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Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual 90001 and up – PDF DOWNLOAD
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Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual 90001 and up
SERIAL NUMBERS:
WA470-90001 and up
WA480-90001 and up
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Description
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual 90001 and up
FILE DETAILS:
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual 90001 and up
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA470-6, WA480-6
Serial Number: 90001 and up
Book Code: SEN04409-06
Language: English
Pages: 1911
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual 90001 and up
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. 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.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual 90001 and up
COVER ................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 0 100 Index............................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 200 Foreword and general information................................................................................................................. 21 Safety notice.................................................................................................................................... 22 How to read the shop manual...................................................................................................................... 27 Explanation of terms for maintenance standard.................................................................................................... 29 Handling of electric equipment and hydraulic component........................................................................................... 31 Handling of connectors newly used for engines.................................................................................................... 40 How to read electric wire code................................................................................................................... 43 Precautions when carrying out operation.......................................................................................................... 46 Method of disassembling and connecting push-pull type coupler.................................................................................... 49 Standard tightening torque table................................................................................................................. 52 Conversion table................................................................................................................................. 56 01 Specification......................................................................................................................................... 0 100 Specification and technical data................................................................................................................. 63 Specification dimension drawing.................................................................................................................. 65 Specifications................................................................................................................................... 66 Weight table..................................................................................................................................... 70 Table of fuel, coolant and lubricants............................................................................................................ 72 10 Structure, function and maintenance standard.......................................................................................................... 0 100 Engine and cooling system........................................................................................................................ 75 Engine mount and transmission mount.............................................................................................................. 76 Cooling system................................................................................................................................... 77 Cooling fan pump................................................................................................................................. 78 Cooling fan motor................................................................................................................................ 86 200 Power train...................................................................................................................................... 93 Power train...................................................................................................................................... 95 Power train system diagram....................................................................................................................... 96 Drive shaft...................................................................................................................................... 98 Power train piping diagram....................................................................................................................... 99 Torque converter................................................................................................................................. 100 Transmission..................................................................................................................................... 108 Transmission control valve....................................................................................................................... 126 ECMV............................................................................................................................................. 130 Main relief valve and torque converter relief valve.............................................................................................. 142 Axle............................................................................................................................................. 144 Differential..................................................................................................................................... 148 Limited slip differential........................................................................................................................ 153 Final drive...................................................................................................................................... 160 300 Steering system.................................................................................................................................. 167 Steering component layout drawing................................................................................................................ 168 Steering column.................................................................................................................................. 169 Steering pump.................................................................................................................................... 170 Steering valve................................................................................................................................... 183 Orbit-roll valve................................................................................................................................. 200 Stop valve....................................................................................................................................... 208 Steering relief valve............................................................................................................................ 209 Steering cylinder................................................................................................................................ 210 Emergency steering motor......................................................................................................................... 212 Emergency steering pump.......................................................................................................................... 213 Joystick steering lever linkage.................................................................................................................. 214 Electrical steering lever........................................................................................................................ 215 Joystick EPC valve............................................................................................................................... 216 400 Brake system..................................................................................................................................... 219 Brake component layout drawing................................................................................................................... 220 Charge valve..................................................................................................................................... 221 Brake valve...................................................................................................................................... 228 Accumulator (for brake).......................................................................................................................... 233 Slack adjuster................................................................................................................................... 234 Brake............................................................................................................................................ 236 Parking brake control............................................................................................................................ 241 Parking brake.................................................................................................................................... 242 Parking brake solenoid valve..................................................................................................................... 244 Emergency parking brake release valve............................................................................................................ 246 500 Undercarriage and frame.......................................................................................................................... 249 Axle mount and center hinge pin.................................................................................................................. 250 Tires............................................................................................................................................ 254 601 Hydraulic system, Part 1......................................................................................................................... 257 Hydraulic component layout drawing............................................................................................................... 258 Work equipment control lever linkage............................................................................................................. 261 Hydraulic tank................................................................................................................................... 264 Power train pump................................................................................................................................. 266 Work equipment pump.............................................................................................................................. 268 Work equipment control valve..................................................................................................................... 288 CLSS............................................................................................................................................. 299 Each function and operation of each valve........................................................................................................ 304 602 Hydraulic system, Part 2......................................................................................................................... 319 PPC valve........................................................................................................................................ 320 Accumulator (for PPC circuit).................................................................................................................... 328 Accumulator (for power train circuit)............................................................................................................ 329 Accumulator (for ECSS)........................................................................................................................... 330 Work equipment PPC cut-off solenoid valve........................................................................................................ 331 700 Work equipment................................................................................................................................... 335 Work equipment linkage........................................................................................................................... 336 Bucket........................................................................................................................................... 339 Bucket positioner and boom kick-out.............................................................................................................. 340 Work equipment cylinder.......................................................................................................................... 346 800 Cab and its attachments.......................................................................................................................... 349 Cab.............................................................................................................................................. 351 Air conditioner.................................................................................................................................. 352 901 Electrical system, Part 1........................................................................................................................ 371 Machine monitor system........................................................................................................................... 372 Machine monitor.................................................................................................................................. 376 902 Electrical system, Part 2........................................................................................................................ 409 Electrical system (Transmission controller system)............................................................................................... 410 Transmission controller.......................................................................................................................... 450 Electrical system (Work equipment controller system)............................................................................................. 452 Work equipment controller........................................................................................................................ 458 903 Electrical system, Part 3........................................................................................................................ 461 Electric transmission control.................................................................................................................... 462 Kickdown switch and hold switch.................................................................................................................. 466 Load meter cancel switch and load meter subtotal switch.......................................................................................... 466 Multi-function knob.............................................................................................................................. 467 Joystick steering knob........................................................................................................................... 468 KOMTRAX system................................................................................................................................... 470 Engine starting circuit.......................................................................................................................... 472 Engine stopping circuit.......................................................................................................................... 474 Preheating circuit............................................................................................................................... 475 Engine power mode selector circuit............................................................................................................... 476 Engine output derating function.................................................................................................................. 477 Automatic warm-up function....................................................................................................................... 477 Parking brake circuit............................................................................................................................ 478 Sensor........................................................................................................................................... 480 20 Standard value table.................................................................................................................................. 0 100 Standard service value table..................................................................................................................... 491 Standard value table for engine.................................................................................................................. 492 Standard value table for chassis................................................................................................................. 493 30 Testing and adjusting................................................................................................................................. 0 101 Testing and adjusting, Part 1.................................................................................................................... 503 Tools for testing, adjusting, and troubleshooting................................................................................................ 505 Testing engine speed............................................................................................................................. 511 Testing exhaust gas color........................................................................................................................ 513 Testing exhaust temperature...................................................................................................................... 515 Adjusting valve clearance........................................................................................................................ 517 Testing compression pressure..................................................................................................................... 519 Testing blow-by pressure......................................................................................................................... 520 Testing engine oil pressure...................................................................................................................... 521 Testing EGR valve drive pressure................................................................................................................. 522 Testing intake air (boost) pressure.............................................................................................................. 523 Handling fuel system equipment................................................................................................................... 524 Releasing residual pressure in fuel system....................................................................................................... 524 Testing fuel pressure............................................................................................................................ 525 Testing fuel return and leak amount.............................................................................................................. 526 Bleeding air from fuel circuit................................................................................................................... 529 Testing fuel circuit for leakage................................................................................................................. 531 Handling of reduced cylinder mode operation...................................................................................................... 532 Handling of no injection cranking operation...................................................................................................... 532 Handling of controller voltage circuit........................................................................................................... 533 Check of muffler and muffler stack for looseness and damage...................................................................................... 534 Check of muffler function........................................................................................................................ 534 Check of installed condition of cylinder head and manifolds...................................................................................... 535 Check of engine piping for damage and looseness.................................................................................................. 535 Testing and adjusting air conditioner compressor belt tension.................................................................................... 536 Testing and adjusting alternator belt tension.................................................................................................... 537 Adjusting transmission speed sensor.............................................................................................................. 538 Adjusting directional lever length............................................................................................................... 539 Adjusting gear shift lever length................................................................................................................ 539 Testing FNR lever and gear shift lever........................................................................................................... 540 Testing and adjusting power train oil pressure................................................................................................... 542 Procedure for flushing torque converter and transmission hydraulic circuit....................................................................... 556 Method of moving machine when transmission valve is broken....................................................................................... 558 Check of axle final drive for oil leakage........................................................................................................ 561 Check of drive shafts for looseness, play and damage............................................................................................. 561 Testing and adjusting steering stop valve........................................................................................................ 562 Testing and adjusting steering wheel............................................................................................................. 564 Testing steering oil pressure.................................................................................................................... 566 Bleeding air from steering circuit............................................................................................................... 569 102 Testing and adjusting, Part 2.................................................................................................................... 571 Testing hydraulic drive fan...................................................................................................................... 573 Adjustment of hydraulic fan speed sensor......................................................................................................... 575 Bleeding air from hydraulic drive fan circuit.................................................................................................... 576 Testing brake pedal.............................................................................................................................. 578 Testing and adjusting brake pedal linkage........................................................................................................ 579 Testing brake performance........................................................................................................................ 580 Testing and adjusting accumulator charge pressure................................................................................................ 581 Testing wheel brake oil pressure................................................................................................................. 583 Testing wear of wheel brake disc................................................................................................................. 585 Bleeding air from wheel brake circuit............................................................................................................ 586 Releasing residual pressure in brake accumulator circuit......................................................................................... 587 Testing parking brake performance................................................................................................................ 587 Testing parking brake oil pressure............................................................................................................... 588 Testing wear of parking brake disc............................................................................................................... 590 Manual release method for parking brake.......................................................................................................... 591 Testing and adjusting work equipment control lever............................................................................................... 592 Testing and adjusting work equipment PPC oil pressure............................................................................................ 593 Testing and adjusting work equipment oil pressure................................................................................................ 596 Bleeding air from work equipment circuit......................................................................................................... 600 Releasing residual pressure in work equipment circuit............................................................................................ 601 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator.... 602 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator................................................. 608 Testing and adjusting bucket positioner.......................................................................................................... 613 Testing and adjusting boom kick-out.............................................................................................................. 615 Checking proximity switch operation pilot lamp................................................................................................... 616 Procedure for testing diodes..................................................................................................................... 617 Preparation work for troubleshooting for electrical system....................................................................................... 618 How to start KOMTRAX terminal operations......................................................................................................... 623 Indicator lamps of KOMTRAX terminal.............................................................................................................. 628 103 Testing and adjusting, Part 3.................................................................................................................... 633 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................................... 634 Special functions of machine monitor (EMMS)...................................................................................................... 637 Pm-clinic inspection table....................................................................................................................... 700 40 Troubleshooting....................................................................................................................................... 0 100 Failure code table and fuse locations............................................................................................................ 705 Failure code table............................................................................................................................... 706 Fuse locations................................................................................................................................... 718 200 General information on troubleshooting........................................................................................................... 723 Points to remember when troubleshooting.......................................................................................................... 724 Sequence of events in troubleshooting............................................................................................................ 725 Testing before troubleshooting................................................................................................................... 726 Classification and procedures of troubleshooting................................................................................................. 727 Information contained in troubleshooting table................................................................................................... 731 Connection table for connector pin numbers....................................................................................................... 733 T- branch box and T- branch adapter table........................................................................................................ 769 301 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 773 Failure code [1500L0] (TORQFLOW transmission: Double meshing).................................................................................... 775 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)............................................................ 776 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)............................................................ 778 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)............................................................ 780 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)............................................................ 782 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).......................................................... 784 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).......................................................... 786 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).......................................................... 788 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).......................................................... 790 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).......................................................... 792 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF).......................................................... 794 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).......................................................... 796 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).......................................................... 798 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................... 800 Failure code [2G43ZG] (Accumulator: Low oil pressure)............................................................................................ 802 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................... 804 302 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 809 Failure code [AA1ANX] (Air cleaner: Clogging).................................................................................................... 812 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............................................................. 814 Failure code [AB00MA] (Alternator: Malfunction).................................................................................................. 816 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)............................................................................. 818 Failure code [B@BAZK] (Engine oil: Low level).................................................................................................... 821 Failure code [B@BCNS] (Coolant: Overheating)..................................................................................................... 822 Failure code [B@BCZK] (Coolant: Low level)....................................................................................................... 824 Failure code [B@C7NS] (Brake oil: Overheating)................................................................................................... 826 Failure code [b@CENS] (Torque converter oil: Overheating)........................................................................................ 828 Failure code [B@CENS] (Torque converter oil: Overheating)........................................................................................ 830 Failure code [B@HANS] (Hydraulic oil: Overheating)............................................................................................... 832 Failure code [CA111] (Abnormality in engine controller).......................................................................................... 834 Failure code [CA115] (Engine Ne or Bkup speed sensor error)...................................................................................... 837 Failure code [CA122] (Charge pressure sensor high error)......................................................................................... 838 Failure code [CA123] (Charge pressure sensor low error).......................................................................................... 840 Failure code [CA131] (Throttle sensor high error)................................................................................................ 842 Failure code [CA132] (Throttle sensor low error)................................................................................................. 844 Failure code [CA135] (Engine oil pressure sensor high error)..................................................................................... 846 Failure code [CA141] (Engine oil pressure sensor low error)...................................................................................... 848 Failure code [CA144] (Coolant sensor high error)................................................................................................. 850 Failure code [CA145] (Coolant sensor low error).................................................................................................. 852 Failure code [CA153] (Charge temperature sensor high error)...................................................................................... 854 Failure code [CA154] (Charge temperature sensor low error)....................................................................................... 856 Failure code [CA187] (Sensor power supply 2 low error)........................................................................................... 858 Failure code [CA221] (Atmospheric pressure sensor high error).................................................................................... 859 Failure code [CA222] (Atmospheric pressure sensor low error)..................................................................................... 861 Failure code [CA227] (Sensor power supply 2 high error).......................................................................................... 862 Failure code [CA234] (Engine overspeed).......................................................................................................... 864 Failure code [CA238] (Ne speed sensor power supply error)........................................................................................ 866 303 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 869 Failure code [CA263] (Fuel temperature sensor high error)........................................................................................ 872 Failure code [CA265] (Fuel temperature sensor low error)......................................................................................... 874 Failure code [CA271] (PCV1 Short circuit)........................................................................................................ 876 Failure code [CA272] (PCV1 Disconnection)........................................................................................................ 878 Failure code [CA273] (PCV2 Short circuit)........................................................................................................ 880 Failure code [CA274] (PCV2 Disconnection)........................................................................................................ 882 Failure code [CA322] (Injector #1 open/short error).............................................................................................. 884 Failure code [CA323] (Injector #5 open/short error).............................................................................................. 886 Failure code [CA324] (Injector #3 open/short error).............................................................................................. 888 Failure code [CA325] (Injector #6 open/short error).............................................................................................. 890 Failure code [CA331] (Injector #2 open/short error).............................................................................................. 892 Failure code [CA332] (Injector #4 open/short error).............................................................................................. 894 Failure code [CA342] (Calibration code inconsistency)............................................................................................ 896 Failure code [CA351] (Injectors drive circuit error)............................................................................................. 897 Failure code [CA352] (Sensor power supply 1 low error)........................................................................................... 899 Failure code [CA386] (Sensor power supply 1 high error).......................................................................................... 900 Failure code [CA431] (Idle validation switch error).............................................................................................. 902 Failure code [CA432] (Idle validation action error).............................................................................................. 904 Failure code [CA441] (Battery voltage low error)................................................................................................. 906 Failure code [CA442] (Battery voltage high error)................................................................................................ 909 Failure code [CA449] Common rail pressure high error 2........................................................................................... 911 Failure code [CA451] (Common rail pressure sensor high error).................................................................................... 912 Failure code [CA452] (Common rail pressure sensor low error)..................................................................................... 914 Failure code [CA553] (Common rail pressure high error 1)......................................................................................... 915 Failure code [CA554] (Common rail pressure sensor in-range error)................................................................................ 916 Failure code [CA559] (Supply pump pressure very low error)....................................................................................... 917 Failure code [CA689] (Engine Ne speed sensor error).............................................................................................. 921 Failure code [CA731] (Engine Bkup speed sensor phase error)...................................................................................... 923 Failure code [CA757] (All continuous data lost error)............................................................................................ 923 Failure code [CA778] (Engine Bkup speed sensor error)............................................................................................ 924 Failure code [CA1228] (EGR valve servo error 1).................................................................................................. 926 Failure code [CA1625] (EGR valve servo error 2).................................................................................................. 927 Failure code [CA1633] (KOMNET datalink timeout error)............................................................................................ 928 Failure code [CA2185] (Throttle sensor supply voltage high error)................................................................................ 930 Failure code [CA2186] (Throttle sensor power supply low error)................................................................................... 931 304 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 933 Failure code [CA2249] (Supply pump pressure very low error 2).................................................................................... 935 Failure code [CA2271] (EGR valve lift sensor high error)......................................................................................... 936 Failure code [CA2272] (EGR valve lift sensor low error).......................................................................................... 938 Failure code [CA2351] (EGR valve solenoid operation short circuit)............................................................................... 939 Failure code [CA2352] (EGR valve solenoid operation disconnect).................................................................................. 941 Failure code [CA2555] (Intake heater relay disconnection error).................................................................................. 942 Failure code [CA2556] (Intake heater relay short circuit error).................................................................................. 944 Failure code [D150KA] (Emergency steering relay: Disconnection).................................................................................. 946 Failure code [D150KB] (Emergency steering relay: Short circuit).................................................................................. 948 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)........................................................... 950 Failure code [D160KA] (Backup lamp relay output: Disconnection).................................................................................. 952 Failure code [D160KB] (Backup lamp relay output: Short circuit).................................................................................. 954 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection).................................................................... 956 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit).................................................................... 958 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)............................................. 960 Failure code [D192KA] (ECSS solenoid: Disconnection)............................................................................................. 962 Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................................................. 963 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...................................................................... 964 Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection).................................................................. 966 Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit).................................................................. 968 Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line)........................................... 970 Failure code [D5ZHKA] (Terminal C signal: Disconnection)......................................................................................... 973 Failure code [D5ZHKB] (Terminal C signal: Short circuit)......................................................................................... 977 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)........................................................................ 980 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)................................................. 985 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).......................................................................... 988 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).............................................................................. 990 Failure code [DAF5KP] (Machine monitor: Low output voltage)...................................................................................... 992 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))................. 996 305 Troubleshooting by failure code (Display of code), Part 5........................................................................................ 999 Failure code [DAQ0KK] (Transmission controller: Low source voltage)..............................................................................1002 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller).......................................................................1004 Failure code [DAQ1KA] (Terminal ACC input: Disconnection)........................................................................................1005 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))...............................................1008 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals).........................................1010 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)).........1011 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)......................................................................1016 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)................1017 Failure code [DB90KK] Work equipment controller: Low source voltage (input)......................................................................1024 Failure code [DB90KT] Work equipment controller: Abnormality in controller.......................................................................1026 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...............................................1028 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...................................................1031 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals).......................................1034 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system).........1035 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)....................................................................1040 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...............1041 Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time............................................................1042 Failure code [DD16LD] ◇ switch (Panel switch 2): Switch is kept pressed for long time............................................................1044 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time............................................................1046 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time............................................................1048 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time.....................................1050 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time.....................................1052 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...........................................................1054 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time................................................1056 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time................................................1058 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time).................................................1060 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time).................................................................1062 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time).......................................................1064 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)..............................................................1066 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)..........................................1070 306 Troubleshooting by failure code (Display of code), Part 6........................................................................................1073 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).............................................................................1076 Failure code [DDK3KA] (Right FNR switch: Disconnection)..........................................................................................1078 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)..............................................................................1081 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)..........................................................1084 Failure code [DDK6KA] (FNR lever switch: Disconnection)..........................................................................................1086 Failure code [DDK6KB] (FNR lever switch: Short circuit)..........................................................................................1090 Failure code [DDS5KA] (Steering pressure switch signal: Disconnected)............................................................................1092 Failure code [DDS5KB] (Steering pressure switch signal: Short circuit)...........................................................................1094 Failure code [DDS5L6] (Steering: Low oil pressure)...............................................................................................1096 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)......................................................................1098 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)....................................................1100 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...................................................................1102 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................................................................1104 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...........................................................1106 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)............................................................................1108 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...........................................................................1112 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)........................................................................1114 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).......................................................................1116 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)..............................................................1118 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)..........................................................................1120 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).............................................................1122 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range).......................................................1124 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...............................................................................1126 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short).....................................................................1128 307 Troubleshooting by failure code (Display of code), Part 7........................................................................................1131 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)......................................................1132 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)........................................................1134 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)..........................................................1136 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................................................................1138 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit).............................................................................1140 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...................................................................1142 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)............................................1145 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).........................................................1148 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)....................................................................1151 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).............................................1154 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).....................................................................1157 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..............................................1160 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...........................................................1163 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)......................................................................1166 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...............................................1169 308 Troubleshooting by failure code (Display of code), Part 8........................................................................................1173 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)..........................................................1175 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...................................1178 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...........................................................1180 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1183 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)................................................1185 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).....................................................................................1188 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..............................................................1190 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)....................................................................................1192 Failure code [DLF1KA] (Transmission input speed sensor: Disconnection)...........................................................................1194 Failure code [DLF1LC] (Transmission input speed sensor: Short circuit)...........................................................................1195 Failure code [DLM3KA] (Fan speed sensor: Disconnection)..........................................................................................1196 Failure code [DLM3LC] (Fan speed sensor: Short circuit)..........................................................................................1198 Failure code [DLT3KA] (Transmission output speed sensor: Disconnection)..........................................................................1200 Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range)..............................................................1202 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).......................................................................1204 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)................................................................1206 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)................................................................1208 Failure code [DV00KB] (Alarm buzzer: Short circuit)..............................................................................................1210 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...............................................................................1212 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...............................................................................1214 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)........................................................1216 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...............................................................................1218 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...............................................................................1219 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)........................................................1220 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..................................................................................1222 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..................................................................................1223 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...........................................................1224 309 Troubleshooting by failure code (Display of code), Part 9........................................................................................1227 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..................................................................................1229 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..................................................................................1230 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...........................................................1232 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)......................................................................................1234 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)......................................................................................1235 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...............................................................1236 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)......................................................................1238 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)......................................................................1240 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...............................................1242 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).....................................................................1244 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).....................................................................1246 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..............................................1248 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).....................................................................1250 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).....................................................................1252 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..............................................1254 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)........................................................................1256 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)........................................................................1258 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)........................................................1260 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).....................................................................................1262 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).....................................................................................1263 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..............................................................1264 Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection)...............................................................................1266 Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)...............................................................................1268 Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection).............................................................................1270 Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit).............................................................................1272 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)......................................................................................1274 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)......................................................................................1276 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...............................................................1278 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..................................................................................1280 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................................................1282 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...........................................................1284 310 Troubleshooting by failure code (Display of code), Part 10.......................................................................................1287 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..................................................................................1290 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..................................................................................1292 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1294 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..................................................................................1296 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..................................................................................1298 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1300 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....................................................................................1302 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....................................................................................1304 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).............................................................1306 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....................................................................................1308 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....................................................................................1310 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).............................................................1312 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..................................................................................1314 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..................................................................................1316 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...........................................................1318 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)......................................................................1320 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)......................................................................1322 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...............................................1324 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection).......................................................................1326 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit).......................................................................1328 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)................................................1330 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine).................................................1332 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)..................................................1335 Failure code [DY30ME] Emergency steering: Operating for more than 1 minute.......................................................................1338 400 Troubleshooting of electrical system (E-mode)....................................................................................................1343 Installing positions of fuses....................................................................................................................1345 Information in troubleshooting table.............................................................................................................1348 E-1 Engine does not start........................................................................................................................1350 E-2 Wiper does not operate.......................................................................................................................1356 E-3 Windshield washer does not operate...........................................................................................................1360 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..............................................................1363 E-5 Working lamp does not light up or go off.....................................................................................................1371 E-6 Turn signal lamp and hazard lamp do not light up or go off...................................................................................1376 E-7 Brake lamp does not light or it keeps lighting up............................................................................................1382 E-8 Backup lamp does not light or it keeps lighting up...........................................................................................1384 E-9 Backup buzzer does not sound or it keeps sounding............................................................................................1386 E-10 Horn does not sound or it keeps sounding....................................................................................................1388 E-11 Alarm buzzer does not sound or it keeps sounding............................................................................................1390 E-12 Air conditioner does not operate or stop....................................................................................................1392 E-13 The KOMTRAX system does not work properly...................................................................................................1396 E-14 When kick-down switch is turned ON, kick-down operation does not start......................................................................1398 E-15 When hold switch is pressed, holding operation does not start...............................................................................1400 E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...........................1402 E-17 Transmission cut-off mode cannot be set or reset............................................................................................1404 E-18 Transmission cut-off set cannot be reset....................................................................................................1406 E-19 FNR switch mode cannot be set or reset......................................................................................................1408 E-20 Fan reverse function cannot be used or reset................................................................................................1410 E-21 Discharge from loader pump does not rise from minimum level.................................................................................1412 E-22 ECSS function cannot be used or reset.......................................................................................................1414 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up.............................................................1416 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate.............................................................1420 E-25 Air cleaner clogging indicator lamp does not light up.......................................................................................1422 E-26 Radiator coolant level caution lamp does not light up.......................................................................................1424 E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up..................................1425 E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up....................1426 E-29 Steering oil pressure caution lamp does not light up........................................................................................1428 E-30 Abnormality in ■ switch (panel switch 1) input..............................................................................................1430 E-31 Abnormality in ◇ switch (panel switch 1) input..............................................................................................1432 E-32 Abnormality in < switch (panel switch 2) input..............................................................................................1434 E-33 Abnormality in > switch (panel switch 2) input..............................................................................................1436 500 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1439 Method of using troubleshooting chart............................................................................................................1441 Table of failure and causes......................................................................................................................1444 H-1 The machine does not start...................................................................................................................1448 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)].......................................1450 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]........................................................1451 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted.......................1452 H-5 Shocks are large at the times of starting and shifting gear..................................................................................1454 H-6 Time lag is large at the times of starting and shifting gear.................................................................................1456 H-7 The torque converter oil temperature is high.................................................................................................1458 H-8 Steering does not turn.......................................................................................................................1459 H-9 Steering does not turn [Machine with joystick steering (if equipped)]........................................................................1460 H-10 Steering response is poor...................................................................................................................1461 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]........................................................1462 H-12 Steering is heavy...........................................................................................................................1463 H-13 When machine turns, it shakes or makes large shocks.........................................................................................1464 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]..........................................1465 H-15 The wheel brake does not work or does not work well.........................................................................................1466 H-16 The wheel brake is not released or it drags.................................................................................................1467 H-17 The parking brake does not work or does not work well.......................................................................................1468 H-18 The parking brake is not released or it drags (including emergency release system)..........................................................1469 H-19 Lift arm does not rise......................................................................................................................1470 H-20 Lift arm speed is low or rising force of lift arm is insufficient...........................................................................1471 H-21 When rising, the lift arm comes to move slowly at specific height...........................................................................1472 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...........................................................................1472 H-23 Hydraulic drifts of the lift arm is large...................................................................................................1472 H-24 The lift arm wobbles during operation.......................................................................................................1472 H-25 Bucket does not tilt back...................................................................................................................1473 H-26 Bucket speed is low or tilting back force is insufficient...................................................................................1474 H-27 The bucket comes to operate slowly in the midst of tilting-back.............................................................................1475 H-28 The bucket cylinder cannot hold down the bucket.............................................................................................1475 H-29 Hydraulic drifts of the bucket is large.....................................................................................................1475 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).....................................................1475 H-31 Lift arm and bucket control levers do not move smoothly and are heavy.......................................................................1476 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls............................................................1477 H-33 Large shock is made when work equipment starts and stops....................................................................................1477 H-34 When work equipment circuit is relieved singly, other work equipment moves..................................................................1477 H-35 ECSS does not operate, and pitching, bouncing occur.........................................................................................1478 600 Troubleshooting of engine (S-mode)...............................................................................................................1481 Method of using troubleshooting chart............................................................................................................1483 S-1 Starting performance is poor.................................................................................................................1486 S-2 Engine does not start........................................................................................................................1488 S-3 Engine does not pick up smoothly.............................................................................................................1492 S-4 Engine stops during operation................................................................................................................1493 S-5 Engine does not rotate smoothly..............................................................................................................1494 S-6 Engine lacks output (or lacks power).........................................................................................................1495 S-7 Exhaust smoke is black (Incomplete combustion)...............................................................................................1496 S-8 Oil is consumed much (or exhaust gas color is blue)..........................................................................................1497 S-9 Engine oil becomes contaminated quickly......................................................................................................1498 S-10 Fuel consumption is excessive...............................................................................................................1499 S-11 Coolant contains oil (blows back or reduces)................................................................................................1500 S-12 Oil pressure drops..........................................................................................................................1501 S-13 Oil level rises (Water, fuel in oil)........................................................................................................1502 S-14 Coolant temperature rises too high (Overheating)............................................................................................1504 S-15 Abnormal noise is made......................................................................................................................1505 S-16 Vibration is excessive......................................................................................................................1506 50 Disassembly and assembly.............................................................................................................................. 0 100 General information on disassembly and assembly..................................................................................................1509 How to read this manual..........................................................................................................................1510 Coating materials list...........................................................................................................................1512 Special tools list...............................................................................................................................1515 Sketches of special tools........................................................................................................................1520 200 Engine and cooling system........................................................................................................................1543 Removal and installation of engine assembly......................................................................................................1544 Removal and installation of engine hood assembly.................................................................................................1548 Removal and installation of radiator assembly....................................................................................................1551 Removal and installation of aftercooler assembly.................................................................................................1554 Removal and installation of oil cooler assembly..................................................................................................1556 Removal and installation of cooling fan and drive motor assembly.................................................................................1558 Removal and installation of fuel supply pump assembly............................................................................................1562 Removal and installation of fuel injector assembly...............................................................................................1568 Removal and installation of cylinder head assembly...............................................................................................1574 Removal and installation of engine front oil seal................................................................................................1582 Removal and Installation of engine rear oil seal.................................................................................................1585 Removal and installation of fuel tank assembly...................................................................................................1590 301 Power train, Part 1..............................................................................................................................1595 Removal and installation of torque converter and transmission assembly...........................................................................1596 Disassembly and assembly of torque converter and transmission assembly...........................................................................1601 Disassembly and assembly of torque converter assembly (Standard specification)...................................................................1634 Disassembly and assembly of torque converter assembly (Lockup specification).....................................................................1639 Disassembly and assembly of clutch pack assembly.................................................................................................1647 302 Power train, Part 2..............................................................................................................................1675 Removal and installation of front axle assembly..................................................................................................1676 Removal and installation of rear axle assembly...................................................................................................1678 Disassembly and assembly of axle housing assembly................................................................................................1684 Disassembly and assembly of differential assembly................................................................................................1693 400 Brake system.....................................................................................................................................1713 Removal and installation of parking brake disc and plate.........................................................................................1714 500 Undercarriage and frame..........................................................................................................................1719 Removal and installation of center hinge pin.....................................................................................................1720 Removal and installation of counterweight........................................................................................................1728 600 Hydraulic system.................................................................................................................................1731 Removal and installation of steering demand valve assembly.......................................................................................1732 Removal and installation of work equipment valve assembly........................................................................................1735 Removal and installation of brake charge valve assembly..........................................................................................1738 Removal and installation of hydraulic tank assembly..............................................................................................1739 Removal and installation of steering and power train pump assembly...............................................................................1741 Removal and installation of work equipment and cooling fan pump assembly.........................................................................1742 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................1744 700 Work equipment...................................................................................................................................1753 Removal and installation of work equipment assembly..............................................................................................1754 800 Cab and its attachments..........................................................................................................................1759 Removal and installation of operator's cab and floor frame assembly..............................................................................1760 Removal and installation of operator's cab glass (stuck glass)...................................................................................1764 Disassembly and assembly of operator's seat assembly.............................................................................................1772 Removal and installation of air conditioner unit assembly........................................................................................1814 900 Electrical system................................................................................................................................1819 Removal and installation of engine controller assembly...........................................................................................1820 Removal and installation of transmission controller assembly.....................................................................................1821 Removal and installation of KOMTRAX terminal assembly............................................................................................1822 80 Appendix..............................................................................................................................................1825 100 Air conditioner..................................................................................................................................1825 Precautions for refrigerant......................................................................................................................1827 Troubleshooting procedure........................................................................................................................1828 Circuit diagram and arrangement of connector pins................................................................................................1830 System diagram...................................................................................................................................1835 Detail of air conditioner unit...................................................................................................................1837 Parts and connectors layout......................................................................................................................1839 Testing with self-diagnosis function (indication on control panel)...............................................................................1843 Testing temperature control......................................................................................................................1846 Testing vent (mode) changeover...................................................................................................................1847 Testing Fresh/Recirc changeover..................................................................................................................1849 Testing inside air temp. sensor and outside air temp. sensor.....................................................................................1851 Testing evaporator temperature sensor............................................................................................................1853 Testing sunlight sensor..........................................................................................................................1854 Testing relays...................................................................................................................................1855 Troubleshooting chart 1..........................................................................................................................1856 Troubleshooting chart 2..........................................................................................................................1857 Information in troubleshooting table.............................................................................................................1860 Troubleshooting for power supply system (Air conditioner does not operate).......................................................................1861 Troubleshooting for compressor and refrigerant system (Air is not cooled)........................................................................1864 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)...............................................................1867 Troubleshooting for temperature control..........................................................................................................1873 Troubleshooting for vent (mode) changeover.......................................................................................................1876 Troubleshooting for Fresh/Recirc air changeover..................................................................................................1879 Troubleshooting with gauge pressure..............................................................................................................1881 Connection of service tool.......................................................................................................................1883 Handling of compressor oil.......................................................................................................................1884 90 Diagrams and drawings................................................................................................................................. 0 100 Hydraulic diagrams and drawings..................................................................................................................1887 Power train hydraulic circuit diagram............................................................................................................1888 Automatic greasing circuit diagram...............................................................................................................1890 Hydraulic circuit diagram........................................................................................................................1893 200 Electrical diagrams and drawings.................................................................................................................1896 Electrical circuit diagram (1/10)................................................................................................................1898 Electrical circuit diagram (2/10)................................................................................................................1899 Electrical circuit diagram (3/10)................................................................................................................1900 Electrical circuit diagram (4/10)................................................................................................................1901 Electrical circuit diagram (5/10)................................................................................................................1902 Electrical circuit diagram (6/10)................................................................................................................1903 Electrical circuit diagram (7/10)................................................................................................................1904 Electrical circuit diagram (8/10)................................................................................................................1905 Electrical circuit diagram (9/10)................................................................................................................1906 Electrical circuit diagram (10/10)...............................................................................................................1907 Work equipment controller system electrical circuit diagram......................................................................................1908 Connector list and stereogram....................................................................................................................1909
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