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KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBERS: 55001 and up
- PUBLICATION NUMBER:SEN00236-17
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Description
KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR MANUAL
KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR 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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
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 instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by 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.
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 reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR MANUAL
COVER .................................................................................................................................................... 1 00 Index and foreword..................................................................................................................................... 0 Index................................................................................................................................................. 3 Composition of shop manual........................................................................................................................ 4 Table of contents................................................................................................................................. 6 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 Specification and technical data...................................................................................................................... 63 Specification and technical data.................................................................................................................. 64 Specification dimension drawing............................................................................................................... 64 Specifications................................................................................................................................ 65 Weight table.................................................................................................................................. 68 Table of fuel, coolant and lubricants......................................................................................................... 70 10 Structure, function and maintenance standard........................................................................................................... 0 Engine and cooling system............................................................................................................................. 73 Engine and cooling system......................................................................................................................... 74 Cooling system................................................................................................................................ 74 Engine mount and transmission mount........................................................................................................... 77 Joint......................................................................................................................................... 78 Cooling fan pump.............................................................................................................................. 80 Cooling fan motor............................................................................................................................. 87 Power train, Part 1................................................................................................................................... 95 Power train, Part 1............................................................................................................................... 96 Power train................................................................................................................................... 96 Power train system diagram.................................................................................................................... 97 Drive shaft................................................................................................................................... 99 Power train piping diagram.................................................................................................................... 102 Torque converter.............................................................................................................................. 104 Torque converter regulator valve.............................................................................................................. 122 Transmission.................................................................................................................................. 124 Transfer...................................................................................................................................... 144 Transmission control valve.................................................................................................................... 146 ECMV.......................................................................................................................................... 152 Main relief valve and torque converter relief valve........................................................................................... 159 Lubrication relief valve...................................................................................................................... 161 Power train, Part 2................................................................................................................................... 163 Power train, Part 2............................................................................................................................... 164 Torque converter oil cooler................................................................................................................... 164 Torque converter oil filter................................................................................................................... 165 Center support................................................................................................................................ 168 Axle.......................................................................................................................................... 170 Differential.................................................................................................................................. 172 Limited slip differential..................................................................................................................... 181 Final drive................................................................................................................................... 186 Steering system....................................................................................................................................... 191 Steering system................................................................................................................................... 192 Steering piping diagram....................................................................................................................... 192 Steering column............................................................................................................................... 193 Steering control valve........................................................................................................................ 194 Steering valve................................................................................................................................ 205 Stop valve.................................................................................................................................... 209 Joystick steering lever linkage (if equipped)................................................................................................. 210 Steering cylinder............................................................................................................................. 211 Emergency steering piping diagram (if equipped)............................................................................................... 214 Diverter valve................................................................................................................................ 215 Brake system.......................................................................................................................................... 221 Brake system...................................................................................................................................... 222 Brake piping diagram.......................................................................................................................... 222 Brake valve................................................................................................................................... 224 Slack adjuster................................................................................................................................ 229 Accumulator charge valve...................................................................................................................... 232 PPC relief valve.............................................................................................................................. 236 Accumulator (for brake)....................................................................................................................... 238 Brake......................................................................................................................................... 240 Parking brake control......................................................................................................................... 243 Parking brake................................................................................................................................. 244 Parking brake solenoid valve.................................................................................................................. 246 Emergency parking brake release valve......................................................................................................... 248 Undercarriage and frame............................................................................................................................... 251 Undercarriage and frame........................................................................................................................... 252 Axle mount.................................................................................................................................... 252 Center hinge pin.............................................................................................................................. 257 Hydraulic system, Part 1.............................................................................................................................. 261 Hydraulic system, Part 1.......................................................................................................................... 262 Hydraulic piping diagram...................................................................................................................... 262 Work equipment control lever linkage.......................................................................................................... 264 Hydraulic tank................................................................................................................................ 265 Steering pump................................................................................................................................. 267 Work equipment hydraulic pump................................................................................................................. 278 Hydraulic system, Part 2.............................................................................................................................. 299 Hydraulic system, Part 2.......................................................................................................................... 300 Control valve................................................................................................................................. 300 CLSS.......................................................................................................................................... 314 Each function and operation of each valve..................................................................................................... 319 Accumulator (for PPC circuit)................................................................................................................. 330 Work equipment electric lever................................................................................................................. 331 Work equipment........................................................................................................................................ 335 Work equipment.................................................................................................................................... 336 Work equipment linkage........................................................................................................................ 336 Bucket........................................................................................................................................ 340 Bucket positioner and boom kick-out........................................................................................................... 342 Work equipment lubrication.................................................................................................................... 343 Work equipment cylinder....................................................................................................................... 345 Cab and its attachments............................................................................................................................... 347 Cab and its attachments........................................................................................................................... 348 ROPS cab...................................................................................................................................... 348 Air conditioner............................................................................................................................... 350 Electrical system, Part 1............................................................................................................................. 359 Electrical system, Part 1......................................................................................................................... 360 Machine monitor system........................................................................................................................ 360 Machine monitor............................................................................................................................... 368 Electrical system, Part 2............................................................................................................................. 423 Electrical system, Part 2......................................................................................................................... 424 Work equipment control system................................................................................................................. 424 Transmission controller system................................................................................................................ 458 Electrical system, Part 3............................................................................................................................. 491 Electrical system, Part 3......................................................................................................................... 492 Electric transmission control................................................................................................................. 492 Engine starting circuit....................................................................................................................... 496 Engine stopping circuit....................................................................................................................... 498 Preheating circuit............................................................................................................................ 499 Parking brake circuit......................................................................................................................... 501 Backup and stop lamp circuits................................................................................................................. 506 Small lamp and head lamp circuits............................................................................................................. 508 Working lamp circuit.......................................................................................................................... 509 Horn circuit.................................................................................................................................. 510 Wiper and window washer circuits.............................................................................................................. 511 Sensor........................................................................................................................................ 514 KOMTRAX system................................................................................................................................ 532 20 Standard value table................................................................................................................................... 0 Standard service value table.......................................................................................................................... 535 Standard service value table...................................................................................................................... 536 Standard service value table for engine....................................................................................................... 536 Standard service value table for chassis...................................................................................................... 537 30 Testing and adjusting.................................................................................................................................. 0 Testing and adjusting, Part 1......................................................................................................................... 547 Testing and adjusting, Part 1..................................................................................................................... 549 Tools for testing, adjusting, and troubleshooting............................................................................................. 549 Measuring engine speed........................................................................................................................ 553 Measuring exhaust gas color................................................................................................................... 555 Measuring exhaust temperature................................................................................................................. 557 Adjusting valve clearance..................................................................................................................... 559 Testing compression pressure.................................................................................................................. 560 Measuring blow-by pressure.................................................................................................................... 562 Measuring engine oil pressure................................................................................................................. 563 Measuring intake air (boost) pressure......................................................................................................... 564 Handling fuel system equipment................................................................................................................ 566 Releasing residual pressure in fuel system.................................................................................................... 566 Testing fuel pressure......................................................................................................................... 567 Testing return rate and leakage............................................................................................................... 568 Bleeding air from fuel circuit................................................................................................................ 571 Testing leakage in fuel system................................................................................................................ 573 Handling reduced cylinder mode operation...................................................................................................... 574 Handling no injection cranking operation...................................................................................................... 574 Handling controller voltage circuit........................................................................................................... 575 Testing and adjusting alternator belt tension................................................................................................. 576 Testing and adjusting air conditioner compressor belt tension................................................................................. 577 Adjusting transmission speed sensor........................................................................................................... 578 Measuring directional lever (Steering wheel specification).................................................................................... 580 Testing and adjusting power train oil pressure................................................................................................ 581 Flushing procedure for torque converter and transmission hydraulic circuit.................................................................... 594 Method of moving machine when transmission valve is broken.................................................................................... 597 Testing and adjusting, Part 2......................................................................................................................... 601 Testing and adjusting, Part 2..................................................................................................................... 603 Testing and adjusting steering stop valve..................................................................................................... 603 Testing and adjusting steering wheel.......................................................................................................... 605 Testing steering oil pressure................................................................................................................. 607 Bleeding air from steering cylinder circuit................................................................................................... 610 Testing hydraulic drive fan................................................................................................................... 611 Bleeding air from hydraulic drive fan circuit................................................................................................. 614 Measuring brake pedal......................................................................................................................... 616 Measuring brake performance................................................................................................................... 617 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas......................................... 618 Testing and adjusting accumulator charge pressure............................................................................................. 623 Testing wheel brake oil pressure.............................................................................................................. 625 Measuring wear of wheel brake disc............................................................................................................ 627 Bleeding air from brake circuit............................................................................................................... 628 Releasing residual pressure in brake accumulator circuit...................................................................................... 630 Testing parking brake performance............................................................................................................. 631 Measuring parking brake oil pressure.......................................................................................................... 632 Testing wear of parking brake disc............................................................................................................ 635 Method of releasing parking brake manually.................................................................................................... 636 Measuring and adjusting work equipment control lever.......................................................................................... 637 Testing and adjusting work equipment PPC oil pressure......................................................................................... 638 Measuring work equipment oil pressure......................................................................................................... 640 Bleeding air from work equipment circuit...................................................................................................... 646 Releasing residual pressure in work equipment circuit......................................................................................... 647 Method of moving machine when removing operator cab (when separate cab and floor specification)............................................... 648 Testing and adjusting bucket positioner....................................................................................................... 649 Testing and adjusting lift arm position detecting lever....................................................................................... 651 Checking proximity switch operation indication lamp........................................................................................... 652 Procedure for testing diodes.................................................................................................................. 653 Preparations for work on troubleshooting of electrical system................................................................................. 654 Testing and adjusting, Part 3......................................................................................................................... 659 Testing and adjusting, Part 3..................................................................................................................... 660 How to start KOMTRAX terminal operations (if equipped)........................................................................................ 660 Indicator lamps of KOMTRAX terminal (if equipped)............................................................................................. 665 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller......... 668 Special functions of machine monitor (EMMS)................................................................................................... 670 Testing and adjusting, Part 4......................................................................................................................... 711 Testing and adjusting, Part 4..................................................................................................................... 712 Special functions of machine monitor (EMMS)................................................................................................... 712 Pm clinic inspection table.................................................................................................................... 750 40 Troubleshooting........................................................................................................................................ 0 General information on troubleshooting................................................................................................................ 755 General information on troubleshooting............................................................................................................ 756 Points to remember when troubleshooting....................................................................................................... 756 Sequence of events in troubleshooting......................................................................................................... 757 Testing before troubleshooting................................................................................................................ 758 Classification and procedures of troubleshooting.............................................................................................. 759 Connection table for connector pin numbers.................................................................................................... 762 T- branch box and T- branch adapter table..................................................................................................... 798 Troubleshooting by failure code (Display of code), Part 1............................................................................................. 803 Troubleshooting by failure code (Display of code), Part 1......................................................................................... 805 Failure codes list............................................................................................................................ 805 Before carrying out troubleshooting for electrical system..................................................................................... 816 Information contained in troubleshooting table................................................................................................ 818 Failure code [1500L0] (TORQFLOW transmission : Double meshing)................................................................................ 820 Failure code [15B0NX] (Transmission filter: Clogged).......................................................................................... 821 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)......................................................... 823 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)......................................................... 825 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)......................................................... 827 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)......................................................... 829 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)....................................................... 831 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)....................................................... 833 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)....................................................... 835 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)....................................................... 837 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)....................................................... 839 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)....................................................... 841 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)....................................................... 843 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)....................................................... 845 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................ 847 Failure code [2G42ZG] (Front accumulator: Low oil pressure)................................................................................... 849 Troubleshooting by failure code(Display of code), Part 2.............................................................................................. 852 Troubleshooting by failure code (Display of code), Part 2......................................................................................... 855 Failure code [2G43ZG] (Rear accumulator: Low oil pressure).................................................................................... 855 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................ 857 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................. 859 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)........................................................... 861 Failure code [AB00MA] (Alternator: Malfunction)............................................................................................... 863 Failure code [B@BAZG] (Low engine oil pressure)............................................................................................... 865 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................. 867 Failure code [B@BCNS] (Coolant: Overheating).................................................................................................. 869 Failure code [B@BCZK] (Coolant: Low level).................................................................................................... 871 Failure code [B@C7NS] (Brake oil: Overheating)................................................................................................ 873 Failure code [b@CENS] (Torque converter oil: Overheating)..................................................................................... 875 Failure code [B@CENS] (Torque converter oil: Overheating)..................................................................................... 877 Failure code [B@GAZK] (Battery electrolyte: Low level)........................................................................................ 879 Failure code [B@HANS] (Hydraulic oil: Overheating)............................................................................................ 881 Failure code [CA111] (Abnormality in engine controller)....................................................................................... 883 Failure code [CA115] (Engine Ne or Bkup speed sensor error)................................................................................... 886 Failure code [CA122] (Charge pressure sensor high error)...................................................................................... 887 Failure code [CA123] (Charge pressure sensor low error)....................................................................................... 889 Failure code [CA131] (Throttle sensor high error)............................................................................................. 890 Failure code [CA132] (Throttle sensor low error).............................................................................................. 892 Failure code [CA135] (Engine oil pressure sensor high error).................................................................................. 893 Failure code [CA141] (Engine oil pressure sensor low error)................................................................................... 895 Failure code [CA144] (Coolant temperature sensor high error).................................................................................. 896 Failure code [CA145] (Coolant temperature sensor low error)................................................................................... 898 Failure code [CA153] (Charge temperature sensor high error)................................................................................... 899 Failure code [CA154] (Charge temperature sensor low error).................................................................................... 901 Failure code [CA187] (Sensor power supply 2 low error)........................................................................................ 901 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................. 902 Failure code [CA222] (Atmospheric pressure sensor low error).................................................................................. 904 Failure code [CA227] (Sensor power supply 2 high error)....................................................................................... 905 Troubleshooting by failure code (Display of code), Part 3............................................................................................. 908 Troubleshooting by failure code (Display of code), Part 3......................................................................................... 910 Failure code [CA234] (Engine overspeed)....................................................................................................... 910 Failure code [CA238] (Ne speed sensor power supply error)..................................................................................... 911 Failure code [CA263] (Fuel temperature sensor high error)..................................................................................... 913 Failure code [CA265] (Fuel temperature sensor low error)...................................................................................... 915 Failure code [CA271] (PCV1 Short circuit)..................................................................................................... 917 Failure code [CA272] (PCV1 Disconnection)..................................................................................................... 919 Failure code [CA273] (PCV2 Short circuit)..................................................................................................... 921 Failure code [CA274] (PCV2 Disconnection)..................................................................................................... 923 Failure code [CA322] (Injector #1 (L/B #1) open/short error).................................................................................. 925 Failure code [CA323] (Injector #5 (L/B #5) open/short error).................................................................................. 927 Failure code [CA324] (Injector #3 (L/B #3) open/short error).................................................................................. 929 Failure code [CA325] (Injector #6 (L/B #6) open/short error).................................................................................. 931 Failure code [CA331] (Injector #2 (L/B #2) open/short error).................................................................................. 933 Failure code [CA332] (Injector #4 (L/B #4) open/short error).................................................................................. 935 Failure code [CA342] (Calibration code inconsistency)......................................................................................... 937 Failure code [CA351] (Injector drive circuit error)........................................................................................... 938 Failure code [CA352] (Sensor power supply 1 low error)........................................................................................ 941 Failure code [CA386] (Sensor power supply 1 high error)....................................................................................... 943 Failure code [CA431] (Idle validation switch error)........................................................................................... 945 Failure code [CA432] (Idle validation action error)........................................................................................... 947 Failure code [CA441] (Battery voltage low error).............................................................................................. 947 Failure code [CA442] (Battery voltage high error)............................................................................................. 948 Failure code [CA449] Common rail pressure high error 2........................................................................................ 948 Failure code [CA451] (Common rail pressure sensor high error)................................................................................. 949 Failure code [CA452] (Common rail pressure sensor low error).................................................................................. 951 Failure code [CA553] (Common rail pressure high error 1)...................................................................................... 952 Failure code [CA554] (Common rail pressure sensor in-range error)............................................................................. 953 Failure code [CA559] (Supply pump pressure very low error).................................................................................... 954 Failure code [CA689] (Engine Ne speed sensor error)........................................................................................... 957 Failure code [CA731] (Engine Bkup speed sensor phase error)................................................................................... 959 Failure code [CA757] (All continuous data lost error)......................................................................................... 959 Failure code [CA778] (Engine Bkup speed sensor error)......................................................................................... 961 Failure code [CA1228] (EGR valve servo error 1)............................................................................................... 963 Failure code [CA1625] (EGR valve servo error 2)............................................................................................... 964 Failure code [CA1626] (Bypass valve solenoid current high error).............................................................................. 965 Failure code [CA1627] (Bypass valve solenoid current low error)............................................................................... 967 Failure code [CA1628] (Bypass valve servo error 1)............................................................................................ 968 Failure code [CA1629] (Bypass valve servo error 2)............................................................................................ 969 Failure code [CA1631] (Bypass valve lift sensor high error)................................................................................... 970 Failure code [CA1632] (Bypass valve lift sensor low error).................................................................................... 972 Failure code [CA1633] (KOMNET datalink timeout error)......................................................................................... 972 Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor...................................................................... 974 Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor..................................................................... 975 Troubleshooting by failure code (Display of code), Part 4............................................................................................. 978 Troubleshooting by failure code (Display of code), Part 4......................................................................................... 980 Failure code [CA1642] (EGR inlet pressure sensor low error)................................................................................... 980 Failure code [CA1653] (EGR inlet pressure sensor high error).................................................................................. 981 Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................................. 983 Failure code [CA2186] (Throttle sensor power supply low error)................................................................................ 985 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................. 985 Failure code [CA2271] (EGR valve lift sensor high error)...................................................................................... 986 Failure code [CA2272] (EGR valve lift sensor low error)....................................................................................... 988 Failure code [CA2351] (EGR valve solenoid operation short circuit)............................................................................ 989 Failure code [CA2352] (EGR valve solenoid operation disconnect)............................................................................... 991 Failure code [CA2555] (Intake heater relay disconnection error)............................................................................... 991 Failure code [CA2556] (Intake heater relay short circuit error)............................................................................... 993 Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)..................................................................... 995 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)................................................................. 997 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)................................................................. 999 Failure code [D192KA] (ECSS solenoid: Disconnection)..........................................................................................1001 Failure code [D192KB] (ECSS solenoid: Short circuit)..........................................................................................1002 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...................................................................1003 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...................................................................1005 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...................................................................1007 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)............................................1009 Failure code [D5ZHKA] (Terminal C signal: Disconnection)......................................................................................1011 Failure code [D5ZHKB] (Terminal C signal: Short circuit)......................................................................................1013 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit).....................................................................1015 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)..............................................1019 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).......................................................................1021 Failure code [DAF3KK] (Machine monitor: Low source voltage (input))...........................................................................1023 Failure code [DAF5KP] (Machine monitor: Low output voltage)...................................................................................1025 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))..............1027 Failure code [DAQ0KK] (Transmission controller: Low source voltage)...........................................................................1029 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)....................................................................1031 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))............................................1033 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)......................................1035 Troubleshooting by failure code (Display of code), Part 6.............................................................................................1092 Troubleshooting by failure code (Display of code), Part 6.........................................................................................1094 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time).......................................1094 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)..........................................................................1096 Failure code [DDK3KA] (Right FNR switch: Disconnection).......................................................................................1098 Failure code [DDK3KB] (Right FNR switch: Short circuit).......................................................................................1100 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...........................................................................1102 Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)...........................................................................1104 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree).......................................................1106 Failure code [DDK6KA] (FNR lever switch: Disconnection).......................................................................................1108 Failure code [DDK6KB] (FNR lever switch: Short circuit).......................................................................................1111 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...................................................................1113 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time).................................................1115 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)................................................................1117 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).....................................................................1119 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)........................................................1121 Failure code [DF10KA] (Transmission shift lever switch: Disconnection)........................................................................1123 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)........................................................................1126 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)....................................................................1128 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)....................................................................1130 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...........................................................1132 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)......................................................................1134 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)..........................................................1136 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)....................................................1138 Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)................................................................1140 Troubleshooting by failure code (Display of code), Part 5.............................................................................................1038 Troubleshooting by failure code (Display of code), Part 5.........................................................................................1041 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))......1041 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...................................................................1043 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system).............1045 Failure code [DB90KK] Work equipment controller: Low source voltage (input)...................................................................1047 Failure code [DB90KT] (Work equipment controller: Abnormality in controller)..................................................................1049 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)............................................1051 Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range)..............................................1053 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)....................................1055 Failure code [DB9RKR] (CAN communication with work equipment controller: Defective communication (Abnormality in target component system))....1057 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction).................................................................1059 Failure code [DB9RMC] (CAN communication with work equipment controller: Defective operation).................................................1061 Failure code [DD15LD] ( ■ switch (Panel switch 1): Switch is kept pressed for long time)......................................................1063 Failure code [DD16LD] (◇ switch (Panel switch 2): Switch is kept pressed for long time).......................................................1065 Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time).......................................................1067 Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time).......................................................1069 Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time)................................1071 Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time)................................1073 Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time)......................................................1075 Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time)...........................................1077 Failure code [DD1GLD] (Load meter mode selector switch (+/–): Switch is kept pressed for long time)...........................................1079 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)..............................................1081 Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree)........................................................................1083 Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit).........................................................1085 Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit).......................................................1087 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...........................................................1089 Troubleshooting by failure code (Display of code), Part 7.............................................................................................1143 Troubleshooting by failure code (Display of code), Part 7.........................................................................................1145 Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)................................................................1145 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...................................................1147 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).....................................................1149 Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range).................................................................1151 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine).....................1153 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)................................................................1155 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line).........................................1158 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)......................................................1161 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection).................................................................1164 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)..........................................1167 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)..................................................................1170 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...........................................1173 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)........................................................1176 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)...................................................................1179 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)............................................1182 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)..............................................1185 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line).......................1187 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)....................................1189 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)...............................................1192 Troubleshooting by failure code (Display of code), Part 8.............................................................................................1195 Troubleshooting by failure code (Display of code), Part 8.........................................................................................1197 Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line).....................................1197 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection).......................................................1199 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)................................1201 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)........................................................1203 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line).................................1205 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree).............................................1207 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)..................................................................................1210 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)......................................................................1212 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...........................................................1214 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing).................................................................................1216 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)..................................................................1218 Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree).........................................................1220 Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit).................................................................1222 Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range).....................................................1224 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)....................................................................1226 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit).............................................................1228 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit).............................................................1230 Failure code [DV00KB] (Alarm buzzer: Short circuit)...........................................................................................1232 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)............................................................................1234 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)............................................................................1235 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line).....................................................1236 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)............................................................................1238 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)............................................................................1239 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line).....................................................1240 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...............................................................................1242 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...............................................................................1243 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)........................................................1245 Troubleshooting by failure code (Display of code), Part 9.............................................................................................1248 Troubleshooting by failure code (Display of code), Part 9.........................................................................................1250 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...............................................................................1250 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...............................................................................1251 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)........................................................1252 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...................................................................................1254 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...................................................................................1256 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)............................................................1258 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)...................................................................1260 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)...................................................................1260 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)............................................1261 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)...................................................................1262 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...................................................................1264 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)............................................1266 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)..................................................................1268 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)..................................................................1270 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...........................................1272 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)..................................................................1274 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)..................................................................1276 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...........................................1278 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection).....................................................................1280 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit).....................................................................1282 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source).....................................................1284 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)..................................................................................1286 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)..................................................................................1287 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...........................................................1288 Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)...................................................................................1289 Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)...................................................................................1290 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...................................................................................1291 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...................................................................................1292 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)............................................................1294 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...............................................................................1296 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...............................................................................1298 Troubleshooting by failure code (Display of code), Part 10............................................................................................1301 Troubleshooting by failure code (Display of code), Part 10........................................................................................1303 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)........................................................1303 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...............................................................................1305 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...............................................................................1307 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)........................................................1309 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...............................................................................1311 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...............................................................................1313 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)........................................................1315 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection).................................................................................1317 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit).................................................................................1319 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)..........................................................1321 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection).................................................................................1323 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit).................................................................................1325 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)..........................................................1327 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...............................................................................1329 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...............................................................................1331 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)........................................................1333 Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection).....................................................................1335 Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit).....................................................................1336 Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)..............................................1337 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection).....................................................................1338 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit).....................................................................1339 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)..............................................1340 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...................................................................1341 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)...................................................................1343 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)............................................1345 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)....................................................................1347 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)....................................................................1349 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line).............................................1351 Troubleshooting of electrical system (E-mode).........................................................................................................1354 Troubleshooting of electrical system (E-mode).....................................................................................................1356 Before carrying out troubleshooting of electrical system......................................................................................1356 Information in troubleshooting table..........................................................................................................1359 E-1 Engine does not start.....................................................................................................................1360 E-2 Wiper does not operate....................................................................................................................1365 E-3 Windshield washer does not operate........................................................................................................1369 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...........................................................1372 E-5 Working lamp does not light up or go off..................................................................................................1380 E-6 Turn signal lamp and hazard lamp do not light up or go off................................................................................1385 E-7 Brake lamp does not light or it keeps lighting up.........................................................................................1391 E-8 Backup lamp does not light or it keeps lighting up........................................................................................1393 E-9 Backup buzzer does not sound or it keeps sounding.........................................................................................1395 E-10 Horn does not sound or it keeps sounding.................................................................................................1397 E-11 Alarm buzzer does not sound or it keeps sounding.........................................................................................1400 E-12 Air conditioner does not operate or stop.................................................................................................1402 E-13 KOMTRAX system does not work properly....................................................................................................1405 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................................................1408 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................1410 Method of using troubleshooting chart.........................................................................................................1410 Table of failure modes and causes.............................................................................................................1412 H-1 Machine does not start....................................................................................................................1416 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]....................................1418 H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)].....................................................1419 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted....................................1420 H-5 Shocks are large at the times of starting and shifting gear...............................................................................1422 H-6 Time lag is large at the times of starting and shifting gear..............................................................................1424 H-7 Torque converter oil temperature is high..................................................................................................1426 H-8 Steering does not turn....................................................................................................................1427 H-9 Steering does not turn [Machine with joystick steering (if equipped)].....................................................................1428 H-10 Steering response is low.................................................................................................................1429 H-11 Turning response of steering is poor [machine with joystick steering (if equipped)]......................................................1430 H-12 Steering is heavy........................................................................................................................1431 H-13 When machine turns, it shakes or makes large shocks......................................................................................1432 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)].......................................1433 H-15 Wheel brake does not work or does not work well..........................................................................................1434 H-16 Wheel brake is not released or it drags..................................................................................................1435 H-17 Parking brake does not work or does not work well........................................................................................1436 H-18 Parking brake is not released or it drags (including emergency release system)...........................................................1437 H-19 Lift arm does not rise...................................................................................................................1438 H-20 Lift arm speed is low or rising force of lift arm is insufficient........................................................................1439 H-21 When rising, lift arm comes to move slowly at specific height............................................................................1440 H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)................................................................................1440 H-23 Hydraulic drifts of lift arm occur often.................................................................................................1440 H-24 Lift arm wobbles during operation........................................................................................................1440 H-25 Bucket does not tilt back................................................................................................................1441 H-26 Bucket speed is low or tilting back force is insufficient................................................................................1442 H-27 Bucket comes to operate slowly in the midst of tilting-back..............................................................................1443 H-28 Bucket cylinder cannot hold down the bucket..............................................................................................1443 H-29 Hydraulic drifts of bucket occur often...................................................................................................1443 H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)..........................................................1443 H-31 During operation of machine, engine speed lowers remarkably or engine stalls.............................................................1444 H-32 Large shocks are made when work equipment starts and stops...............................................................................1444 H-33 When work equipment circuit is relieved singly, other work equipment moves...............................................................1444 H-34 ECSS does not operate, and pitching and bouncing occur...................................................................................1445 Troubleshooting of engine (S-mode)....................................................................................................................1447 Troubleshooting of engine (S-mode)................................................................................................................1449 Method of using troubleshooting chart.........................................................................................................1449 S-1 Engine does not start easily..............................................................................................................1452 S-2 Engine does not start.....................................................................................................................1454 S-3 Engine does not pick up smoothly..........................................................................................................1458 S-4 Engine stops during operation.............................................................................................................1459 S-5 Engine does not rotate smoothly (Engine hunts.)...........................................................................................1460 S-6 Engine lacks output (or lacks power)......................................................................................................1461 S-7 Exhaust smoke is black (Incomplete combustion)............................................................................................1462 S-8 Oil is consumed much (or exhaust gas color is blue).......................................................................................1464 S-9 Engine oil becomes contaminated quickly...................................................................................................1465 S-10 Fuel consumption is excessive............................................................................................................1466 S-11 Coolant contains oil (blows back or reduces).............................................................................................1467 S-12 Oil pressure drops.......................................................................................................................1468 S-13 Oil level rises (Water, fuel in oil).....................................................................................................1469 S-14 Coolant temperature rises too high (Overheating).........................................................................................1471 S-15 Abnormal noise is made...................................................................................................................1472 S-16 Vibration is excessive...................................................................................................................1473 50 Disassembly and assembly............................................................................................................................... 0 General information on disassembly and assembly.......................................................................................................1475 How to read this manual...........................................................................................................................1476 Coating materials list............................................................................................................................1478 Special tool list.................................................................................................................................1481 Sketches of special tools.........................................................................................................................1485 Engine and cooling system, Part 1.....................................................................................................................1493 Removal and installation of engine assembly.......................................................................................................1494 Removal and installation of radiator assembly.....................................................................................................1499 Removal and installation of air aftercooler.......................................................................................................1501 Removal and installation of cooling fan and fan motor assembly....................................................................................1502 Removal and installation of radiator guard and cooling fan motor assembly.........................................................................1504 Removal and installation of fuel tank assembly....................................................................................................1507 Removal and installation of hood..................................................................................................................1509 Engine and cooling system, Part 2.....................................................................................................................1513 Removal and installation of fuel supply pump assembly.............................................................................................1514 Removal and installation of cylinder head assembly................................................................................................1518 Removal and installation of fuel injector assembly................................................................................................1529 Removal and installation of engine front seal.....................................................................................................1532 Removal and installation of engine rear seal......................................................................................................1536 Power train, Part 1...................................................................................................................................1543 Removal and installation of torque converter and transmission assembly............................................................................1544 Disconnection and connection of power train unit..................................................................................................1550 Disassembly and assembly of input transfer assembly...............................................................................................1554 Disassembly and assembly of torque converter assembly (Lockup specification)......................................................................1561 Disassembly and assembly of torque converter assembly (Lockup-less specification).................................................................1574 Power train, Part 2...................................................................................................................................1587 Disassembly and assembly of transmission assembly.................................................................................................1588 Disassembly and assembly of transfer and parking brake assembly...................................................................................1618 Removal and installation of front axle assembly...................................................................................................1634 Removal and installation of rear axle assembly....................................................................................................1636 Power train, Part 3...................................................................................................................................1639 Removal and installation of front differential assembly...........................................................................................1640 Disassembly and assembly of differential assembly (LSD specification).............................................................................1642 Disassembly and assembly of differential assembly (LSD-less specification)........................................................................1656 Disassembly and assembly of final drive assembly (Front and rear).................................................................................1668 Brake system..........................................................................................................................................1677 Brake system......................................................................................................................................1678 Removal and installation of brake assembly (Front and rear)...................................................................................1678 Disassembly and assembly of brake assembly (Front and rear)...................................................................................1680 Disassembly and assembly of slack adjuster assembly...........................................................................................1686 Disassembly and assembly of brake accumulator charge valve assembly...........................................................................1687 Undercarriage and frame...............................................................................................................................1689 Removal and installation of center hinge pin......................................................................................................1690 Hydraulic system......................................................................................................................................1699 Removal and installation of hydraulic tank assembly...............................................................................................1700 Removal and installation of cooling pump assembly.................................................................................................1703 Removal and installation of fan pump assembly.....................................................................................................1704 Removal and installation of work equipment pump assembly..........................................................................................1705 Removal and installation of steering, torque converter charge and EPC pump assembly...............................................................1707 Removal and installation of work equipment valve assembly.........................................................................................1708 Disassembly and assembly of work equipment control valve assembly.................................................................................1711 Disassembly and assembly of steering cylinder assembly............................................................................................1714 Disassembly and assembly of lift arm and/bucket cylinder assembly.................................................................................1718 Removal and installation of steering valve assembly...............................................................................................1724 Work equipment........................................................................................................................................1727 Removal and installation of work equipment assembly...............................................................................................1728 Removal and installation of large counterweight assembly..........................................................................................1732 Removal and installation of small counterweight assembly..........................................................................................1733 Cab and its attachments...............................................................................................................................1735 Removal and installation of operator's cab assembly (Separate cab and floor specification)........................................................1736 Removal and installation of operator's cab and floor frame assembly (Cab-floor unit specification)................................................1741 Removal and installation of operator's cab glass (Stuck glass)....................................................................................1745 Disassembly and assembly of operator’s seat assembly..............................................................................................1754 Electrical system.....................................................................................................................................1789 Removal and installation of engine controller assembly............................................................................................1790 Removal and installation of transmission controller assembly......................................................................................1791 Removal and installation of work equipment controller assembly....................................................................................1792 Removal and installation of KOMTRAX terminal assembly.............................................................................................1793 Removal and installation of air conditioner unit assembly.........................................................................................1794 90 Diagrams and drawings.................................................................................................................................. 0 Hydraulic diagrams and drawings.......................................................................................................................1799 Automatic greasing circuit diagram................................................................................................................1800 Power train hydraulic circuit diagram.............................................................................................................1803 Brake hydraulic circuit diagram...................................................................................................................1805 Work equipment hydraulic circuit diagram..........................................................................................................1807 Electrical diagrams and drawings......................................................................................................................1810 Electrical diagrams and drawings..................................................................................................................1812 Air conditioner electrical circuit diagram....................................................................................................1812 Electrical circuit diagram (1/7)..............................................................................................................1813 Electrical circuit diagram (2/7)..............................................................................................................1814 Electrical circuit diagram (3/7)..............................................................................................................1815 Electrical circuit diagram (4/7)..............................................................................................................1816 Electrical circuit diagram (5/7)..............................................................................................................1817 Electrical circuit diagram (6/7)..............................................................................................................1818 Electrical circuit diagram (7/7)..............................................................................................................1819 Connector arrangement diagram.................................................................................................................1820
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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