supply Line................................................ 968 D5ZHKA............................................................................................................................ 970 Terminal C Signal: Disconnection.............................................................................................. 970 D5ZHKB............................................................................................................................ 974 Terminal C Signal: Short Circuit.............................................................................................. 974 D5ZHKZ............................................................................................................................ 978 Terminal C Signal: Disconnection Or Short Circuit............................................................................. 978 D5ZHL6............................................................................................................................ 982 Terminal C Signal: Signal Does Not Match Engine Running Or Stopped State...................................................... 982 DA80L4............................................................................................................................ 986 Auto Grease Controller: ON/OFF Signals Disagree............................................................................... 986 DAF3KK............................................................................................................................ 988 Machine Monitor: Low Source Voltage (Input)................................................................................... 988 DAF5KP............................................................................................................................ 990 Machine Monitor: Low Output Voltage........................................................................................... 990 DAFRKR............................................................................................................................ 994 CAN Communication With Machine Monitor: Defective Communication (Abnormality In Target Component System)...................... 994 DAQ0KK............................................................................................................................ 996 Transmission Controller: Low Source Voltage................................................................................... 996 DAQ0KT............................................................................................................................ 998 Transmission Controller: Abnormality In Controller............................................................................ 998 DAQ1KA............................................................................................................................ 999 Terminal ACC Input: Disconnection............................................................................................. 999 DAQ2KK............................................................................................................................1002 Transmission Controller Load Power Supply Line: Low Source Voltage (Input)....................................................1002 DAQ9KQ............................................................................................................................1004 Transmission Controller Model Selection: Disagreement of Model Selection Signals..............................................1004 DAQRKR............................................................................................................................1005 CAN Communication with Transmission Controller: Defective Communication (Abnormality in Target Component System)..............1005 DAQRMA............................................................................................................................1007 Transmission Controller Option Setting: Malfunction...........................................................................1007 DB2RKR............................................................................................................................1008 CAN Communication with Engine Controller: Defective Communication (Abnormality in Target Component System)....................1008 DB90KK............................................................................................................................1010 Work Equipment Controller: Low Source Voltage (Input).........................................................................1010 DB90KT............................................................................................................................1012 Work Equipment Controller: Abnormality in Controller..........................................................................1012 DB92KK............................................................................................................................1014 Work Equipment Controller Load Power Supply Line: Low Source Voltage (Input)..................................................1014 DB95KX............................................................................................................................1016 Work Equipment Controller Power Supply Output: Out of Input Signal Range......................................................1016 DB99KQ............................................................................................................................1018 Work Equipment Controller Model Selection: Disagreement in Model Selection Signals............................................1018 DB9RKR............................................................................................................................1019 CAN Communication With Work Equipment Controller: Defective Communication (Abnormality in Target Component System)............1019 DB9RMA............................................................................................................................1021 Work equipment controller option setting: Malfunction.........................................................................1021 DB9RMC............................................................................................................................1022 CAN Communication With Transmission Controller, Engine Controller and Machine Monitor: Defective Operation....................1022 DD15LD............................................................................................................................1026 n Switch (Panel Switch 1): Switch Is Kept Pressed For Long Time...............................................................1026 DD16LD............................................................................................................................1028 Ø Switch (Panel Switch 2): Switch is Kept Pressed for Long Time...............................................................1028 DD17LD............................................................................................................................1030 < Switch (Panel Switch 3): Switch Is Kept Pressed For Long Time...............................................................1030 DD18LD............................................................................................................................1032 > Switch (Panel Switch 4): Switch Is Kept Pressed For Long Time...............................................................1032 DD1ALD............................................................................................................................1034 Remote Positioner Raise/lower Set Switch (Raise): Switch Is Kept Pressed For Long Time........................................1034 DD1BLD............................................................................................................................1036 Remote Positioner Raise/lower Set Switch (Lower): Switch Is Kept Pressed For Long Time........................................1036 DD1CLD............................................................................................................................1038 Load Meter Subtotal Switch: Switch Is Kept Pressed For Long Time..............................................................1038 DD1FLD............................................................................................................................1040 Load Meter Mode Selector Switch (A/B): Switch Is Kept Pressed For Long Time...................................................1040 DD1GLD............................................................................................................................1042 Load Meter Mode Selector Switch (+/-): Switch Is Kept Pressed For Long Time...................................................1042 DD1HLD............................................................................................................................1044 Load Meter Display Selector Switch: Switch Is Kept Pressed For Long Time......................................................1044 DD1NLD............................................................................................................................1046 Fan Reverse Switch: Switch Is Kept Pressed For Long Time......................................................................1046 DD1NL4............................................................................................................................1048 Fan Automatic Reverse Switch: Switch Is Kept Pressed For Long Time............................................................1048 DDB6L4............................................................................................................................1050 Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree...................................................................1050 DDD1LD............................................................................................................................1054 Remote Positioner Bucket Angle Set Switch: Switch Is Kept Pressed For Long Time...............................................1054 DDE5MA............................................................................................................................1056 Emergency Steering Drive Switch: Malfunction..................................................................................1056 DDK3KA............................................................................................................................1058 Right FNR Switch: Disconnection...............................................................................................1058 DDK4KA............................................................................................................................1061 Joystick Steering FNR Switch: Disconnection...................................................................................1061 DDK5L4............................................................................................................................1064 Joystick Steering Shift-Up/Down Switch: ON/OFF Signals Disagree...............................................................1064 DDK6KA............................................................................................................................1066 FNR Lever Switch: Disconnection...............................................................................................1066 DDK6KB............................................................................................................................1070 FNR Lever Switch: Short Circuit...............................................................................................1070 DDS5KA............................................................................................................................1072 Steering Pressure Switch Signal: Disconnected.................................................................................1072 DDS5KB............................................................................................................................1074 Steering pressure Switch Signal: Short Circuit................................................................................1074 DDS5L6............................................................................................................................1076 Steering: Low Oil Pressure....................................................................................................1076 DDT0L4............................................................................................................................1078 Shift Mode Selector Switch: ON/OFF Signals Disagree...........................................................................1078 DDT4LD............................................................................................................................1080 Transmission Cut-Off Set Switch: Switch Is Kept Pressed For Long Time.........................................................1080 DDW9LD............................................................................................................................1082 Kick-Down Switch: Switch Is Kept Pressed For Long Time........................................................................1082 DDWLLD............................................................................................................................1084 Hold Switch: Switch Is Kept Pressed For Long Time.............................................................................1084 DDY0LD............................................................................................................................1086 Load Meter Cancel Switch: Switch Is Kept Pressed For Long Time................................................................1086 DF10KA............................................................................................................................1088 Transmission Shift Lever Switch: Disconnected.................................................................................1088 DF10KB............................................................................................................................1092 Transmission Shift Lever Switch: Short Circuit................................................................................1092 DGF1KA............................................................................................................................1094 Transmission Oil Temperature Sensor: Disconnected.............................................................................1094 DGF1KB............................................................................................................................1096 Transmission Oil Temperature Sensor: Short Circuit............................................................................1096 DGH2KX............................................................................................................................1098 Hydraulic Oil Temperature Sensor: Out Of Input Signal Range...................................................................1098 DGR2KA............................................................................................................................1100 Rear Brake Oil Temperature Sensor: Disconnected...............................................................................1100 DGR2KX............................................................................................................................1102 Rear Brake Oil Temperature Sensor: Out Of Input Signal Range..................................................................1102 DGT1KX............................................................................................................................1104 Torque converter oil temperature sensor: Out of input signal range............................................................1104 DH21KA............................................................................................................................1106 Loader Pump Pressure Sensor: Disconnection....................................................................................1106 DH21KB............................................................................................................................1108 Loader Pump Pressure Sensor: Power Supply Line Short..........................................................................1108 DHPCKX............................................................................................................................1110 Lift Arm Cylinder Bottom Pressure Sensor: Out Of Input Signal Range...........................................................1110 DHPDKX............................................................................................................................1112 Lift Arm Cylinder Head Pressure Sensor: Out Of Input Signal Range.............................................................1112 DHT1KX............................................................................................................................1114 Transmission Cut-Off Pressure Sensor: Out Of Input Signal Range...............................................................1114 DHT8KA............................................................................................................................1116 Steering Pump Pressure Sensor: Disconnection..................................................................................1116 DHT8KB............................................................................................................................1118 Steering Pump Pressure Sensor: Short Circuit..................................................................................1118 DK59KA............................................................................................................................1120 Lift Arm EPC Lever Potentiometer (Main): Disconnection........................................................................1120 DK59KY............................................................................................................................1123 Lift Arm EPC Lever Potentiometer (Main): Short Circuit With Power Supply Line.................................................1123 DK59L8............................................................................................................................1126 Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree..............................................................1126 DK5AKA............................................................................................................................1129 Lift Arm EPC Lever Potentiometer (Sub): Disconnection.........................................................................1129 DK5AKY............................................................................................................................1132 Lift Arm EPC Lever Potentiometer (Sub): Short Circuit With Power Supply Line..................................................1132 DK5BKA............................................................................................................................1135 Bucket EPC Lever Potentiometer (Main): Disconnection..........................................................................1135 DK5BKY............................................................................................................................1138 Bucket EPC Lever Potentiometer (Main): Short Circuit With Power Supply Line...................................................1138 DK5BL8............................................................................................................................1141 Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree................................................................1141 DK5CKA............................................................................................................................1144 Bucket EPC Lever Potentiometer (Sub): Disconnection...........................................................................1144 DK5CKY............................................................................................................................1147 Bucket EPC Lever Potentiometer (Sub): Short Circuit With Power Supply Line....................................................1147 DK5FKA............................................................................................................................1150 Joystick Steering EPC Lever Potentiometer (Main): Disconnection...............................................................1150 DK5FKY............................................................................................................................1154 Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line........................................1154 DK5GKA............................................................................................................................1156 Joystick Steering EPC Lever Potentiometer (Sub): Disconnection................................................................1156 DK5GKY............................................................................................................................1159 Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit With Power Supply Line.........................................1159 DK5FL8............................................................................................................................1161 Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree.....................................................1161 DKA0KA............................................................................................................................1164 Lift Arm Angle Sensor: Disconnection..........................................................................................1164 DKA0KY............................................................................................................................1166 Lift Arm Angle Sensor: Short Circuit With Power Supply Line...................................................................1166 DKA0L0............................................................................................................................1168 Lift Arm Angle Sensor: Double Meshing.........................................................................................1168 DLF1KA............................................................................................................................1170 Transmission Input Speed Sensor: Disconnection................................................................................1170 DLF1LC............................................................................................................................1172 Transmission Input Speed Sensor: Short Circuit................................................................................1172 DLM3KA............................................................................................................................1174 Fan Speed Sensor: Disconnection...............................................................................................1174 DLM3LC............................................................................................................................1176 Fan Speed Sensor: Short Circuit...............................................................................................1176 DLT3KA............................................................................................................................1178 Transmission Output Speed Sensor: Disconnection...............................................................................1178 DLT3LC............................................................................................................................1180 Transmission Output Speed Sensor: Out Of Input Signal Range...................................................................1180 DT20KB............................................................................................................................1182 Transmission Cut-Off Indicator Lamp: Short Circuit............................................................................1182 DUM1KB............................................................................................................................1184 Remote Positioner Raise Set Indicator Lamp: Short Circuit.....................................................................1184 DUM2KB............................................................................................................................1186 Remote Positioner Lower Set Indicator Lamp: Short Circuit.....................................................................1186 DV00KB............................................................................................................................1188 Alarm Buzzer: Short Circuit...................................................................................................1188 DW4PKA............................................................................................................................1190 Lift Arm Raise EPC Solenoid: Disconnection....................................................................................1190 DW4PKB............................................................................................................................1192 Lift Arm Raise EPC Solenoid: Short Circuit....................................................................................1192 DW4PKY............................................................................................................................1194 Lift Arm Raise EPC Solenoid: Short Circuit With Power Supply Line.............................................................1194 DW4QKA............................................................................................................................1196 Lift Arm Lower EPC Solenoid: Disconnection....................................................................................1196 DW4QKB............................................................................................................................1198 Lift Arm Lower EPC Solenoid: Short Circuit....................................................................................1198 DW4QKY............................................................................................................................1200 Lift Arm Lower EPC Solenoid: Short Circuit With Power Supply Line.............................................................1200 DW4RKA............................................................................................................................1202 Bucket Tilt EPC Solenoid: Disconnection.......................................................................................1202 DW4RKB............................................................................................................................1204 Bucket Tilt EPC Solenoid: Short Circuit.......................................................................................1204 DW4RKY............................................................................................................................1206 Bucket Tilt EPC Solenoid: Short Circuit With Power Supply Line................................................................1206 DW4SKA............................................................................................................................1208 Bucket Dump EPC Solenoid: Disconnection.......................................................................................1208 DW4SKB............................................................................................................................1210 Bucket Dump EPC Solenoid: Short Circuit.......................................................................................1210 DW4SKY............................................................................................................................1212 Bucket Dump EPC Solenoid: Short Circuit With Power Supply Line................................................................1212 DW7BKA............................................................................................................................1214 Fan Reverse Solenoid: Disconnection...........................................................................................1214 DW7BKB............................................................................................................................1216 Fan Reverse Solenoid: Short Circuit...........................................................................................1216 DW7BKY............................................................................................................................1218 Fan Reverse Solenoid: Short Circuit With Power Supply Line....................................................................1218 DWM1KA............................................................................................................................1220 Work Equipment Neutral Lock Solenoid: Disconnection...........................................................................1220 DWM1KB............................................................................................................................1222 Work Equipment Neutral Lock Solenoid: Short Circuit...........................................................................1222 DWM1KY............................................................................................................................1224 Work Equipment Neutral Lock Solenoid: Short Circuit With Power Supply Line....................................................1224 DWN6KA............................................................................................................................1226 Lift Arm Raise Magnet Detent Solenoid: Disconnection..........................................................................1226 DWN6KB............................................................................................................................1228 Lift Arm Raise Magnet Detent Solenoid: Short Circuit..........................................................................1228 DWN6KY............................................................................................................................1230 Lift Arm Raise Magnet Detent Solenoid: Short Circuit With Power Supply Line...................................................1230 DWN7KA............................................................................................................................1232 Lift Arm Float Magnet Detent Solenoid: Disconnection..........................................................................1232 DWN7KB............................................................................................................................1234 Lift Arm Float Magnet Detent Solenoid: Short Circuit..........................................................................1234 DWN7KY............................................................................................................................1236 Lift Arm Float Magnet Detent Solenoid: Short Circuit With Power Supply Line...................................................1236 DWN8KA............................................................................................................................1238 Bucket Tilt Magnet Detent Solenoid: Disconnection.............................................................................1238 DWN8KB............................................................................................................................1240 Bucket Tilt Magnet Detent Solenoid: Short Circuit.............................................................................1240 DWN8KY............................................................................................................................1242 Bucket Tilt Magnet Detent Solenoid: Shorted With The Power Source.............................................................1242 DX16KA............................................................................................................................1244 Fan Pump EPC Solenoid: Disconnection..........................................................................................1244 DX16KB............................................................................................................................1246 Fan Pump EPC Solenoid: Short Circuit..........................................................................................1246 DX16KY............................................................................................................................1248 Fan Pump EPC Solenoid: Short Circuit With Power Supply Line...................................................................1248 DXA1KA............................................................................................................................1250 Loader Pump PC-EPC Solenoid: Disconnection....................................................................................1250 DXA1KB............................................................................................................................1252 Loader Pump PC-EPC Solenoid: Short Circuit....................................................................................1252 DXANKA............................................................................................................................1254 Steering Pump PC-EPC Solenoid: Disconnection..................................................................................1254 DXANKB............................................................................................................................1256 Steering Pump PC-EPC Solenoid: Short Circuit..................................................................................1256 DXH1KA............................................................................................................................1258 Lockup ECMV Solenoid: Disconnection...........................................................................................1258 DXH1KB............................................................................................................................1260 Lockup ECMV Solenoid: Short Circuit...........................................................................................1260 DXH1KY............................................................................................................................1262 Lockup ECMV Solenoid: Short Circuit With Power Supply Line....................................................................1262 DXH4KA............................................................................................................................1264 1st Clutch ECMV Solenoid: Disconnection.......................................................................................1264 DXH4KB............................................................................................................................1266 1st Clutch ECMV Solenoid: Short Circuit.......................................................................................1266 DXH4KY............................................................................................................................1268 1st Clutch ECMV Solenoid: Short Circuit With Power Supply Line................................................................1268 DXH5KA............................................................................................................................1270 2nd Clutch ECMV Solenoid: Disconnection.......................................................................................1270 DXH5KB............................................................................................................................1272 2nd Clutch ECMV Solenoid: Short Circuit.......................................................................................1272 DXH5KY............................................................................................................................1274 2nd Clutch ECMV Solenoid: Short Circuit With Power Supply Line................................................................1274 DXH6KA............................................................................................................................1276 3rd Clutch ECMV Solenoid: Disconnection.......................................................................................1276 DXH6KB............................................................................................................................1278 3rd cluTch ECMV Solenoid: Short Circuit.......................................................................................1278 DXH6KY............................................................................................................................1280 3rd Clutch ECMV Solenoid: Short Circuit With Power Supply Line................................................................1280 DXH7KA............................................................................................................................1282 R Clutch ECMV Solenoid: Disconnection.........................................................................................1282 DXH7KB............................................................................................................................1284 R Clutch ECMV Solenoid: Short Circuit.........................................................................................1284 DXH7KY............................................................................................................................1286 R Clutch ECMV Solenoid: Short Circuit With Power Supply Line..................................................................1286 DXH8KA............................................................................................................................1288 F Clutch ECMV Solenoid: Disconnection.........................................................................................1288 DXH8KB............................................................................................................................1290 F Clutch ECMV Solenoid: Short Circuit.........................................................................................1290 DXH8KY............................................................................................................................1292 F Clutch ECMV Solenoid: Short Circuit With Power Supply Line..................................................................1292 DXHHKA............................................................................................................................1294 4th Clutch ECMV Solenoid: Disconnection.......................................................................................1294 DXHHKB............................................................................................................................1296 4th Clutch ECMV Solenoid: Short Circuit.......................................................................................1296 DXHHKY............................................................................................................................1298 4th Clutch ECMV Solenoid: Short Circuit With Power Supply Line................................................................1298 DXHLKA............................................................................................................................1300 Joystick Steering Right EPC Solenoid: Disconnection...........................................................................1300 DXHLKB............................................................................................................................1302 Joystick Steering Right EPC Solenoid: Short Circuit...........................................................................1302 DXHLKY............................................................................................................................1304 Joystick steering right EPC solenoid: Short circuit with power supply line....................................................1304 DXHMKA............................................................................................................................1306 Joystick Steering Left EPC Solenoid: Disconnection............................................................................1306 DXHMKB............................................................................................................................1308 Joystick Steering Left EPC Solenoid: Short Circuit............................................................................1308 DXHMKY............................................................................................................................1310 Joystick Steering Left EPC Solenoid: Short Circuit With Power Supply Line.....................................................1310 DY30MA............................................................................................................................1312 Motor-Driven Emergency Steering Pump Failure (During Operation Of Machine)....................................................1312 DY30MC............................................................................................................................1315 Motor-Driven Emergency Steering Pump Failure (Malfunction In Manual Mode).....................................................1315 DY30ME............................................................................................................................1318 Emergency Steering: Operating For More Than 1 Minute..........................................................................1318 E-1...............................................................................................................................1321 Engine Does Not Start.........................................................................................................1321 E-2...............................................................................................................................1328 Wiper does not operate........................................................................................................1328 E-3...............................................................................................................................1332 Windshield Washer Does Not Operate............................................................................................1332 E-4...............................................................................................................................1335 Headlamp, Clearance Lamp, Tail Lamp, And License Lamp Do Not Light Up Or Go Off...............................................1335 E-5...............................................................................................................................1343 Working Lamp Does Not Light Up Or Go Off......................................................................................1343 E-6...............................................................................................................................1348 Turn Signal Lamp And Hazard Lamp Do Not Light Up Or Go Off....................................................................1348 E-7...............................................................................................................................1354 Brake Lamp Does Not Light Or It Keeps Lighting Up.............................................................................1354 E-8...............................................................................................................................1356 Backup Lamp Does Not Light Or It Keeps Lighting Up............................................................................1356 E-9...............................................................................................................................1358 Backup Buzzer Does Not Sound Or It Keeps Sounding.............................................................................1358 E-10..............................................................................................................................1360 Horn Does Not Sound Or It Keeps Sounding......................................................................................1360 E-11..............................................................................................................................1362 Alarm Buzzer Does Not Sound Or It Keeps Sounding..............................................................................1362 E-12..............................................................................................................................1364 Air Conditioner Does Not Operate Or Stop......................................................................................1364 E-13..............................................................................................................................1368 The KOMTRAX System Does Not Work Properly.....................................................................................1368 E-14..............................................................................................................................1370 When Kick-down Switch Is Turned ON, Kick-down Operation Does Not Start........................................................1370 E-15..............................................................................................................................1372 When Hold Switch Is Pressed, Holding Operation Does Not Start.................................................................1372 E-16..............................................................................................................................1374 Transmission Is Kept In Neutral, Or Brake Drags When Directional Lever Is Operated While Parking Brake Is Applied.............1374 E-17..............................................................................................................................1376 Transmission Cut-off Mode Cannot Be Set Or Reset..............................................................................1376 E-18..............................................................................................................................1378 Transmission Cut-off Set Cannot Be Reset......................................................................................1378 E-19..............................................................................................................................1380 FNR Switch Mode Cannot Be Set Or Reset........................................................................................1380 E-20..............................................................................................................................1382 Fan Reverse Function Cannot Be Used Or Reset..................................................................................1382 E-21..............................................................................................................................1384 Discharge From Loader Pump Does Not Rise From Minimum Level...................................................................1384 E-22..............................................................................................................................1386 ECSS Function Cannot Be Used Or Reset.........................................................................................1386 E-23..............................................................................................................................1388 When Parking Brake Is Turned ON, Parking Brake Indicator Lamp Does Not Light Up...............................................1388 E-24..............................................................................................................................1392 When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate...............................................1392 E-25..............................................................................................................................1394 Air Cleaner Clogging Indicator Lamp Does Not Light Up.........................................................................1394 E-26..............................................................................................................................1396 Radiator Coolant Level Caution Lamp Does Not Light Up.........................................................................1396 E-27..............................................................................................................................1397 Hydraulic Oil Temperature Gauge Does Not Rise And Hydraulic Oil Temperature Caution Lamp Does Not Light Up....................1397 E-28..............................................................................................................................1398 Torque Converter Oil Temperature Gauge Does Not Rise And Torque Converter Oil Temperature Caution Lamp Does Not Light Up......1398 E-29..............................................................................................................................1400 Steering Oil Pressure Caution Lamp Does Not Light Up..........................................................................1400 E-30..............................................................................................................................1402 Abnormality In n Switch (Panel Switch 1) Input................................................................................1402 E-31..............................................................................................................................1404 Abnormality In ‡ Switch (Panel Switch 1) Input................................................................................1404 E-32..............................................................................................................................1406 Abnormality In < Switch (Panel Switch 2) Input................................................................................1406 E-33..............................................................................................................................1408 Abnormality In > Switch (Panel Switch 2) Input................................................................................1408 H-MODE HYDRAULIC AND MECHANICAL SYSTEM............................................................................................1410 Method Of Using Troubleshooting Chart.........................................................................................1410 Table Of Failure And Causes...................................................................................................1412 H-1...........................................................................................................................1416 The Machine Does Not Start................................................................................................1416 H-2...........................................................................................................................1418 Torque Converter Lockup Is Not Switched Off (Engine Stalls) [Machine With Lockup Clutch (If Equipped)]....................1418 H-3...........................................................................................................................1419 Torque Converter Lockup Is Not Switched On [Machine With Lockup Clutch (If Equipped)].....................................1419 H-4...........................................................................................................................1420 The Travel Speed Is Slow, The Thrusting Force Is Weak, The Uphill Traveling Power Is Weak, And The Gear Is Not Shifted....1420 H-5...........................................................................................................................1422 Shocks Are Large At The Times Of Starting And Shifting Gear...............................................................1422 H-6...........................................................................................................................1424 Time Lag Is Large At The Times Of Starting And Shifting Gear..............................................................1424 H-7...........................................................................................................................1426 The Torque Converter Oil Temperature Is High..............................................................................1426 H-8...........................................................................................................................1427 Steering Does Not Turn....................................................................................................1427 H-9...........................................................................................................................1428 Steering Does Not Turn [Machine With Joystick Steering (If Equipped)].....................................................1428 H-10..........................................................................................................................1429 Steering Response Is Poor.................................................................................................1429 H-11..........................................................................................................................1430 Turning, Response Of Steering Is Poor [Machine With Joystick Steering (If Equipped)]......................................1430 H-12..........................................................................................................................1431 Steering Is Stiff.........................................................................................................1431 H-13..........................................................................................................................1432 When Machine Turns, It Shakes Or Makes Large Shocks.......................................................................1432 H-14..........................................................................................................................1433 When Machine Turns, It Shakes Or Makes Large Shocks [Machine With Joystick Steering (If Equipped)]........................1433 H-15..........................................................................................................................1434 The Wheel Brake Does Not Work Or Does Not Work Well.......................................................................1434 H-16..........................................................................................................................1435 The Wheel Brake Is Not Released Or It Drags...............................................................................1435 H-17..........................................................................................................................1436 The Parking Brake Does Not Work Or Does Not Work Well.....................................................................1436 H-18..........................................................................................................................1437 The Parking Brake Is Not Released Or It Drags (Including Emergency Release System)........................................1437 H-19..........................................................................................................................1438 Lift Arm Does Not Rise....................................................................................................1438 H-20..........................................................................................................................1439 LIft Arm Speed Is Low Or Rising Force Of Lift Arm Is Insufficient.........................................................1439 H-21..........................................................................................................................1440 When Rising, The Lift Arm Comes To Move Slowly At Specific Height.........................................................1440 H-22..........................................................................................................................1440 The Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Floats).........................................................1440 H-23..........................................................................................................................1440 Hydraulic Drift Of The Lift Arm Is Large..................................................................................1440 H-24..........................................................................................................................1440 The Lift Arm Wobbles During Operation.....................................................................................1440 H-25..........................................................................................................................1441 Bucket Does Not Tilt Back.................................................................................................1441 H-26..........................................................................................................................1442 Bucket Speed Is Low Or Tilting Back Force Is Insufficient.................................................................1442 H-27..........................................................................................................................1443 The Bucket Comes To Operate Slowly In The Midst Of Tilting-back...........................................................1443 H-28..........................................................................................................................1443 The Bucket Cylinder Cannot Hold Down The Bucket...........................................................................1443 H-29..........................................................................................................................1443 Hydraulic Drift Of The Bucket Is Large....................................................................................1443 H-30..........................................................................................................................1443 The Bucket Wobbles During Travel With Cargo (The Work Equipment Valve Is Set To “Hold”)...................................1443 H-31..........................................................................................................................1444 Lift Arm And Bucket Control Levers Do Not Move Smoothly And Are Heavy.....................................................1444 H-32..........................................................................................................................1445 During Operation Of The Machine, Engine Speed Lowers Remarkably Or Engine Stalls..........................................1445 H-33..........................................................................................................................1445 Large Shock Is Made When Work Equipment Starts And Stops..................................................................1445 H-34..........................................................................................................................1445 When Work Equipment Circuit Is Relieved Singly, Other Work Equipment Moves................................................1445 H-35..........................................................................................................................1446 ECSS Does Not Operate, And Pitching, Bouncing Occur.......................................................................1446 50 DISASSEMBLY AND ASSEMBLY...............................................................................................................1447 HOW TO READ THIS MANUAL...............................................................................................................1451 Removal And Installation Of Assemblies............................................................................................1451 Special Tools.................................................................................................................1451 Removal.......................................................................................................................1451 Installation..................................................................................................................1451 Disassembly And Assembly Of Assemblies............................................................................................1452 Special Tools.................................................................................................................1452 Disassembly...................................................................................................................1452 Assembly......................................................................................................................1453 SPECIAL TOOLS LIST....................................................................................................................1454 Sketches of special tools.........................................................................................................1459 CONNECTOR REPAIR PROCEDURES...........................................................................................................1480 Stripping Insulation..............................................................................................................1480 Wire Inspection...................................................................................................................1480 Contact Terminal Removal (HD30 Type)..............................................................................................1481 Crimping Contact Terminal (HD30 Type).............................................................................................1482 Insertion Of Contact Terminal (HD30 Type).........................................................................................1483 Contact Terminal Removal (DT Type)................................................................................................1484 Crimping Contact Terminal (DT Type)...............................................................................................1485 Insertion Of Contact Terminal (DT Type)...........................................................................................1486 ENGINE AND COOLING SYSTEM.............................................................................................................1487 Engine............................................................................................................................1487 Removal.......................................................................................................................1487 Installation..................................................................................................................1491 Engine Hood.......................................................................................................................1492 Removal.......................................................................................................................1492 Installation..................................................................................................................1494 Radiator..........................................................................................................................1495 Removal.......................................................................................................................1495 Installation..................................................................................................................1498 Aftercooler.......................................................................................................................1499 Removal.......................................................................................................................1499 Installation..................................................................................................................1501 Oil Cooler........................................................................................................................1502 Removal.......................................................................................................................1502 Installation..................................................................................................................1503 Cooling Fan And Drive Motor.......................................................................................................1504 Removal.......................................................................................................................1504 Installation..................................................................................................................1508 Fuel Supply Pump..................................................................................................................1509 Removal.......................................................................................................................1509 Installation..................................................................................................................1513 Fuel Injector.....................................................................................................................1518 Removal.......................................................................................................................1518 Installation..................................................................................................................1521 Cylinder Head.....................................................................................................................1526 Removal.......................................................................................................................1526 Installation..................................................................................................................1532 Engine Front Oil Seal.............................................................................................................1535 Removal.......................................................................................................................1535 Installation..................................................................................................................1536 Engine Rear Oil Seal..............................................................................................................1537 Removal.......................................................................................................................1537 Installation..................................................................................................................1538 Fuel Tank.........................................................................................................................1542 Removal.......................................................................................................................1542 Installation..................................................................................................................1545 POWER TRAIN...........................................................................................................................1546 Torque Converter And Transmission.................................................................................................1546 Removal.......................................................................................................................1546 Installation..................................................................................................................1552 Disassembly...................................................................................................................1553 Assembly......................................................................................................................1572 Torque Converter (Standard Specification).........................................................................................1597 Disassembly...................................................................................................................1597 Assembly......................................................................................................................1600 Torque Converter (Lockup Specification)...........................................................................................1603 Disassembly...................................................................................................................1603 Assembly......................................................................................................................1607 Clutch Pack.......................................................................................................................1613 Disassembly...................................................................................................................1613 Assembly......................................................................................................................1630 Front Axle........................................................................................................................1649 Removal.......................................................................................................................1649 Installation..................................................................................................................1651 Rear Axle.........................................................................................................................1652 Removal.......................................................................................................................1652 Installation..................................................................................................................1658 Axle Housing......................................................................................................................1660 Disassembly...................................................................................................................1660 Assembly......................................................................................................................1665 Differential......................................................................................................................1672 Disassembly...................................................................................................................1673 Assembly......................................................................................................................1681 BRAKE SYSTEM..........................................................................................................................1696 Parking Brake Disc And Plate......................................................................................................1696 Removal.......................................................................................................................1696 Installation..................................................................................................................1699 UNDERCARRIAGE AND FRAME...............................................................................................................1700 Center Hinge Pin..................................................................................................................1700 Removal.......................................................................................................................1700 Installation..................................................................................................................1705 Counterweight.....................................................................................................................1710 Removal.......................................................................................................................1710 Installation..................................................................................................................1712 HYDRAULIC SYSTEM......................................................................................................................1713 Steering Demand Valve.............................................................................................................1713 Removal.......................................................................................................................1713 Installation..................................................................................................................1716 Work Equipment Valve..............................................................................................................1717 Removal.......................................................................................................................1717 Installation..................................................................................................................1720 Brake Charge Valve................................................................................................................1721 Removal.......................................................................................................................1721 Installation..................................................................................................................1721 Hydraulic Tank....................................................................................................................1722 Removal.......................................................................................................................1722 Installation..................................................................................................................1724 Steering And Power Train Pump.....................................................................................................1725 Removal.......................................................................................................................1725 Installation..................................................................................................................1725 Work Equipment And Cooling Fan Pump...............................................................................................1726 Removal.......................................................................................................................1726 Installation..................................................................................................................1727 Hydraulic Cylinder................................................................................................................1728 Disassembly...................................................................................................................1729 Assembly......................................................................................................................1732 WORK EQUIPMENT........................................................................................................................1738 Removal...........................................................................................................................1738 Installation......................................................................................................................1741 CAB AND ITS ATTACHMENTS...............................................................................................................1743 Operator's Cab And Floor Frame....................................................................................................1743 Removal.......................................................................................................................1743 Installation..................................................................................................................1747 Operator's Cab Glass (Stuck Glass)................................................................................................1748 Removal.......................................................................................................................1748 Installation..................................................................................................................1750 Operator's Seat...................................................................................................................1758 Disassembly...................................................................................................................1758 Assembly......................................................................................................................1765 Manufactured By GRAMMER (Seat)....................................................................................................1770 Upper seat....................................................................................................................1770 Suspension....................................................................................................................1778 Air Conditioner Unit..............................................................................................................1810 Removal.......................................................................................................................1810 Engine Controller.................................................................................................................1816 Removal.......................................................................................................................1816 Installation..................................................................................................................1816 Transmission Controller...........................................................................................................1817 Removal.......................................................................................................................1817 Installation..................................................................................................................1817 KOMTRAX Terminal..................................................................................................................1818 Removal.......................................................................................................................1818 Installation..................................................................................................................1818 90 DIAGRAMS AND DRAWINGS..................................................................................................................1819 100 HYDRAULIC DIAGRAMS AND DRAWINGS...................................................................................................1819 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM - WITHOUT LOOKUP CLUTCH.....................................................................1820 POWER TRAIN HYDRAULIC DIAGRAM - WITH LOOKUP CLUTCH................................................................................1821 AUTOMATIC GREASING CIRCUIT DIAGRAM................................................................................................1822 AUTOMATIC GREASING CITCUIT DIAGRAM ASSEMBLY / PARTS...............................................................................1823 HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................1825 200 ELECTRICAL DIAGRAMS AND DRAWINGS..................................................................................................1829 ELECTRICAL CIRCUIT DIAGRAM (1/10).................................................................................................1831 ELECTRICAL CIRCUIT DIAGRAM (2/10).................................................................................................1833 ELECTRICAL CIRCUIT DIAGRAM (3/10).................................................................................................1835 ELECTRICAL CIRCUIT DIAGRAM (4/10).................................................................................................1837 ELECTRICAL CIRCUIT DIAGRAM 5/10)..................................................................................................1839 ELECTRICAL CIRCUIT DIAGRAM (6/10).................................................................................................1841 ELECTRICAL CIRCUIT DIAGRAM (7/10).................................................................................................1843 ELECTRICAL CIRCUIT DIAGRAM (8/10).................................................................................................1845 ELECTRICAL CIRCUIT DIAGRAM (9/10).................................................................................................1847 ELECTRICAL CIRCUIT DIAGRAM (10/10)................................................................................................1849 WORK EQUIPMENT CONTROLLER SYSTEM ELECTRICAL CIRCUIT DIAGRAM.......................................................................1851 CONECTOR LIST AND STEREOGRAM......................................................................................................1853
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
