Komatsu WA500-6 WHEEL LOADER Service Repair Manual
Description:
Komatsu WA500-6 WHEEL LOADER Service Repair Manual
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
(00) Index and Forward Section 00 explains the safety information, basic information, Torque tables, conversion tables, Coating Materials table, electric wire code information.
(01) General Section 01 lists the general machine dimensions, performance specifications, component weights, and fuel, coolant, and lubricant specification charts.
(10) Structure, Function, and Maintenance Standard Section 10 explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgment standards when inspecting disassembled parts.
(20) Standard Value Tables Section 20 explains the standard values for a new machine and judgment 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 Section 30 explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
(40) Troubleshooting Section 40 includes the troubleshooting charts correlating Problems to Causes.
(50) Disassembly and Assembly Section 50 explains the order to be followed when removing, installing, disassembling, or assembling each component, as well as precautions to be taken for these operations.
(90) Diagrams and Schematics Section 90 has the foldout drawings for the machine.
Table of Contents:
Komatsu WA500-6 WHEEL LOADER Service Repair Manual
CEBM18104 - WA500-6 sn A920001 - A92999........................................................................... 1
CONTENTS...................................................................................................... 2
REVISED PAGES................................................................................................. 3
SAFETY........................................................................................................ 21
SAFETY NOTICE............................................................................................. 21
IMPORTANT SAFETY NOTICE............................................................................... 21
General Precautions................................................................................... 21
Preparations for Work................................................................................. 22
Precautions During Work............................................................................... 22
GENERAL....................................................................................................... 23
HOW TO READ THE SHOP MANUAL................................................................................... 24
Volumes................................................................................................... 24
Distribution and Updating................................................................................. 24
Filing Method............................................................................................. 24
Revised Edition Mark...................................................................................... 24
Revisions................................................................................................. 24
Symbols................................................................................................... 24
HOISTING INSTRUCTIONS......................................................................................... 25
Hoisting.................................................................................................. 25
Making Signs.............................................................................................. 25
Precautions............................................................................................... 25
Precautions for Sling Work............................................................................ 25
Precautions for Using Mobile Crane.................................................................... 26
Precautions for Using Overhead Hoist Crane............................................................ 26
Selecting Wire Ropes...................................................................................... 27
AIR CONDITIONER CIRCUITS...................................................................................... 28
Precautions for Handling Hoses and Tubes.................................................................. 28
Disconnecting Hoses and Tubes......................................................................... 28
Connecting Hoses and Tubes............................................................................ 28
MAINTENANCE STANDARD TERMS.................................................................................... 29
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT..................................................................... 31
Handling Electric Equipment............................................................................... 31
Handling Wiring Harnesses and Connectors.............................................................. 31
Main Failures Occurring in Wiring Harness............................................................. 31
Removing, Installing, and Drying Connectors and Wiring Harnesses...................................... 32
Handling Controller................................................................................... 36
Troubleshooting Electric Circuits..................................................................... 36
Handling Hydraulic Equipment.............................................................................. 37
Handling Connectors Used for Engines...................................................................... 39
Slide Lock Type....................................................................................... 39
Pull Lock Type........................................................................................ 40
Push Lock Type........................................................................................ 40
Turn-housing Type (Round Green Connector)............................................................. 42
PRECAUTIONS FOR OPERATIONS.................................................................................... 43
Precautions when Carrying Out Removal Work................................................................ 43
Precautions when Carrying Out Installation Work........................................................... 44
Precautions when Completing the Operation................................................................. 45
PUSH-PULL COUPLER............................................................................................. 46
Type 1.................................................................................................... 46
Disconnection......................................................................................... 46
Connection............................................................................................ 46
Type 2.................................................................................................... 47
Disconnection......................................................................................... 47
Connection............................................................................................ 47
Type 3.................................................................................................... 48
Disconnection......................................................................................... 48
Connection............................................................................................ 48
COATING MATERIALS............................................................................................. 49
STANDARD TIGHTENING TORQUE.................................................................................... 51
Standard Tightening Torques of Bolts and Nuts............................................................. 51
Tightening Torques for Split Flange Bolts................................................................. 52
Tightening Torques for O-Ring Boss Piping Joints.......................................................... 52
Tightening Torques for O-Ring Boss Plugs.................................................................. 53
Tightening Torques for Hoses (Taper Seal Type and Face Seal Type)......................................... 53
Tightening Toques for Face Seal Joints.................................................................... 54
For 102, 107, and 114 Engine Series (Bolts and Nuts).................................................. 54
For 102, 107, and 114 Engine Series (Eye Joints)...................................................... 54
For 102, 107, and 114 Engine Series (Taper Screws).................................................... 55
ELECTRIC WIRE CODE............................................................................................ 56
How to Read Electric Wire Code............................................................................ 56
CONVERSION TABLES............................................................................................. 57
Method of Using the Conversion Table...................................................................... 57
01 GENERAL........................................................................................................ 63
SPECIFICATIONS................................................................................................ 64
Dimension Drawing......................................................................................... 64
Specification Tables...................................................................................... 65
WEIGHT TABLE.................................................................................................. 68
FUEL, COOLANT, AND LUBRICANTS................................................................................. 70
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD.................................................................... 73
ENGINE AND COOLING SYSTEM..................................................................................... 79
Cooling System............................................................................................ 79
Engine and Transmission Mount............................................................................. 82
Joint..................................................................................................... 84
Cooling Fan Pump.......................................................................................... 86
Servo Valve............................................................................................... 94
Cooling Fan Motor......................................................................................... 98
Hydraulic Motor....................................................................................... 102
Suction Valve......................................................................................... 103
Reversible Valve...................................................................................... 104
Safety Valve.......................................................................................... 105
POWER TRAIN................................................................................................... 106
Drive Line Components..................................................................................... 106
Power Train System Diagram................................................................................ 107
Without Lockup Clutch................................................................................. 107
With Lockup Clutch.................................................................................... 108
Drive Shaft............................................................................................... 110
Power Train Piping Diagram................................................................................ 114
Torque Converter without Lockup Clutch.................................................................... 116
Power Transmission Route.............................................................................. 122
Oil Flow.............................................................................................. 123
Torque Converter with Lockup Clutch....................................................................... 124
Power Transmission Route: Lockup Clutch Disengaged.................................................... 131
Power Transmission Route: Lockup Clutch Engaged....................................................... 132
Oil Flow.............................................................................................. 133
Torque Converter Regulator Valve.......................................................................... 134
Transmission with Lockup Clutch........................................................................... 136
Disc Clutch........................................................................................... 150
Power Transmission Route.............................................................................. 152
Transfer.............................................................................................. 162
Transmission Control Valve (without Lockup Clutch)........................................................ 164
Transmission Control Value (with Lockup Clutch)........................................................... 168
ECMV (Electronic Control Modulation Valve)................................................................ 172
Pressure Control Valve and Fill Switch................................................................ 173
Operation of ECMV..................................................................................... 174
For Lockup Clutch..................................................................................... 177
Main Relief Valve and Torque Converter Relief Valve....................................................... 180
Outline............................................................................................... 182
Operation............................................................................................. 182
Lubrication Relief Valve.................................................................................. 184
Torque Converter Oil Cooler............................................................................... 186
Torque Converter Oil Filter............................................................................... 188
Center Support............................................................................................ 190
Axle...................................................................................................... 194
Front Axle............................................................................................ 194
Rear Axle............................................................................................. 196
Differential.............................................................................................. 198
Front Differential.................................................................................... 198
Front Differential (with Limited Slip Differential)................................................... 199
Rear Differential..................................................................................... 200
Rear Differential (with Limited Slip Differential).................................................... 201
Limited Slip Differential (if equipped)............................................................... 207
Final Drive............................................................................................... 213
STEERING SYSTEM............................................................................................... 217
Steering Piping Diagram................................................................................... 217
Steering Column........................................................................................... 218
Steering Control Valve.................................................................................... 220
Steering Relief Valve..................................................................................... 227
Safety Suction Valve...................................................................................... 229
Steering Valve............................................................................................ 231
Stop Valve................................................................................................ 236
Joystick Steering Lever Linkage (if equipped)............................................................. 237
Steering Cylinder......................................................................................... 238
Emergency Steering (if equipped).......................................................................... 239
Piping Diagram........................................................................................ 239
Diverter Valve (for emergency steering)............................................................... 240
Operation............................................................................................. 244
BRAKE SYSTEM.................................................................................................. 246
Piping Diagram............................................................................................ 246
Brake Valve............................................................................................... 248
Slack Adjuster............................................................................................ 254
Accumulator Charge Valve.................................................................................. 257
PPC Relief Valve.......................................................................................... 261
Accumulator (for Brake)................................................................................... 263
Brake..................................................................................................... 264
Parking Brake Control..................................................................................... 268
Parking Brake............................................................................................. 270
Parking Brake Solenoid Valve.............................................................................. 272
Emergency Parking Brake Release Valve..................................................................... 274
UNDERCARRIAGE AND FRAME....................................................................................... 276
Axle Mount................................................................................................ 276
Center Hinge Pin.......................................................................................... 280
HYDRAULIC SYSTEM.............................................................................................. 284
Hydraulic Piping Diagram.................................................................................. 284
Work Equipment Control Lever Linkage...................................................................... 286
Hydraulic Tank............................................................................................ 287
Steering Pump............................................................................................. 290
Pump Unit............................................................................................. 292
Servo Valve........................................................................................... 297
LS Valve.............................................................................................. 300
CO Valve.............................................................................................. 300
Work Equipment Hydraulic Pump HPV190...................................................................... 302
LS Valve.............................................................................................. 309
PC Valve.............................................................................................. 315
PC-EPC Valve.......................................................................................... 322
Control Valve............................................................................................. 326
CLSS (Closed Center Load-Sensing System).................................................................. 340
Function and Operation of Each Valve...................................................................... 346
Pressure Compensation Valve........................................................................... 346
LS Shuttle Valve...................................................................................... 352
LS Bypass Valve....................................................................................... 354
ECSS Control Valve.................................................................................... 356
Accumulator Pressure Relief Valve..................................................................... 358
Accumulator Charge Valve.............................................................................. 360
Accumulator (for PPC Circuit)............................................................................. 365
Work Equipment Electric Lever............................................................................. 366
WORK EQUIPMENT................................................................................................ 372
Work Equipment Linkage.................................................................................... 372
Bucket.................................................................................................... 376
Bucket 5.6 M3 (with Bolt-On Cutting Edge)............................................................. 376
Bucket 5.2 M3 (with Teeth and Segment Edge)........................................................... 377
Bucket Positioner and Boom Kickout........................................................................ 378
Work Equipment Lubrication................................................................................ 379
CAB AND ITS ATTACHMENTS....................................................................................... 381
ROPS Cab.................................................................................................. 381
Air Conditioner........................................................................................... 383
Air Conditioner Piping Diagram........................................................................ 383
Cooling Circuit Diagram............................................................................... 384
Air Conditioner Unit.................................................................................. 385
Condenser............................................................................................. 386
Receiver.............................................................................................. 388
Air Conditioner Panel................................................................................. 389
ELECTRICAL SYSTEM............................................................................................. 392
Machine Monitor System.................................................................................... 392
Machine Monitor Circuits.............................................................................. 394
Machine Monitor....................................................................................... 400
Machine Monitor Operation Switches.................................................................... 402
Items Displayed on Monitor............................................................................ 403
Character Display Function............................................................................ 413
Operator Mode Functions................................................................................... 414
Service Mode Functions.................................................................................... 417
Service Mode Menu..................................................................................... 418
Electrical System Failure History Display Function.................................................... 422
Mechanical System Failure History Display Function.................................................... 424
Real-Time Monitor Function............................................................................ 425
Engine Reduced-Cylinder (Cylinder Cut-out) Function................................................... 431
No Injection Cranking Function........................................................................ 432
Adjustment Function................................................................................... 433
Maintenance Monitoring Function....................................................................... 435
Operating Information Display Function................................................................ 439
Optional Device Selecting Function.................................................................... 441
Machine Serial Number Input Function.................................................................. 441
Model Selection Function.............................................................................. 441
Load Meter Function (if equipped)..................................................................... 442
Rear Side of Machine Monitor.............................................................................. 449
Connector Signal Tables............................................................................... 451
Work Equipment Control System............................................................................. 459
Work Equipment Controller............................................................................. 459
Work Equipment Controls............................................................................... 461
Remote Positioner..................................................................................... 469
Lift Arm Positioner................................................................................... 471
Semi-Automatic Digging................................................................................ 476
Pump Swash Plate Control.............................................................................. 479
Joystick Steering Control............................................................................. 482
Real-Time Monitor..................................................................................... 484
Diagnosis............................................................................................. 489
Input and Output Signals.............................................................................. 490
Transmission Controller System............................................................................ 493
Electrical Circuit Diagram............................................................................ 493
Transmission Controller Gearshifting Control.......................................................... 495
Auto-Shift Points Table............................................................................... 499
Transmission Controller Protection Function........................................................... 500
Engine Control........................................................................................ 503
Transmission Cutoff Control........................................................................... 506
ECSS Function......................................................................................... 508
Economy Lamp.......................................................................................... 510
Cooling Fan Control................................................................................... 511
Right FNR Switch Control (if equipped)................................................................ 515
Joystick Control...................................................................................... 517
Real-Time Monitor..................................................................................... 520
Diagnosis............................................................................................. 528
Input and Output Signals.............................................................................. 529
ELECTRONIC TRANSMISSION CONTROL............................................................................... 532
Combination Switch........................................................................................ 534
Engine Starting Circuit................................................................................... 536
Engine Stopping Circuit................................................................................... 538
Preheating Circuit........................................................................................ 539
Parking Brake Circuit..................................................................................... 541
Backup and Stop Lamp circuit.............................................................................. 546
Small Lamp and Head Lamp Circuits......................................................................... 548
Working Lamp Circuit...................................................................................... 549
Horn Circuit.............................................................................................. 550
Wiper and Window Washer Circuits.......................................................................... 551
Sensors and Switches...................................................................................... 554
Input Shaft Speed Sensor.............................................................................. 554
Output Shaft Speed Sensor............................................................................. 554
Left Brake Pressure Sensor............................................................................ 555
Transmission Oil Temperature Sensor................................................................... 556
Torque Converter Oil Temperature Sensor............................................................... 556
Hydraulic Oil Temperature Sensor...................................................................... 556
Axle Oil Temperature Sensor........................................................................... 556
Kickdown Hold Switch.................................................................................. 557
Joystick Knob (if equipped)........................................................................... 558
Right FNR Switch (if equipped)........................................................................ 559
Lift Arm Angle Sensor (if equipped)................................................................... 560
Loader Pump Pressure Sensor........................................................................... 561
Lift Arm Cylinder Bottom Pressure Sensor.............................................................. 561
Lift Arm Cylinder Head Pressure Sensor (Load Meter) (if equipped)..................................... 561
Fuel Level Sensor..................................................................................... 563
Parking Brake Pressure Switch......................................................................... 564
Stop Lamp Pressure Switch............................................................................. 564
Air Cleaner Clogging Sensor........................................................................... 565
Transmission Clogging Sensor.......................................................................... 566
Steering Oil Pressure Sensor Switch................................................................... 567
Radiator Coolant Level Sensor......................................................................... 568
Brake Accumulator Pressure Switch (front and rear).................................................... 569
Battery Electrolyte Level Sensor...................................................................... 570
Accelerator Pedal Sensor.............................................................................. 571
Emergency Brake Pressure Switch (front)............................................................... 572
Emergency Brake Pressure Switch (rear)................................................................ 572
KOMTRAX Terminal System................................................................................... 573
KOMTRAX Terminal...................................................................................... 574
20 STANDARD VALUE TABLES.......................................................................................... 577
STANDARD VALUE TABLES......................................................................................... 579
Standard Service Value Table for Engine................................................................... 579
Standard Service Value Table for Chassis.................................................................. 580
MACHINE POSTURE............................................................................................... 587
30 TESTING AND ADJUSTING.......................................................................................... 589
TOOLS......................................................................................................... 593
Tools for Testing, Adjusting, and Troubleshooting......................................................... 593
ENGINE COMPONENTS............................................................................................. 597
Measuring Engine Speed.................................................................................... 597
Measuring Exhaust Gas Color............................................................................... 600
Using Handy Smoke Checker (A1)........................................................................ 600
Using Smoke Meter (A2)................................................................................ 600
Measuring Exhaust Temperature............................................................................. 602
Adjusting Valve Clearance................................................................................. 604
Testing Compression Pressure.............................................................................. 606
Measuring Blow-By Pressure................................................................................ 609
Measuring Engine Oil Pressure............................................................................. 611
Measuring Intake Air (Boost) Pressure..................................................................... 612
FUEL SYSTEM................................................................................................... 614
Handling Fuel System Equipment............................................................................ 614
Releasing Residual Pressure in Fuel System................................................................ 614
Testing Fuel Pressure..................................................................................... 615
Testing Fuel Return Rate and Leakage...................................................................... 616
Bleeding Air from Fuel Circuit............................................................................ 620
Testing Leakage in Fuel System............................................................................ 622
Handling Reduced-Cylinder Mode Operation.................................................................. 623
Handling No-Injection Cranking Operation.................................................................. 623
Handling Controller Voltage Circuit....................................................................... 623
BELTS......................................................................................................... 624
Alternator Belt Tension................................................................................... 624
Air Conditioner Compressor Belt Tension................................................................... 625
TRANSMISSION SPEED SENSOR..................................................................................... 626
DIRECTIONAL LEVER............................................................................................. 628
POWER TRAIN OIL PRESSURES..................................................................................... 629
Measuring................................................................................................. 631
Transmission Main Relief Pressure..................................................................... 631
Torque Converter Relief Pressure...................................................................... 632
Torque Converter Outlet Pressure...................................................................... 633
Lockup Clutch Pressure................................................................................ 634
F (Forward) Clutch Pressure........................................................................... 635
R (Reverse) Clutch Pressure........................................................................... 636
1st Clutch Pressure................................................................................... 637
2nd Clutch Pressure................................................................................... 638
3rd Clutch Pressure................................................................................... 639
4th Clutch Pressure................................................................................... 640
Lubrication Pressure.................................................................................. 641
Adjusting................................................................................................. 642
Transmission Main Relief Valve........................................................................ 642
Torque Converter Relief Valve......................................................................... 642
FLUSHING TRANSMISSION SYSTEM.................................................................................. 643
Torque Converter and Transmission Hydraulic Circuit....................................................... 643
WHEN TRANSMISSION VALVE FAILS................................................................................. 646
Moving Machine when Transmission Valve is Broken.......................................................... 646
STEERING SYSTEM............................................................................................... 648
Steering Stop Valve....................................................................................... 648
Testing............................................................................................... 648
Adjusting............................................................................................. 649
Steering Wheel............................................................................................ 650
Measuring Play........................................................................................ 650
Measuring Operating Effort............................................................................ 651
Measuring Operating Time.............................................................................. 652
Steering Oil Pressure..................................................................................... 653
Measuring Steering Relief Pressure.................................................................... 653
Measuring Pilot Circuit Pressure...................................................................... 655
Measuring LS Circuit Pressure......................................................................... 656
Adjusting Steering Relief Pressure.................................................................... 657
Bleeding Air From Steering Cylinder Circuit............................................................... 658
HYDRAULIC FAN................................................................................................. 659
Measuring Fan Speed....................................................................................... 659
Measuring Fan Drive Oil Pressure.......................................................................... 660
Measuring Fan Reverse Solenoid Output Pressure............................................................ 661
Bleeding Air from Hydraulic Drive Fan Circuit............................................................. 662
BRAKE SYSTEM.................................................................................................. 664
Measuring Brake Pedal..................................................................................... 664
Measuring Brake Performance............................................................................... 665
Accumulator Charge Pressure............................................................................... 666
Testing Wheel Brake Oil Pressure.......................................................................... 669
Measuring Wear of Brake Disc.............................................................................. 671
Bleeding Air from Brake Circuit........................................................................... 673
Bleeding Air from Slack Adjuster...................................................................... 673
Bleeding Air from Brake Cylinder...................................................................... 674
Releasing Residual Pressure in Brake Accumulator Circuit.................................................. 675
Parking Brake............................................................................................. 676
Testing Parking Brake Performance..................................................................... 676
Measuring Parking Brake Oil Pressure.................................................................. 677
Testing Wear of Parking Brake Disc.................................................................... 681
Releasing Parking Brake Manually...................................................................... 682
WORK EQUIPMENT................................................................................................ 683
Control Lever............................................................................................. 683
Measuring Operating Effort............................................................................ 683
Measuring Stroke...................................................................................... 683
PPC Oil Pressure.......................................................................................... 684
Shutoff Valve Basic Pressure.......................................................................... 684
Shutoff Valve Output Pressure......................................................................... 686
Oil Pressure.............................................................................................. 687
Preparation Work...................................................................................... 687
Measuring Work Equipment Relief Pressure.............................................................. 687
Measuring Unload Pressure............................................................................. 688
Measuring LS Differential Pressure.................................................................... 689
Adjusting Unload Valve................................................................................ 692
Adjusting Work Equipment Relief Pressure.............................................................. 692
Adjusting LS Differential Pressure.................................................................... 693
Bleeding Air from Work Equipment Circuit.................................................................. 694
From Work Equipment Pump (piston pump)................................................................ 694
From Hydraulic Cylinder............................................................................... 694
Releasing Residual Pressure in Hydraulic Circuit.......................................................... 695
Between Respective Hydraulic Cylinders and Control Valve.............................................. 695
From ECSS (Travel Damper) Circuit..................................................................... 695
Moving Machine When Removing Operator Cab................................................................. 696
Bucket Positioner......................................................................................... 697
Testing and Adjusting................................................................................. 697
Adjusting Clearance................................................................................... 697
Adjusting Bucket-Levelness Detecting Proximity Switch................................................. 698
Adjusting Maximum Tilt-Detecting Proximity Switch..................................................... 699
Position-Detecting Lever.................................................................................. 700
Checking Proximity Switch Operation Pilot Lamp............................................................ 701
ELECTRICAL SYSTEM............................................................................................. 702
Troubleshooting........................................................................................... 702
Procedure for Testing Diodes.......................................................................... 702
Using Digital-Type Circuit Tester..................................................................... 702
Using Analog-Type Circuit Tester...................................................................... 703
Preparation Work for Troubleshooting Electrical System.................................................... 704
Machine Monitor....................................................................................... 704
Transmission Controller............................................................................... 705
Work Equipment Controller............................................................................. 706
KOMTRAX Terminal...................................................................................... 706
KOMTRAX TERMINAL SYSTEM....................................................................................... 707
Starting KOMTRAX Terminal Operations...................................................................... 707
Station Opening Check in Machine Side................................................................. 707
Application for the Start of Use...................................................................... 711
KOMTRAX Terminal Indicator Lamps (if equipped)........................................................ 712
MACHINE MONITOR SYSTEM........................................................................................ 715
Adjusting Replaced, Reassembled, or Added Sensor, Controller.............................................. 715
Adjustment for User’s Needs........................................................................... 716
Normal and Special Functions of Machine Monitor........................................................... 717
Normal Functions: Operator Mode....................................................................... 717
Special Functions: Service Mode....................................................................... 717
Functions and Flow of Service Mode........................................................................ 718
Operator Mode............................................................................................. 721
Service Meter/Clock Display Function (1).............................................................. 721
Load Meter Function (if equipped) (2)................................................................. 721
Odometer Display Function (3)......................................................................... 721
Maintenance Monitoring Function (4)................................................................... 722
Telephone Number Input Function (5)................................................................... 722
Language Selection Function (6)....................................................................... 722
Monitor Brightness Adjustment Function (7)............................................................ 722
Time Adjustment Function (8).......................................................................... 723
Travel Speed/Engine Speed Display Selecting Function (9).............................................. 723
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)................................. 723
Action Code Display Function (11)..................................................................... 724
Failure Code Display Function (12).................................................................... 724
Service Mode.............................................................................................. 726
Switching to Service Mode and Screen Display (1)...................................................... 726
Electrical System Failure History Display Function (ELECTRIC FAULT) (2)............................... 728
Mechanical System Failure History Display Function (MACHINE FAULT) (3)................................ 730
Real-Time Monitoring Function (REAL-TIME MONITOR) (4)................................................. 731
Real-Time Monitoring Codes Tables..................................................................... 734
Cylinder Cutout Function (CYLINDER CUT-OUT) (5)....................................................... 759
No-Injection Cranking Function (NO INJECTION) (6)..................................................... 760
Adjustment Function (TUNING) (7)...................................................................... 761
Maintenance Monitoring Function (MAINTENANCE MONITOR) (8)............................................. 792
Operating Information Display Function (OPERATION INFO) (9)........................................... 797
Optional Device Selecting Function (OPTIONAL SELECT) (10)............................................. 800
Machine Serial Number Input Function (MACHINE No. SET) (11)........................................... 804
Model Selection Function (MACHINE WA500) (12)......................................................... 805
Initialize Function (INITIALIZE) (13)................................................................. 806
Appendix.............................................................................................. 806
PM CLINIC INSPECTION TABLES................................................................................... 807
40 TROUBLESHOOTING................................................................................................ 811
TROUBLESHOOTING POINTS........................................................................................ 827
TROUBLESHOOTING EVENTS........................................................................................ 829
MAINTENANCE PRECAUTIONS....................................................................................... 830
Precautions when Handling Electrical Equipment............................................................ 830
Handling Electronic Control Unit.......................................................................... 835
Points to Remember when Troubleshooting Electrical Circuits............................................... 836
ELECTRIC WIRE CODE............................................................................................ 837
How to Read Electric Wire Code............................................................................ 837
Type, Symbol, and Material............................................................................ 837
Dimensions............................................................................................ 838
Color Codes Table..................................................................................... 839
Circuits and Color Codes.............................................................................. 840
Classification by Thickness........................................................................... 840
HANDLING HYDRAULIC EQUIPMENT.................................................................................. 841
CHECKS BEFORE TROUBLESHOOTING................................................................................. 843
Categories and Method of Using Troubleshooting Charts..................................................... 844
Troubleshooting Individual Electrical Circuits............................................................ 845
Chart Use............................................................................................. 847
Chart Tips............................................................................................ 847
Troubleshooting Individual Hydraulic Circuits............................................................. 848
CONNECTOR PIN NUMBERS......................................................................................... 850
Connection Tables for Connector PIN Numbers............................................................... 850
X-Type Connectors..................................................................................... 850
SWP-Type Connectors................................................................................... 852
M-Type Connectors..................................................................................... 854
S-Type Connectors..................................................................................... 856
MIC-Type Connectors................................................................................... 858
AMP040-Type Connectors................................................................................ 860
AMP070-Type Connectors................................................................................ 862
AMP Connector......................................................................................... 864
L-Type Connector...................................................................................... 864
PA-Type Connector..................................................................................... 865
Bendix (MS) Connector................................................................................. 865
KES1 (Automobile) Connectors.......................................................................... 866
F-Type Connector...................................................................................... 867
Connectors for Relay (Socket-Type).................................................................... 868
HD30 Series Connectors................................................................................ 869
DT Series Connectors.................................................................................. 874
DTM Series Connectors................................................................................. 876
DTHD Series Connectors................................................................................ 876
DTP Series Connectors................................................................................. 877
DRC26 Series Connectors............................................................................... 878
DRC12, 16 Series Connectors........................................................................... 880
AMP Connectors for Pump Controller (CH700)............................................................ 881
BOSCH Connectors for Engine........................................................................... 882
SUMITOMO Connectors for Engine........................................................................ 883
CANNON Connector for Engine........................................................................... 884
AMP Connectors for Engine............................................................................. 885
FRAMATOME Connectors for Engine....................................................................... 886
PACKARD Connectors for Engine......................................................................... 888
DT Series Connectors for Engine....................................................................... 889
T-BRANCH BOX and T-BRANCH ADAPTER TABLE....................................................................... 890
MODE CHART.................................................................................................... 895
INFORMATION IN TESTING PROCEDURES............................................................................. 898
TROUBLESHOOTING BY FAILURE CODE............................................................................... 900
Failure Code Table........................................................................................ 900
FUSE BOX AND SLOW-BLOW FUSES.................................................................................. 914
Connection Table.......................................................................................... 914
Fuse Box A............................................................................................ 914
Fuse Box B............................................................................................ 914
Slow-Blow Fuses....................................................................................... 915
FAILURE CODES................................................................................................. 916
1500LO.................................................................................................... 917
TORQFLOW Transmission: Double Meshing................................................................. 917
15BONX.................................................................................................... 918
Transmission Filter: Clogging......................................................................... 918
15SAL1.................................................................................................... 920
ECMV F Clutch: When Command Current is OFF, Fill Signal is ON......................................... 920
15SALH.................................................................................................... 922
ECMV F Clutch: When Command Current is ON, Fill Signal is OFF......................................... 922
15SBL1.................................................................................................... 924
ECMV R Clutch: When Command Current is OFF, Fill Signal is ON......................................... 924
15SBLH.................................................................................................... 926
ECMV R Clutch: When Command Current is ON, Fill Signal is OFF......................................... 926
15SEL1.................................................................................................... 928
ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON....................................... 928
15SELH.................................................................................................... 930
ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF....................................... 930
15SFL1.................................................................................................... 932
ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON....................................... 932
15SFLH.................................................................................................... 934
ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF....................................... 934
15SGL1.................................................................................................... 936
ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON....................................... 936
15SGLH.................................................................................................... 938
ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF....................................... 938
15SHL1.................................................................................................... 940
ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON....................................... 940
15SHLH.................................................................................................... 942
ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF....................................... 942
2F00MA.................................................................................................... 944
Parking Brake: Malfunction............................................................................ 944
2G42ZG.................................................................................................... 946
Front Accumulator: Low Oil Pressure................................................................... 946
2G43ZG.................................................................................................... 948
Rear Accumulator: Low Oil Pressure.................................................................... 948
44K0L4.................................................................................................... 950
Bucket Positioner: ON/OFF Signals Disagree............................................................ 950
AA1ANX.................................................................................................... 952
Air Cleaner: Clogging................................................................................. 952
AB00L6.................................................................................................... 954
Alternator: Signal Disagrees with Operating State of Engine........................................... 954
AB00MA.................................................................................................... 956
Alternator: Malfunction............................................................................... 956
B@BAZG.................................................................................................... 958
Engine: Low Engine Oil Pressure....................................................................... 958
B@BAZK.................................................................................................... 960
Engine Oil: Low Level................................................................................. 960
B@BCNS.................................................................................................... 962
Engine: Coolant: Overheating.......................................................................... 962
B@BCZK.................................................................................................... 964
Engine: Coolant: Low Level............................................................................ 964
B@C7NS.................................................................................................... 966
Brake: Brake Oil: Overheating......................................................................... 966
b@CENS.................................................................................................... 968
Torque Converter Oil: Overheating..................................................................... 968
B@CENS.................................................................................................... 970
Torque Converter Oil: Overheating..................................................................... 970
B@GAZK.................................................................................................... 972
Battery Electrolyte: Low Level........................................................................ 972
B@HANS.................................................................................................... 974
Hydraulic Oil: Overheating............................................................................ 974
CA111..................................................................................................... 976
Abnormality in Engine Controller...................................................................... 976
CA115..................................................................................................... 979
Engine Ne or Bkup Speed Sensor Error.................................................................. 979
CA122..................................................................................................... 980
Charge Pressure Sensor High Error..................................................................... 980
CA123..................................................................................................... 982
Charge Pressure Sensor Low Error...................................................................... 982
CA131..................................................................................................... 984
Throttle Sensor High Error............................................................................ 984
CA132..................................................................................................... 986
Throttle Sensor Low Error............................................................................. 986
CA135..................................................................................................... 988
Engine Oil Pressure Sensor High Error................................................................. 988
CA141..................................................................................................... 990
Engine Oil Pressure Sensor Low Error.................................................................. 990
CA144..................................................................................................... 992
Coolant Temperature Sensor High Error................................................................. 992
CA145..................................................................................................... 994
Coolant Temperature Sensor Low Error.................................................................. 994
CA153..................................................................................................... 996
Charge Temperature Sensor High Error.................................................................. 996
CA154..................................................................................................... 998
Charge Temperature Sensor Low Error................................................................... 998
CA187..................................................................................................... 999
Sensor Power Supply 2 Low Error....................................................................... 999
CA221.....................................................................................................1000
Atmospheric Pressure Sensor High Error................................................................1000
CA222.....................................................................................................1002
Atmospheric Pressure Sensor Low Error.................................................................1002
CA227.....................................................................................................1004
Sensor Power Supply 2 High Error......................................................................1004
CA234.....................................................................................................1006
Engine Overspeed......................................................................................1006
CA238.....................................................................................................1008
Ne Speed Sensor Power Supply Error....................................................................1008
CA263.....................................................................................................1010
Fuel Temperature Sensor High Error....................................................................1010
CA265.....................................................................................................1012
Fuel Temperature Sensor Low Error.....................................................................1012
CA271.....................................................................................................1014
PCV1 Short Circuit....................................................................................1014
CA272.....................................................................................................1016
PCV1 Disconnection....................................................................................1016
CA273.....................................................................................................1018
PCV2 Short Circuit....................................................................................1018
CA274.....................................................................................................1020
PCV2 Disconnection....................................................................................1020
CA322.....................................................................................................1022
Injector #1 (L/B #1) Open/Short Error.................................................................1022
CA323.....................................................................................................1024
Injector #5 (L/B #5) Open/Short Error.................................................................1024
CA324.....................................................................................................1026
Injector #3 (L/B #3) Open/Short Error.................................................................1026
CA325.....................................................................................................1028
Injector #6 (L/B #6) Open/Short Error.................................................................1028
CA331.....................................................................................................1030
Injector #2 (L/B #2) Open/Short Error.................................................................1030
CA332.....................................................................................................1032
Injector #4 (L/B #4) Open/Short Error.................................................................1032
CA342.....................................................................................................1034
Calibration Code Data Inconsistency...................................................................1034
CA351.....................................................................................................1035
Injectors Drive Circuit Error.........................................................................1035
CA352.....................................................................................................1038
Sensor Power Supply 1 Low Error.......................................................................1038
CA386.....................................................................................................1040
Sensor Power Supply 1 High Error......................................................................1040
CA431.....................................................................................................1042
Idle Validation Switch Error..........................................................................1042
CA432.....................................................................................................1044
Idle Validation Action Error..........................................................................1044
CA441.....................................................................................................1045
Battery Voltage Low Error.............................................................................1045
CA442.....................................................................................................1046
Battery Voltage High Error............................................................................1046
CA449.....................................................................................................1047
Common Rail Pressure High Error 2.....................................................................1047
CA451.....................................................................................................1048
Common Rail Pressure Sensor High Error................................................................1048
CA452.....................................................................................................1050
Common Rail Pressure Sensor Low Error.................................................................1050
CA553.....................................................................................................1051
Common Rail Pressure High Error 1.....................................................................1051
CA554.....................................................................................................1052
Common Rail Pressure In-Range Error...................................................................1052
CA559.....................................................................................................1054
Supply Pump Pressure Very Low Error 1.................................................................1054
Checksheet for No-Pressure Feed...................................................................1056
CA689.....................................................................................................1058
Engine Ne Speed Sensor Error..........................................................................1058
CA731.....................................................................................................1060
Engine Bkup Speed Sensor Phase Error..................................................................1060
CA757.....................................................................................................1061
All Continuous Data Lost Error........................................................................1061
CA778.....................................................................................................1062
Engine Bkup Speed Sensor Error........................................................................1062
CA1228....................................................................................................1064
EGR Valve Servo Error 1...............................................................................1064
CA1625....................................................................................................1065
EGR Valve Servo Error 2...............................................................................1065
CA1626....................................................................................................1066
Bypass Valve Solenoid Current High Error..............................................................1066
CA1627....................................................................................................1068
Bypass Valve Solenoid Drive Circuit Disconnection Error...............................................1068
CA1628....................................................................................................1069
Bypass Valve Servo Error 1............................................................................1069
CA1629....................................................................................................1070
Bypass Valve Servo Error 2............................................................................1070
CA1631....................................................................................................1072
Bypass Valve Lift Sensor High Error...................................................................1072
CA1632....................................................................................................1074
Bypass Valve Lift Sensor Low Error....................................................................1074
CA1633....................................................................................................1075
KOMNET Datalink Timeout Error.........................................................................1075
CA1642....................................................................................................1076
Abnormally Low Signal in EGR Inlet Pressure Sensor (s/n up to 55120)..................................1076
EGR Inlet Pressure Sensor Low Error...................................................................1077
CA1653....................................................................................................1078
Abnormally High Signal in EGR Inlet Pressure Sensor (s/n up to 55120).................................1078
EGR Inlet Pressure Sensor High Error .................................................................1080
CA2185....................................................................................................1082
Throttle Sensor Supply Voltage High Error.............................................................1082
CA2186....................................................................................................1084
Throttle Sensor Power Supply Low Error................................................................1084
CA2249....................................................................................................1085
Supply Pump Pressure Very Low Error 2.................................................................1085
CA2271....................................................................................................1086
EGR Valve Lift Sensor High Error......................................................................1086
CA2272....................................................................................................1088
EGR Valve Lift Sensor Low Error.......................................................................1088
CA2351....................................................................................................1090
EGR Valve Solenoid Operation Short Circuit............................................................1090
CA2352....................................................................................................1092
EGR Valve Solenoid Operation Disconnection Error......................................................1092
CA2555....................................................................................................1093
Intake Heater Relay Disconnection Error...............................................................1093
CA2556....................................................................................................1094
Intake Heater Relay Short Circuit Error...............................................................1094
D160KZ....................................................................................................1096
Backup Lamp Relay: Disconnection or Short Circuit.....................................................1096
D191KA....................................................................................................1098
Joystick Steering Neutral Safety Relay: Disconnection.................................................1098
D191KB....................................................................................................1100
Joystick Steering Neutral Safety Relay: Short Circuit.................................................1100
D192KA....................................................................................................1102
ECSS Solenoid: Disconnection..........................................................................1102
D192KB....................................................................................................1103
ECSS Solenoid: Short Circuit..........................................................................1103
D192KY....................................................................................................1104
ECSS Solenoid Relay: Short Circuit with Power Supply Line.............................................1104
D193KA....................................................................................................1106
Joystick Steering Solenoid Cut Relay: Disconnection...................................................1106
D193KB....................................................................................................1108
Joystick Steering Solenoid Cut Relay: Short Circuit...................................................1108
D193KY....................................................................................................1110
Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line............................1110
D5ZHKA....................................................................................................1112
Terminal C Signal: Disconnection......................................................................1112
D5ZHKB....................................................................................................1116
Terminal C Signal: Short Circuit......................................................................1116
D5ZHKZ....................................................................................................1118
Terminal C Signal: Disconnection or Short Circuit.....................................................1118
D5ZHL6....................................................................................................1122
Terminal C Signal: Signal Does Not Match Engine Running or Stopped State..............................1122
DA80L4....................................................................................................1124
Auto-Grease Controller: ON/OFF Signals Disagree.......................................................1124
DAF3KK....................................................................................................1126
Machine Monitor: Low Source Voltage (input)...........................................................1126
DAF5KP....................................................................................................1128
Machine Monitor: Low Output Voltage...................................................................1128
DAFRKR....................................................................................................1132
Machine Monitor: CAN Defective Communication..........................................................1132
DAQ0KK....................................................................................................1134
Transmission Controller: Low Source Voltage...........................................................1134
DAQ0KT....................................................................................................1136
Transmission Controller: Abnormality in Controller....................................................1136
DAQ2KK....................................................................................................1138
Transmission Controller Load Power Supply Line: Low Source Voltage (input)............................1138
DAQ9KQ....................................................................................................1140
Transmission Controller: Disagreement of Model Selection Signals......................................1140
DAQRKR....................................................................................................1142
Transmission Controller: CAN Defective Communication..................................................1142
DAQRMA....................................................................................................1144
Transmission Controller Option Setting: Malfunction...................................................1144
DB2RKR....................................................................................................1146
Engine Controller: CAN Defective Communication........................................................1146
DB90KK....................................................................................................1148
Work Equipment Controller: Low Source Voltage (input).................................................1148
DB90KT....................................................................................................1150
Work Equipment Controller: Abnormality in Controller..................................................1150
DB92KK....................................................................................................1152
Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)..........................1152
DB95KX....................................................................................................1154
Work Equipment Controller Power Supply Output: Out-of-Input Signal Range..............................1154
DB99KQ....................................................................................................1156
Work Equipment Controller: Disagreement of Model Selection Signals....................................1156
DB9RKR....................................................................................................1158
Work Equipment Controller: CAN Defective Communication................................................1158
DB9RMA....................................................................................................1160
Work Equipment Controller Option Setting: Malfunction.................................................1160
DB9RMC....................................................................................................1162
Work Equipment Controller: CAN Communication Defective Operation......................................1162
DD15LD....................................................................................................1164
Switch (Panel Switch 1 n): Switch is Kept Pressed for Long Time.......................................1164
DD16LD....................................................................................................1166
Switch (Panel Switch 2 ‡): Switch is Kept Pressed for Long Time.......................................1166
DD17LD....................................................................................................1168
Switch (Panel Switch 3 <): Switch is Kept Pressed for Long Time.......................................1168
DD18LD....................................................................................................1170
Switch (Panel Switch 4 >): Switch is Kept Pressed for Long Time.......................................1170
DD1ALD....................................................................................................1172
Remote Positioner Raise/Lower Set Switch (raise): Switch Is Kept Pressed for Long Time................1172
DD1BLD....................................................................................................1174
Remote Positioner Raise/Lower Set Switch (lower): Switch is Kept Pressed for Long Time................1174
DD1CLD....................................................................................................1176
Load Meter Subtotal Switch: Switch is Kept Pressed for Long Time......................................1176
DD1FLD....................................................................................................1178
Load Meter Mode Selector Switch (A/B): Switch is Kept Pressed for Long Time...........................1178
DD1GLD....................................................................................................1180
Load Meter Mode Selector Switch (+/-): Switch is Kept Pressed for Long Time...........................1180
DD1HLD....................................................................................................1182
Load Meter Display Selector Switch: Switch is Kept Pressed for Long Time..............................1182
DDA7L4....................................................................................................1184
RPM Set ON/OFF Switch: ON/OFF Signals Disagree........................................................1184
DDA8KB....................................................................................................1186
RPM Set Idle UP/DOWN Selector Switch (idle UP): Short Circuit.........................................1186
DDA9KB....................................................................................................1188
RPM Set Idle UP/DOWN Selector Switch (idle DOWN): Short Circuit.......................................1188
DDB6L4....................................................................................................1190
Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree...........................................1190
DDD1LD....................................................................................................1194
Remote Positioner Bucket Angle Set Switch: Switch is Kept Pressed for Long Time.......................1194
DDE5MA....................................................................................................1196
Emergency Steering Drive Switch: Malfunction..........................................................1196
DDK3KA....................................................................................................1198
Right FNR Switch: Disconnection.......................................................................1198
DDK3KB....................................................................................................1201
Right FNR Switch: Short Circuit.......................................................................1201
DDK4KA....................................................................................................1204
Joystick Steering FNR Switch: Disconnection...........................................................1204
DDK4KB....................................................................................................1207
Joystick Steering FNR Switch: Short Circuit...........................................................1207
DDK5L4....................................................................................................1210
Joystick Steering with Shift UP/DOWN Switch: ON/OFF Signals Disagree..................................1210
DDK6KA....................................................................................................1212
FNR Lever Switch: Disconnection.......................................................................1212
DDK6KB....................................................................................................1215
FNR Lever Switch: Short Circuit.......................................................................1215
DDT0L4....................................................................................................1218
Shift Mode Selector Switch: ON/OFF Signals Disagree...................................................1218
DDT4LD....................................................................................................1220
Transmission Cutoff Set Switch: Switch is Kept Pressed for Long Time..................................1220
DDW9LD....................................................................................................1222
Kickdown Switch: Switch is Kept Pressed for Long Time.................................................1222
DDWLLD....................................................................................................1224
Hold Switch: Switch is Kept Pressed Down for Long Time................................................1224
DDY0LD....................................................................................................1226
Load Meter Cancel Switch: Switch is Kept Pressed for Long Time........................................1226
DF10KA....................................................................................................1228
Transmission Shift Lever Switch: Disconnection........................................................1228
DF10KB....................................................................................................1231
Transmission Shift Lever Switch: Short Circuit........................................................1231
DGF1KA....................................................................................................1234
Transmission Oil Temperature Sensor: Disconnection....................................................1234
DGF1KB....................................................................................................1236
Transmission Oil Temperature Sensor: Short Circuit....................................................1236
DGH2KX....................................................................................................1238
Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range...........................................1238
DGR2KA....................................................................................................1240
Rear Brake Oil Temperature Sensor: Disconnection......................................................1240
DGR2KX....................................................................................................1242
Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range.............................................1242
DGT1KX....................................................................................................1244
Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range....................................1244
DH21KA....................................................................................................1246
Work Equipment Pump Oil Pressure Sensor: Disconnection................................................1246
DH21KB....................................................................................................1248
Work Equipment Pump Oil Pressure Sensor: Short Circuit................................................1248
DHPCKX....................................................................................................1250
Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range...................................1250
DHPDKX....................................................................................................1252
Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range.....................................1252
DHT1KX....................................................................................................1254
Left Brake Pressure Sensor: Out-of-Input Signal.......................................................1254
DHT2L6....................................................................................................1256
Transmission Filter Clogging Sensor: Signal Disagrees with Operating and Stopped States of Engine.....1256
DK59KA....................................................................................................1258
Lift Arm EPC Lever Potentiometer (Main): Disconnection................................................1258
DK59KY....................................................................................................1261
Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line.........................1261
DK59L8....................................................................................................1264
Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree......................................1264
DK5AKA....................................................................................................1268
Lift Arm EPC Lever Potentiometer (Sub): Disconnection.................................................1268
DK5AKY....................................................................................................1271
Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne..........................1271
DK5BKA....................................................................................................1274
Bucket EPC Lever Potentiometer (Main): Disconnection..................................................1274
DK5BKY....................................................................................................1277
Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...........................1277
DK5BL8....................................................................................................1280
Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree........................................1280
DK5CKA....................................................................................................1283
Bucket EPC Lever Potentiometer (Sub): Disconnection...................................................1283
DK5CKY....................................................................................................1286
Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line............................1286
DK5DKA....................................................................................................1289
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Disconnection..............................1289
DK5DKY....................................................................................................1292
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line.......1292
DK5DL8....................................................................................................1294
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Analog Signals Disagree....................1294
DK5EKA....................................................................................................1298
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Disconnection...............................1298
DK5EKY....................................................................................................1300
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line........1300
DK5FKA....................................................................................................1302
Joystick Steering EPC Lever Potentiometer (Main): Disconnection.......................................1302
DK5FKY....................................................................................................1304
Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line................1304
DK5GKA....................................................................................................1306
Joystick Steering EPC Lever Potentiometer (Sub): Disconnection........................................1306
DK5GKY....................................................................................................1308
Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line.................1308
DK5FL8....................................................................................................1310
Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree.............................1310
DKA0KA....................................................................................................1314
Lift Arm Angle Sensor: Disconnection..................................................................1314
DKA0KX....................................................................................................1316
Lift Arm Angle Sensor: Out-of-Input Signal Range......................................................1316
DKA0KY....................................................................................................1320
Lift Arm Angle Sensor: Short Circuit with Power Supply Line...........................................1320
DKA0L0....................................................................................................1322
Lift Arm Angle Sensor: Double Meshing.................................................................1322
DLF1KA....................................................................................................1324
Transmission Input Shaft Speed Sensor: Disconnection..................................................1324
DLF1LC....................................................................................................1326
Transmission Input Shaft Speed Sensor: Speed Signals Disagree.........................................1326
DLT4KB....................................................................................................1328
Transmission Input Shaft Speed Sensor: Short Circuit..................................................1328
DLT4KX....................................................................................................1330
Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range.....................................1330
DT20KB....................................................................................................1332
Transmission Cutoff Indicator Lamp: Short Circuit.....................................................1332
DUM1KB....................................................................................................1334
Remote Positioner Raise Set Indicator Lamp: Short Circuit.............................................1334
DUM2KB....................................................................................................1336
Remote Positioner Lower Set Indicator Lamp: Short Circuit.............................................1336
DV00KB....................................................................................................1338
Alarm Buzzer: Short Circuit...........................................................................1338
DW4PKA....................................................................................................1340
Lift Arm Raise EPC Solenoid: Disconnection............................................................1340
DW4PKB....................................................................................................1342
Lift Arm Raise EPC Solenoid: Short Circuit............................................................1342
DW4PKY....................................................................................................1344
Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line.....................................1344
DW4QKA....................................................................................................1346
Lift Arm Lower EPC Solenoid: Disconnection............................................................1346
DW4QKB....................................................................................................1348
Lift Arm Lower EPC Solenoid: Short Circuit............................................................1348
DW4QKY....................................................................................................1350
Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line.....................................1350
DW4RKA....................................................................................................1352
Bucket Tilt EPC Solenoid: Disconnection...............................................................1352
DW4RKB....................................................................................................1354
Bucket Tilt EPC Solenoid: Short Circuit...............................................................1354
DW4RKY....................................................................................................1356
Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line........................................1356
DW4SKA....................................................................................................1358
Buck Dump EPC Solenoid: Disconnection.................................................................1358
DW4SKB....................................................................................................1360
Bucket Dump EPC Solenoid: Short Circuit...............................................................1360
DW4SKY....................................................................................................1362
Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line........................................1362
DW7BKA....................................................................................................1364
Fan Reverse Solenoid: Disconnection...................................................................1364
DW7BKB....................................................................................................1366
Fan Reverse Solenoid: Short Circuit...................................................................1366
DW7BKY....................................................................................................1368
Fan Reverse Solenoid: Short Circuit with Power Supply Line............................................1368
DW7DKA....................................................................................................1370
Hydraulic Drive Fan Neutral Solenoid: Disconnection...................................................1370
DW7DKB....................................................................................................1371
Hydraulic Drive Fan Neutral Solenoid: Short Circuit...................................................1371
DW7DKY....................................................................................................1372
Hydraulic Drive Fan Solenoid: Short Circuit with Power Supply Line....................................1372
DWM1KA....................................................................................................1374
Work Equipment Neutral Lock Solenoid: Disconnection...................................................1374
DWM1KB....................................................................................................1376
Work Equipment Neutral Lock Solenoid: Short Circuit...................................................1376
DWM1KY....................................................................................................1378
Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line............................1378
DWN6KA....................................................................................................1380
Lift Arm Raise Magnet Detent Solenoid: Disconnection..................................................1380
DWN6KB....................................................................................................1382
Lift Arm Raise Magnet Detent Solenoid: Short Circuit..................................................1382
DWN6KY....................................................................................................1384
Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line...........................1384
DWN7KA....................................................................................................1386
Lift Arm Float Magnet Detent Solenoid: Disconnection..................................................1386
DWN7KB....................................................................................................1388
Lift Arm Float Magnet Detent Solenoid: Short Circuit..................................................1388
DWN7KY....................................................................................................1390
Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line...........................1390
DWN8KA....................................................................................................1392
Bucket Tilt Magnet Detent Solenoid: Disconnection.....................................................1392
DWN8KB....................................................................................................1394
Bucket Tilt Magnet Detent Solenoid: Short Circuit.....................................................1394
DWN8KY....................................................................................................1396
Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source.....................................1396
DX16KA....................................................................................................1398
Fan Pump EPC Solenoid: Disconnection..................................................................1398
DX16KB....................................................................................................1399
Fan Pump EPC Solenoid: Short Circuit..................................................................1399
DX16KY....................................................................................................1400
Fan Pump EPC Solenoid: Short Circuit with Power Supply Line...........................................1400
DXA1KA....................................................................................................1401
Pump PC-EPC Solenoid: Disconnection...................................................................1401
DXA1KB....................................................................................................1402
Pump PC-EPC Solenoid: Short Circuit...................................................................1402
DXH1KA....................................................................................................1404
Lockup ECMV Solenoid: Disconnection...................................................................1404
DXH1KB....................................................................................................1406
Lockup ECMV Solenoid: Short Circuit...................................................................1406
DXH1KY....................................................................................................1408
Lockup ECMV Solenoid: Short Circuit with Power Supply Line............................................1408
DXH4KA....................................................................................................1410
1st Clutch ECMV Solenoid: Disconnection...............................................................1410
DXH4KB....................................................................................................1412
1st Clutch ECMV Solenoid: Short Circuit...............................................................1412
DXH4KY....................................................................................................1414
1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line........................................1414
DXH5KA....................................................................................................1416
2nd Clutch ECMV Solenoid: Disconnection...............................................................1416
DXH5KB....................................................................................................1418
2nd Clutch ECMV Solenoid: Short Circuit...............................................................1418
DXH5KY....................................................................................................1420
2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line........................................1420
DXH6KA....................................................................................................1422
3rd Clutch ECMV Solenoid: Disconnection...............................................................1422
DXH6KB....................................................................................................1424
3rd Clutch ECMV Solenoid: Short Circuit...............................................................1424
DXH6KY....................................................................................................1426
3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line........................................1426
DXH7KA....................................................................................................1428
R Clutch ECMV Solenoid: Disconnection.................................................................1428
DXH7KB....................................................................................................1430
R Clutch ECMV Solenoid: Short Circuit.................................................................1430
DXH7KY....................................................................................................1432
R Clutch ECMV Solenoid: Short Circuit with Power Supply Line..........................................1432
DXH8KA....................................................................................................1434
F Clutch ECMV Solenoid: Disconnection.................................................................1434
DXH8KB....................................................................................................1436
F Clutch ECMV Solenoid: Short Circuit.................................................................1436
DXH8KY....................................................................................................1438
F Clutch ECMV Solenoid: Short Circuit with Power Supply Line..........................................1438
DXHHKA....................................................................................................1440
4th Clutch ECMV Solenoid: Disconnection...............................................................1440
DXHHKB....................................................................................................1442
4th Clutch ECMV Solenoid: Short Circuit...............................................................1442
DXHHKY....................................................................................................1444
4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line........................................1444
DXHJKA....................................................................................................1446
3-Spool Valve Extract EPC Solenoid: Disconnection.....................................................1446
DXHJKB....................................................................................................1447
3-Spool Valve Extract EPC Solenoid: Short Circuit.....................................................1447
DXHJKY....................................................................................................1448
3-Spool Valve Extract EPC Solenoid: Short Circuit with Power Supply Line..............................1448
DXHKKA....................................................................................................1450
3-Spool Valve Retract EPC Solenoid: Disconnection.....................................................1450
DXHKKB....................................................................................................1451
3-Spool Valve Retract EPC Solenoid: Short Circuit.....................................................1451
DXHKKY....................................................................................................1452
3-Spool Valve Retract EPC Solenoid: Short Circuit with Power Supply Line..............................1452
DXHLKA....................................................................................................1454
Joystick Steering Right EPC Solenoid: Disconnection...................................................1454
DXHLKB....................................................................................................1456
Joystick Steering Right EPC Solenoid: Short Circuit...................................................1456
DXHLKY....................................................................................................1459
Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line............................1459
DXHMKA....................................................................................................1462
Joystick Steering Left EPC Solenoid: Disconnection....................................................1462
DXHMKB....................................................................................................1464
Joystick Steering Left EPC Solenoid: Short Circuit....................................................1464
DXHMKY....................................................................................................1467
Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line.............................1467
TROUBLESHOOTING: E-MODE.......................................................................................1470
Troubleshooting Electrical System.........................................................................1470
Information in Troubleshooting Table..................................................................1470
E-1.......................................................................................................1472
Engine Does Not Start.................................................................................1472
E-2.......................................................................................................1478
Wiper Does Not Operate................................................................................1478
E-3.......................................................................................................1482
Windshield Washer Does Not Operate....................................................................1482
E-4.......................................................................................................1486
Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off.......................1486
E-5.......................................................................................................1494
Working Lamp Does Not Light Up or Go Off..............................................................1494
E-6.......................................................................................................1500
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off............................................1500
E-7.......................................................................................................1506
Brake Lamp Does Not Light or It Keeps Lighting Up.....................................................1506
E-8.......................................................................................................1510
Backup Lamp Does Not Light or It Keeps Lighting Up....................................................1510
E-9.......................................................................................................1512
Backup Buzzer Does Not Sound or It Keeps Sounding.....................................................1512
E-10......................................................................................................1514
Horn Does Not Sound or It Keeps Sounding..............................................................1514
E-11......................................................................................................1518
Alarm Buzzer Does Not Sound or It Keeps Sounding......................................................1518
E-12......................................................................................................1520
Air Conditioner Does Not Operate or Stop..............................................................1520
E-13......................................................................................................1524
KOMTRAX System Does Not Work Properly.................................................................1524
Lamp Display Section of KOMTRAX Terminal..........................................................1526
TROUBLESHOOTING: H-MODE.......................................................................................1528
Troubleshooting Hydraulic and Mechanical Systems..........................................................1528
Using Troubleshooting Chart...........................................................................1528
Failure Codes and Causes Table............................................................................1530
H-1.......................................................................................................1534
Machine Does Not Start................................................................................1534
H-2.......................................................................................................1536
Torque Converter Lockup is Not Switched OFF (Engine Stalls)...........................................1536
H-3.......................................................................................................1537
Torque Converter Lockup is Not Switched ON............................................................1537
H-4.......................................................................................................1538
Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted....1538
H-5.......................................................................................................1542
Large Shocks When Starting and Shifting Gears.........................................................1542
H-6.......................................................................................................1546
Large Time Lag When Starting and Shifting Gear........................................................1546
H-7.......................................................................................................1550
Torque Converter Oil Temperature is High..............................................................1550
H-8.......................................................................................................1551
Steering Does Not Turn................................................................................1551
H-9.......................................................................................................1552
Steering Does Not Turn (Joystick Steering, if equipped)...............................................1552
H-10......................................................................................................1553
Steering Response is Poor.............................................................................1553
H-11......................................................................................................1554
Steering Turning Response is Poor (Joystick Steering, if Equipped)....................................1554
H-12......................................................................................................1555
Steering is Heavy.....................................................................................1555
H-13......................................................................................................1556
When Machine Turns, It Shakes or Jerks................................................................1556
H-14......................................................................................................1557
When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)...............................1557
H-15......................................................................................................1558
Wheel Brake Does Not Work or Does Not Work Well.......................................................1558
H-16......................................................................................................1559
Wheel Brake is Not Released or It Drags...............................................................1559
H-17......................................................................................................1560
Parking Brake Does Not Work or Does Not Work Well.....................................................1560
H-18......................................................................................................1561
Parking Brake is Not Released or It Drags.............................................................1561
H-19......................................................................................................1562
Lift Arm Does Not Rise................................................................................1562
H-20......................................................................................................1563
Lift Arm is Low or Rising Force is Insufficient.......................................................1563
H-21......................................................................................................1564
When Rising, Lift Arm Starts to Move Slowly at a Specific Height......................................1564
H-22......................................................................................................1564
Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats).............................................1564
H-23......................................................................................................1564
Hydraulic Drifts of the Lift Arm Occur Often..........................................................1564
H-24......................................................................................................1565
Lift Arm Wobbles During Operation.....................................................................1565
H-25......................................................................................................1566
Bucket Does Not Tilt Back.............................................................................1566
H-26......................................................................................................1567
Bucket Speed is Low or Tilting-Back Force Is Insufficient.............................................1567
H-27......................................................................................................1568
Bucket Starts to Operate Slowly in the Midst of Tilting Back..........................................1568
H-28......................................................................................................1568
Bucket Cylinder Cannot Hold Down the Bucket...........................................................1568
H-29......................................................................................................1568
Hydraulic Drifts of the Bucket Occur Often............................................................1568
H-30......................................................................................................1569
Bucket Wobbles During Travel with Load................................................................1569
H-31......................................................................................................1569
During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls...........................1569
H-32......................................................................................................1569
Large Shocks When Work Equipment Starts and Stops.....................................................1569
H-33......................................................................................................1569
When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves............................1569
H-34......................................................................................................1570
ECSS Does Not Operate; Pitching and Bouncing Occur....................................................1570
TROUBLESHOOTING: S-MODE.......................................................................................1571
Troubleshooting Engine....................................................................................1571
Using Troubleshooting Charts..........................................................................1571
S-1.......................................................................................................1574
Engine Does Not Start Easily..........................................................................1574
S-2.......................................................................................................1578
Engine Does Not Start.................................................................................1578
S-3.......................................................................................................1586
Engine Does Not Pick Up Smoothly......................................................................1586
S-4.......................................................................................................1588
Engine Stops During Operation.........................................................................1588
S-5.......................................................................................................1590
Engine Does Not Rotate Smoothly.......................................................................1590
S-6.......................................................................................................1592
Engine Lacks Output (or Lacks Power)..................................................................1592
S-7.......................................................................................................1594
Exhaust Smoke is Black (Incomplete Combustion)........................................................1594
S-8.......................................................................................................1597
Oil Consumption is Excessive (or Exhaust Smoke is Blue)...............................................1597
S-9.......................................................................................................1598
Engine Oil Becomes Contaminated Quickly...............................................................1598
S-10......................................................................................................1599
Fuel Consumption is Excessive.........................................................................1599
S-11......................................................................................................1600
Coolant Contains Oil (Blows Back or Reduces)..........................................................1600
S-12......................................................................................................1602
Oil Pressure Drops....................................................................................1602
S-13......................................................................................................1604
Oil Level Rises (Water, Fuel in Oil)..................................................................1604
S-14......................................................................................................1608
Coolant Temperature Rises Too High (Overheating)......................................................1608
S-15......................................................................................................1610
Abnormal Noise is Made................................................................................1610
S-16......................................................................................................1612
Vibration is Excessive................................................................................1612
50 DISASSEMBLY AND ASSEMBLY.......................................................................................1613
HOW TO READ THIS MANUAL.......................................................................................1619
Removal and Installation of Assemblies....................................................................1619
Disassembly and Assembly of Assemblies....................................................................1621
COATING MATERIALS LIST........................................................................................1623
SPECIAL TOOLS LIST............................................................................................1627
SKETCHES OF SPECIAL TOOLS.....................................................................................1632
CONNECTOR REPAIR PROCEDURES...................................................................................1639
Stripping Insulation......................................................................................1639
Wire Inspection...........................................................................................1639
Contact Terminal Removal (HD30 Type)......................................................................1640
Crimping Contact Terminal (HD30 Type).....................................................................1641
Insertion Of Contact Terminal (HD30 Type).................................................................1642
Contact Terminal Removal (DT Type)........................................................................1643
Crimping Contact Terminal (DT Type).......................................................................1644
Insertion Of Contact Terminal (DT Type)...................................................................1645
ENGINE AND COOLING SYSTEM.....................................................................................1646
Engine....................................................................................................1646
Removal...............................................................................................1646
Installation..........................................................................................1652
Radiator..................................................................................................1654
Removal...............................................................................................1654
Installation..........................................................................................1656
Air Aftercooler...........................................................................................1657
Removal...............................................................................................1657
Installation..........................................................................................1658
Cooling Fan and Fan Motor.................................................................................1659
Removal...............................................................................................1659
Installation..........................................................................................1661
Radiator Guard and Cooling Fan............................................................................1662
Removal...............................................................................................1662
Installation..........................................................................................1665
Fuel Tank.................................................................................................1666
Removal...............................................................................................1666
Installation..........................................................................................1668
Engine Hood...............................................................................................1669
Removal...............................................................................................1669
Installation..........................................................................................1672
Fuel Supply Pump..........................................................................................1673
Removal...............................................................................................1673
Installation..........................................................................................1677
Cylinder Head.............................................................................................1679
Removal...............................................................................................1679
Installation..........................................................................................1689
Fuel Injector.............................................................................................1695
Removal...............................................................................................1695
Installation..........................................................................................1697
Engine Front Seal.........................................................................................1699
Removal...............................................................................................1699
Installation..........................................................................................1701
Engine Rear Seal..........................................................................................1704
Removal...............................................................................................1704
Installation..........................................................................................1707
POWER TRAIN...................................................................................................1711
Torque Converter and Transmission Assembly................................................................1711
Removal...............................................................................................1711
Installation..........................................................................................1718
Power Train...............................................................................................1720
Preparation...........................................................................................1720
Disconnection.........................................................................................1722
Connection............................................................................................1724
Input Transfer............................................................................................1726
Disassembly...........................................................................................1726
Assembly..............................................................................................1730
Torque Converter (Lockup Specification)...................................................................1735
Disassembly...........................................................................................1735
Assembly..............................................................................................1743
Torque Converter (Without Lockup).........................................................................1753
Disassembly...........................................................................................1753
Assembly..............................................................................................1760
Transmission..............................................................................................1768
Disassembly...........................................................................................1768
Assembly..............................................................................................1787
Transfer and Parking Brake Assembly.......................................................................1808
Disassembly...........................................................................................1809
Assembly..............................................................................................1819
Front Axle................................................................................................1831
Removal...............................................................................................1831
Installation..........................................................................................1833
Rear Axle.................................................................................................1834
Removal...............................................................................................1834
Installation..........................................................................................1836
Front Differential........................................................................................1837
Removal...............................................................................................1837
Installation..........................................................................................1838
Differential (with Limited Slip Differential).............................................................1839
Disassembly...........................................................................................1839
Assembly..............................................................................................1845
Differential (without Limited Slip Differential)..........................................................1857
Disassembly...........................................................................................1857
Assembly..............................................................................................1863
Final Drive (Front and Rear)..............................................................................1872
Disassembly...........................................................................................1872
Assembly..............................................................................................1876
BRAKE SYSTEM..................................................................................................1881
Brakes (Front and Rear)...................................................................................1881
Removal...............................................................................................1881
Installation..........................................................................................1883
Disassembly...........................................................................................1884
Assembly..............................................................................................1888
Slack Adjuster............................................................................................1892
Brake Accumulator Charge Valve............................................................................1893
UNDERCARRIAGE AND FRAME.......................................................................................1894
Center Hinge Pin..........................................................................................1894
Removal...............................................................................................1895
Installation..........................................................................................1899
HYDRAULIC SYSTEM..............................................................................................1904
Hydraulic Tank............................................................................................1904
Removal...............................................................................................1904
Installation..........................................................................................1908
Cooling Pump..............................................................................................1909
Removal...............................................................................................1909
Installation..........................................................................................1910
Fan Pump..................................................................................................1911
Removal...............................................................................................1911
Installation..........................................................................................1912
Work Equipment Pump.......................................................................................1913
Removal...............................................................................................1913
Installation..........................................................................................1915
Steering, Torque Converter Charge, and EPC Pump Assembly..................................................1916
Removal...............................................................................................1916
Installation..........................................................................................1917
Work Equipment Valve......................................................................................1918
Removal...............................................................................................1918
Installation..........................................................................................1921
Work Equipment Control Valve Assembly.....................................................................1922
Disassembly and Assembly..............................................................................1922
Steering Cylinder.........................................................................................1926
Disassembly...........................................................................................1926
Assembly..............................................................................................1929
Lift Arm and Bucket Cylinder..............................................................................1931
Disassembly...........................................................................................1931
Assembly..............................................................................................1935
Steering Valve............................................................................................1940
Removal...............................................................................................1940
Installation..........................................................................................1941
WORK EQUIPMENT................................................................................................1942
Work Equipment............................................................................................1942
Removal...............................................................................................1942
Installation..........................................................................................1946
Counterweight (Large).....................................................................................1948
Removal...............................................................................................1948
Installation..........................................................................................1949
Counterweight (Small).....................................................................................1950
Removal...............................................................................................1950
Installation..........................................................................................1950
CAB AND ITS ATTACHMENTS.......................................................................................1951
Cab (Separate Cab and Floor)..............................................................................1951
Removal...............................................................................................1951
Installation..........................................................................................1958
Cab and Floor Frame (Cab-Floor Unit)......................................................................1959
Installation..........................................................................................1964
Cab Glass (Stuck Glass)...................................................................................1965
Removal...............................................................................................1966
Installation..........................................................................................1967
Operator Seat (Upper Seat)................................................................................1975
Storage Box...........................................................................................1975
Seat Pad and Backrest Upholstery......................................................................1975
Mechanical Lumbar Support.............................................................................1976
Armrests (if equipped)................................................................................1977
Backrest..............................................................................................1978
Backrest Adjustment...................................................................................1980
Seat Angle and Seat Depth Adjuster....................................................................1981
Covers................................................................................................1983
Slide Rails...........................................................................................1984
Operator Seat (Suspension)................................................................................1985
Top Cover.............................................................................................1985
Front Cover...........................................................................................1985
Bellows...............................................................................................1986
Bowden Pull Wire and Handle (Vertical Shock Absorber Adjustment)......................................1988
Vertical Shock Absorber...............................................................................1992
Compressor............................................................................................1994
Height Level Controller...............................................................................1998
Compressed-Air Hoses..................................................................................2004
Bowden Pull Wires and Handle (Height Adjustment)......................................................2008
Pneumatic Spring......................................................................................2012
Air Tank for Additional Air Supply....................................................................2014
Cable Harness.........................................................................................2016
Suspension System (Upper Part)........................................................................2018
Suspension System (Lower Part)........................................................................2022
Swinging Structure....................................................................................2026
ELECTRICAL SYSTEM.............................................................................................2030
Engine Controller.........................................................................................2030
Removal...............................................................................................2030
Installation..........................................................................................2030
Transmission Controller...................................................................................2031
Removal...............................................................................................2031
Installation..........................................................................................2031
Work Equipment Controller.................................................................................2032
Removal...............................................................................................2032
Installation..........................................................................................2032
KOMTRAX Terminal..........................................................................................2033
Air Conditioner Unit......................................................................................2034
Removal...............................................................................................2034
Installation..........................................................................................2038
90 DIAGRAMS AND SCHEMATICS........................................................................................2039
HYDRAULIC SYSTEM..............................................................................................2041
Power Train Hydraulic Circuit.............................................................................2041
Without Lockup Clutch.................................................................................2041
With Lockup Clutch....................................................................................2042
Brake Hydraulic Circuit...................................................................................2043
Without Forced Brake Cooling System...................................................................2043
With Forced Brake Cooling System......................................................................2044
Work Equipment............................................................................................2045
ELECTRICAL SYSTEM.............................................................................................2046
Air Conditioner Electrical Circuit........................................................................2046
Electrical Circuit Diagram (1/7)..........................................................................2047
Electrical Circuit Diagram (2/7)..........................................................................2048
Electrical Circuit Diagram (3/7)..........................................................................2049
Electrical Circuit Diagram (4/7)..........................................................................2050
Electrical Circuit Diagram (5/7)..........................................................................2051
Electrical Circuit Diagram (6/7)..........................................................................2052
Electrical Circuit Diagram (7/7)..........................................................................2053
Connector List and Stereogram.............................................................................2054
Chassis...............................................................................................2054
Operator's Compartment................................................................................2055
Engine and Transmission...............................................................................2056
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KOMATSU WA500-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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