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KOMATSU WA500-6R WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU WA500-6R WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBERS 60001 and up
- PUBLICATION NUMBER:SEN02876
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Description
KOMATSU WA500-6R WHEEL LOADER SERVICE REPAIR MANUAL
KOMATSU WA500-6R WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU WA500-6R WHEEL LOADER SERVICE REPAIR MANUAL
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU WA500-6R WHEEL LOADER SERVICE REPAIR MANUAL
COVER ............................................................................................................................................... 1 00 Index and foreword................................................................................................................................ 0 Index............................................................................................................................................ 3 Composition of shop manual................................................................................................................... 4 Table of contents............................................................................................................................ 6 Foreword and general information................................................................................................................. 19 Safety notice................................................................................................................................ 20 How to read the shop manual.................................................................................................................. 25 Explanation of terms for maintenance standard................................................................................................ 27 Handling of electric equipment and hydraulic component....................................................................................... 29 Handling of connectors newly used for engines................................................................................................ 38 How to read electric wire code............................................................................................................... 41 Precautions when carrying out operation...................................................................................................... 44 Method of disassembling and connecting push-pull type coupler................................................................................ 47 Standard tightening torque table............................................................................................................. 50 Conversion table............................................................................................................................. 54 01 Specification..................................................................................................................................... 0 Specification and technical data................................................................................................................. 61 Specification dimension drawing.............................................................................................................. 62 Specifications............................................................................................................................... 63 Weight table................................................................................................................................. 66 Table of fuel, coolant and lubricants........................................................................................................ 68 10 Structure, function and maintenance standard...................................................................................................... 0 Engine and cooling system........................................................................................................................ 71 Cooling system............................................................................................................................... 72 Engine mount and transmission mount.......................................................................................................... 75 Power train, Part 1.............................................................................................................................. 77 Power train.................................................................................................................................. 78 Power train system diagram................................................................................................................... 79 Joint........................................................................................................................................ 81 Drive shaft.................................................................................................................................. 82 Power train piping diagram................................................................................................................... 83 Torque converter............................................................................................................................. 84 Torque converter regulator valve............................................................................................................. 102 Transmission................................................................................................................................. 104 Transfer..................................................................................................................................... 124 Transmission control valve................................................................................................................... 126 ECMV......................................................................................................................................... 130 Main relief valve and torque converter relief valve.......................................................................................... 137 Lubrication relief valve..................................................................................................................... 139 Power train, Part 2.............................................................................................................................. 141 Torque converter oil cooler.................................................................................................................. 142 Torque converter oil filter.................................................................................................................. 143 Center support............................................................................................................................... 146 Axle......................................................................................................................................... 148 Differential................................................................................................................................. 150 Limited slip differential.................................................................................................................... 159 Final drive.................................................................................................................................. 164 Steering system.................................................................................................................................. 169 Steering piping diagram...................................................................................................................... 170 Steering column.............................................................................................................................. 171 Steering control valve....................................................................................................................... 172 Steering valve............................................................................................................................... 183 Stop valve................................................................................................................................... 187 Joystick steering lever linkage (if equipped)................................................................................................ 188 Steering cylinder............................................................................................................................ 189 Emergency steering piping diagram (if equipped).............................................................................................. 192 Diverter valve............................................................................................................................... 193 Brake system..................................................................................................................................... 199 Brake piping diagram......................................................................................................................... 200 Brake valve.................................................................................................................................. 202 Slack adjuster............................................................................................................................... 207 Accumulator charge valve..................................................................................................................... 210 PPC relief valve............................................................................................................................. 214 Accumulator (for brake)...................................................................................................................... 216 Brake........................................................................................................................................ 218 Parking brake control........................................................................................................................ 221 Parking brake................................................................................................................................ 222 Parking brake solenoid valve................................................................................................................. 224 Emergency parking brake release valve........................................................................................................ 226 Undercarriage and frame.......................................................................................................................... 229 Axle mount................................................................................................................................... 230 Center hinge pin............................................................................................................................. 235 Hydraulic system, Part 1......................................................................................................................... 239 Hydraulic piping diagram..................................................................................................................... 240 Work equipment control lever linkage......................................................................................................... 242 Hydraulic tank............................................................................................................................... 243 Cooling fan motor............................................................................................................................ 245 Cooling fan pump............................................................................................................................. 252 Steering pump................................................................................................................................ 259 Work equipment hydraulic pump................................................................................................................ 270 Hydraulic system, Part 2......................................................................................................................... 291 Control valve................................................................................................................................ 292 CLSS......................................................................................................................................... 306 Each function and operation of each valve.................................................................................................... 311 Accumulator (for PPC circuit)................................................................................................................ 322 Work equipment electric lever................................................................................................................ 323 Work equipment................................................................................................................................... 327 Work equipment linkage....................................................................................................................... 328 Bucket....................................................................................................................................... 332 Bucket positioner and boom kick-out.......................................................................................................... 334 Work equipment lubrication................................................................................................................... 335 Cab and its attachments.......................................................................................................................... 339 ROPS cab..................................................................................................................................... 340 Air conditioner.............................................................................................................................. 342 Electrical system, Part 1........................................................................................................................ 351 Machine monitor system....................................................................................................................... 352 Machine monitor.............................................................................................................................. 360 Electrical system, Part 2........................................................................................................................ 415 Work equipment control system................................................................................................................ 416 Transmission controller system............................................................................................................... 450 Electrical system, Part 3........................................................................................................................ 483 Electric transmission control................................................................................................................ 484 Engine starting circuit...................................................................................................................... 488 Engine stopping circuit...................................................................................................................... 490 Preheating circuit........................................................................................................................... 491 Parking brake circuit........................................................................................................................ 493 Backup and stop lamp circuits................................................................................................................ 498 Small lamp and head lamp circuits............................................................................................................ 500 Working lamp circuit......................................................................................................................... 501 Horn circuit................................................................................................................................. 502 Wiper and window washer circuits............................................................................................................. 503 Sensor....................................................................................................................................... 506 KOMTRAX terminal system (if equipped)........................................................................................................ 524 20 Standard value table.............................................................................................................................. 0 Standard service value table..................................................................................................................... 527 Standard service value table for engine...................................................................................................... 528 Standard service value table for chassis..................................................................................................... 529 30 Testing and adjusting............................................................................................................................. 0 Testing and adjusting, Part 1.................................................................................................................... 539 Tools for testing, adjusting, and troubleshooting............................................................................................ 541 Measuring engine speed....................................................................................................................... 548 Measuring exhaust gas color.................................................................................................................. 550 Measuring exhaust temperature................................................................................................................ 552 Adjusting valve clearance.................................................................................................................... 554 Testing compression pressure................................................................................................................. 555 Measuring blow-by pressure................................................................................................................... 557 Measuring engine oil pressure................................................................................................................ 558 Measuring intake air (boost) pressure........................................................................................................ 559 Handling fuel system equipment............................................................................................................... 561 Releasing residual pressure in fuel system................................................................................................... 561 Testing fuel pressure........................................................................................................................ 562 Testing return rate and leakage.............................................................................................................. 563 Bleeding air from fuel circuit............................................................................................................... 566 Testing leakage in fuel system............................................................................................................... 568 Handling reduced cylinder mode operation..................................................................................................... 569 Handling no injection cranking operation..................................................................................................... 569 Handling controller voltage circuit.......................................................................................................... 570 Testing and adjusting alternator belt tension................................................................................................ 571 Testing and adjusting air conditioner compressor belt tension................................................................................ 572 Adjusting transmission speed sensor.......................................................................................................... 573 Measuring directional lever (Steering wheel specification)................................................................................... 575 Testing and adjusting power train oil pressure............................................................................................... 576 Flushing procedure for torque converter and transmission hydraulic circuit................................................................... 589 Method of moving machine when transmission valve is broken................................................................................... 592 Testing and adjusting, Part 2.................................................................................................................... 595 Testing and adjusting steering stop valve.................................................................................................... 597 Testing and adjusting steering wheel......................................................................................................... 599 Testing steering oil pressure................................................................................................................ 601 Bleeding air from steering cylinder circuit.................................................................................................. 604 Testing hydraulic drive fan.................................................................................................................. 605 Bleeding air from hydraulic drive fan circuit................................................................................................ 608 Measuring brake pedal........................................................................................................................ 610 Measuring brake performance.................................................................................................................. 611 Testing and adjusting accumulator charge pressure............................................................................................ 612 Testing and adjusting accumulator charge pressure............................................................................................ 617 Testing wheel brake oil pressure............................................................................................................. 619 Measuring wear of wheel brake disc........................................................................................................... 621 Bleeding air from brake circuit.............................................................................................................. 622 Releasing residual pressure in brake accumulator circuit..................................................................................... 624 Testing parking brake performance............................................................................................................ 625 Measuring parking brake oil pressure......................................................................................................... 626 Testing wear of parking brake disc........................................................................................................... 629 Method of releasing parking brake manually................................................................................................... 630 Measuring and adjusting work equipment control lever......................................................................................... 631 Testing and adjusting work equipment PPC oil pressure........................................................................................ 632 Measuring work equipment oil pressure........................................................................................................ 634 Bleeding air from work equipment circuit..................................................................................................... 640 Releasing residual pressure in work equipment circuit........................................................................................ 641 Method of moving machine when removing operator cab (when splittable cab is used)............................................................ 642 Testing and adjusting bucket positioner...................................................................................................... 643 Testing and adjusting lift arm position detecting lever...................................................................................... 645 Checking proximity switch operation indication lamp.......................................................................................... 646 Procedure for testing diodes................................................................................................................. 647 Preparations for work on troubleshooting of electrical system................................................................................ 648 Testing and adjusting, Part 3.................................................................................................................... 653 Starting KOMTRAX terminal operations......................................................................................................... 654 Indicator lamps of KOMTRAX terminal.......................................................................................................... 660 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller........ 663 Special functions of machine monitor (EMMS).................................................................................................. 665 Testing and adjusting, Part 4.................................................................................................................... 705 Special functions of machine monitor (EMMS).................................................................................................. 706 Pm clinic inspection table................................................................................................................... 744 40 Troubleshooting................................................................................................................................... 0 Failure codes list and fuse locations............................................................................................................ 749 Failure codes list........................................................................................................................... 750 Fuse locations............................................................................................................................... 761 General information on troubleshooting........................................................................................................... 765 Points to remember when troubleshooting...................................................................................................... 766 Sequence of events in troubleshooting........................................................................................................ 767 Testing before troubleshooting............................................................................................................... 768 Classification and procedures of troubleshooting............................................................................................. 769 Information contained in troubleshooting table............................................................................................... 770 Phenomena looking like troubles and troubleshooting Nos...................................................................................... 772 Connection table for connector pin numbers................................................................................................... 774 T- branch box and T- branch adapter table.................................................................................................... 810 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 815 Failure code [1500L0] (TORQFLOW transmission : Double meshing)............................................................................... 817 Failure code [15B0NX] (Transmission filter: Clogged)......................................................................................... 818 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................ 820 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................ 822 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................ 824 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................ 826 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...................................................... 828 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...................................................... 830 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...................................................... 832 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...................................................... 834 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...................................................... 836 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...................................................... 838 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...................................................... 840 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...................................................... 842 Failure code [2F00MA] (Parking brake: Malfunction)........................................................................................... 844 Failure code [2G42ZG] (Front accumulator: Low oil pressure).................................................................................. 846 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 849 Failure code [2G43ZG] (Rear accumulator: Low oil pressure)................................................................................... 852 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)........................................................................... 854 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................ 856 Failure code [AB00L6] (Alternator: Signal does not match engine running or stopped state).................................................... 858 Failure code [AB00MA] (Alternator: Malfunction).............................................................................................. 860 Failure code [B@BAZG] (Engine oil: Low oil pressure)......................................................................................... 862 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................ 864 Failure code [B@BCNS] (Coolant: Overheating)................................................................................................. 866 Failure code [B@BCZK] (Coolant: Low level)................................................................................................... 868 Failure code [B@C7NS] (Brake oil: Overheating)............................................................................................... 870 Failure code [b@CENS] (Torque converter oil: Overheating).................................................................................... 872 Failure code [B@CENS] (Torque converter oil: Overheating).................................................................................... 874 Failure code [B@GAZK] (Battery electrolyte: Low level)....................................................................................... 876 Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................................... 878 Failure code [CA111] (Abnormality in engine controller)...................................................................................... 880 Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................................. 883 Failure code [CA122] (Charge pressure sensor high error)..................................................................................... 884 Failure code [CA123] (Charge pressure sensor low error)...................................................................................... 886 Failure code [CA131] (Throttle sensor high error)............................................................................................ 887 Failure code [CA132] (Throttle sensor low error)............................................................................................. 889 Failure code [CA135] (Engine oil pressure sensor high error)................................................................................. 890 Failure code [CA141] (Engine oil pressure sensor low error).................................................................................. 892 Failure code [CA144] (Coolant temperature sensor high error)................................................................................. 894 Failure code [CA145] (Coolant temperature sensor low error).................................................................................. 896 Failure code [CA153] (Charge temperature sensor high error).................................................................................. 898 Failure code [CA154] (Charge temperature sensor low error)................................................................................... 900 Failure code [CA187] (Sensor power supply 2 voltage low error)............................................................................... 900 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................ 901 Failure code [CA222] (Atmospheric pressure sensor low error)................................................................................. 903 Failure code [CA227] (Sensor power supply 2 voltage high error).............................................................................. 904 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 907 Failure code [CA234] (Engine overspeed)...................................................................................................... 909 Failure code [CA238] (Ne speed sensor power supply error).................................................................................... 910 Failure code [CA263] (Fuel temperature sensor high error).................................................................................... 912 Failure code [CA265] (Fuel temperature sensor low error)..................................................................................... 914 Failure code [CA271] (PCV1 Short circuit).................................................................................................... 916 Failure code [CA272] (PCV1 Disconnection).................................................................................................... 918 Failure code [CA273] (PCV2 Short circuit).................................................................................................... 920 Failure code [CA274] (PCV2 Disconnection).................................................................................................... 922 Failure code [CA322] (Injector #1 open/short error).......................................................................................... 924 Failure code [CA323] (Injector #5 open/short error).......................................................................................... 926 Failure code [CA324] (Injector #3 open/short error).......................................................................................... 928 Failure code [CA325] (Injector #6 open/short error).......................................................................................... 930 Failure code [CA331] (Injector #2 open/short error).......................................................................................... 932 Failure code [CA332] (Injector #4 open/short error).......................................................................................... 934 Failure code [CA342] (Engine controller data inconsistency).................................................................................. 936 Failure code [CA351] (Injector drive circuit error).......................................................................................... 937 Failure code [CA352] (Sensor power supply 1 low error)....................................................................................... 940 Failure code [CA386] (Sensor power supply 1 high error)...................................................................................... 942 Failure code [CA431] (Idle validation switch error).......................................................................................... 944 Failure code [CA432] (Idle validation action error).......................................................................................... 946 Failure code [CA441] (Battery voltage low error)............................................................................................. 946 Failure code [CA442] (Battery voltage high error)............................................................................................ 947 Failure code [CA449] Common rail pressure high error 2....................................................................................... 947 Failure code [CA451] (Common rail pressure sensor high error)................................................................................ 948 Failure code [CA452] (Common rail pressure sensor low error)................................................................................. 950 Failure code [CA553] (Common rail pressure high error 1)..................................................................................... 951 Failure code [CA554] (Common rail pressure sensor in-range error)............................................................................ 952 Failure code [CA559] (Supply pump pressure very low error 1)................................................................................. 953 Failure code [CA689] (Engine Ne speed sensor error).......................................................................................... 958 Failure code [CA731] (Engine Bkup speed sensor phase error).................................................................................. 960 Failure code [CA757] (All continuous data lost error)........................................................................................ 960 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................ 962 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................ 964 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 967 Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................................ 970 Failure code [CA2186] (Throttle sensor power supply low error)............................................................................... 972 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................ 972 Failure code [CA2555] (Intake heater relay disconnection error).............................................................................. 973 Failure code [CA2556] (Intake heater relay short circuit error).............................................................................. 974 Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit).................................................................... 976 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)................................................................ 978 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)................................................................ 980 Failure code [D192KA] (ECSS solenoid: Disconnection)......................................................................................... 982 Failure code [D192KB] (ECSS solenoid: Short circuit)......................................................................................... 983 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line).................................................................. 984 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection).................................................................. 986 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit).................................................................. 988 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)........................................... 990 Failure code [D5ZHKA] (Terminal C signal: Disconnection)..................................................................................... 992 Failure code [D5ZHKB] (Terminal C signal: Short circuit)..................................................................................... 994 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit).................................................................... 996 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)............................................. 998 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)......................................................................1000 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...........................................................................1002 Failure code [DAF5KP] (Machine monitor: Low output voltage)..................................................................................1004 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)..............1006 Failure code [DAQ0KK] (Transmission controller: Low source voltage)..........................................................................1008 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...................................................................1010 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)............................................1012 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals).....................................1014 Troubleshooting by failure code (Display of code), Part 5........................................................................................1017 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)......1020 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)..................................................................1022 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)............1024 Failure code [DB90KK] Work equipment controller: Low source voltage (input)..................................................................1026 Failure code [DB90KT] (Work equipment controller: Abnormality in controller).................................................................1028 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...........................................1030 Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range).............................................1032 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)...................................1034 Failure code [DB9RKR] (CAN communication with work equipment controller: Defective communication (Abnormality in target component system)....1036 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................................................................1038 Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation)..................................................1040 Failure code [DD15LD] (■ switch (Panel switch 1): Switch is kept pressed for long time)......................................................1042 Failure code [DD16LD] (◇ switch (Panel switch 2): Switch is kept pressed for long time)......................................................1044 Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)......................................................1046 Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)......................................................1048 Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time)...............................1050 Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time)...............................1052 Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time).....................................................1054 Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time)..........................................1056 Failure code [DD1GLD] (Load meter mode selector switch (+/-): Switch is kept pressed for long time)..........................................1058 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time).............................................1060 Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree).......................................................................1062 Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)........................................................1064 Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit)......................................................1066 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)..........................................................1068 Troubleshooting by failure code (Display of code), Part 6........................................................................................1071 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)......................................1074 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).........................................................................1076 Failure code [DDK3KA] (Right FNR switch: Disconnection)......................................................................................1078 Failure code [DDK3KB] (Right FNR switch: Short circuit)......................................................................................1080 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)..........................................................................1082 Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)..........................................................................1084 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)......................................................1086 Failure code [DDK6KA] (FNR lever switch: Disconnection)......................................................................................1088 Failure code [DDK6KB] (FNR lever switch: Short circuit)......................................................................................1092 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)..................................................................1094 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)................................................1096 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...............................................................1098 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)....................................................................1100 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time).......................................................1102 Failure code [DF10KA] (Transmission shift lever switch: Disconnection).......................................................................1104 Failure code [DF10KB] (Transmission shift lever switch: Short circuit).......................................................................1108 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)...................................................................1110 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...................................................................1112 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)..........................................................1114 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection).....................................................................1116 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).........................................................1118 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...................................................1120 Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)...............................................................1122 Troubleshooting by failure code (Display of code), Part 7........................................................................................1125 Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)...............................................................1128 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)..................................................1130 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)....................................................1132 Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range)................................................................1134 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine)....................1136 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...............................................................1138 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)........................................1142 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).....................................................1145 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)................................................................1148 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).........................................1151 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).................................................................1154 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..........................................1157 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree).......................................................1160 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)..................................................................1163 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...........................................1166 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection).............................................1169 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)......................1171 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)...................................1173 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)..............................................1176 Troubleshooting by failure code (Display of code), Part 8........................................................................................1179 Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1182 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)......................................................1184 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...............................1186 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection).......................................................1188 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)................................1190 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)............................................1192 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).................................................................................1196 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range).....................................................................1198 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..........................................................1200 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)................................................................................1202 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection).................................................................1204 Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)........................................................1206 Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)................................................................1208 Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range)....................................................1210 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...................................................................1212 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)............................................................1214 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)............................................................1216 Failure code [DV00KB] (Alarm buzzer: Short circuit)..........................................................................................1218 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...........................................................................1220 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...........................................................................1221 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)....................................................1222 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...........................................................................1224 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...........................................................................1225 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)....................................................1226 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..............................................................................1228 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..............................................................................1230 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line).......................................................1232 Troubleshooting by failure code (Display of code), Part 9........................................................................................1235 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..............................................................................1237 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..............................................................................1238 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line).......................................................1240 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)..................................................................................1242 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)..................................................................................1244 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...........................................................1246 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)..................................................................1248 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)..................................................................1248 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)...........................................1249 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)..................................................................1250 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)..................................................................1252 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...........................................1254 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).................................................................1256 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).................................................................1258 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..........................................1260 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).................................................................1262 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).................................................................1264 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..........................................1266 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)....................................................................1268 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)....................................................................1270 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Short circuit with power supply line).............................................1272 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).................................................................................1274 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).................................................................................1275 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..........................................................1276 Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)..................................................................................1277 Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)..................................................................................1278 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)..................................................................................1279 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)..................................................................................1280 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...........................................................1282 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..............................................................................1284 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..............................................................................1286 Troubleshooting by failure code (Display of code), Part 10.......................................................................................1289 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line).......................................................1292 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..............................................................................1294 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..............................................................................1296 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line).......................................................1298 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..............................................................................1300 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..............................................................................1302 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line).......................................................1304 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)................................................................................1306 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)................................................................................1308 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).........................................................1310 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)................................................................................1312 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)................................................................................1314 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).........................................................1316 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..............................................................................1318 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..............................................................................1320 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line).......................................................1322 Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)....................................................................1324 Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)....................................................................1325 Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line).............................................1326 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)....................................................................1327 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)....................................................................1328 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line).............................................1329 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)..................................................................1330 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)..................................................................1332 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...........................................1334 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...................................................................1336 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...................................................................1338 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)............................................1340 Troubleshooting of electrical system (E-mode)....................................................................................................1343 Fuse locations...............................................................................................................................1345 Information in troubleshooting table.........................................................................................................1348 E-1 Engine does not start....................................................................................................................1349 E-2 Wiper does not operate...................................................................................................................1354 E-3 Windshield washer does not operate.......................................................................................................1358 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..........................................................1361 E-5 Working lamp does not light up or go off.................................................................................................1369 E-6 Turn signal lamp and hazard lamp do not light up or go off...............................................................................1374 E-7 Brake lamp does not light or it keeps lighting up........................................................................................1380 E-8 Backup lamp does not light or it keeps lighting up.......................................................................................1382 E-9 Backup buzzer does not sound or it keeps sounding........................................................................................1384 E-10 Horn does not sound or it keeps sounding................................................................................................1386 E-11 Alarm buzzer does not sound or it keeps sounding........................................................................................1389 E-12 Air conditioner does not operate or stop................................................................................................1391 E-13 KOMTRAX system does not work properly...................................................................................................1394 E-14 Electric priming pump does not operate or does not stop automatically...................................................................1396 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1399 Method of using troubleshooting chart........................................................................................................1401 Table of failure modes and causes............................................................................................................1404 H-1 Machine does not start...................................................................................................................1408 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...................................1410 H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)]....................................................1411 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted...................................1412 H-5 Shocks are large at the times of starting and shifting gear..............................................................................1414 H-6 Time lag is large at the times of starting and shifting gear.............................................................................1416 H-7 Torque converter oil temperature is high.................................................................................................1418 H-8 Steering does not turn...................................................................................................................1419 H-9 Steering does not turn [Machine with joystick steering (if equipped)]....................................................................1420 H-10 Steering response is low................................................................................................................1421 H-11 Turning response of steering is poor [machine with joystick steering (if equipped)].....................................................1422 H-12 Steering is heavy.......................................................................................................................1423 H-13 When machine turns, it shakes or makes large shocks.....................................................................................1424 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]......................................1425 H-15 Wheel brake does not work or does not work well.........................................................................................1426 H-16 Wheel brake is not released or it drags.................................................................................................1427 H-17 Parking brake does not work or does not work well.......................................................................................1428 H-18 Parking brake is not released or it drags (including emergency release system)..........................................................1429 H-19 Lift arm does not rise..................................................................................................................1430 H-20 Lift arm speed is low or rising force of lift arm is insufficient.......................................................................1431 H-21 When rising, lift arm comes to move slowly at specific height...........................................................................1432 H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)...............................................................................1432 H-23 Hydraulic drifts of lift arm occur often................................................................................................1432 H-24 Lift arm wobbles during operation.......................................................................................................1432 H-25 Bucket does not tilt back...............................................................................................................1433 H-26 Bucket speed is low or tilting back force is insufficient...............................................................................1434 H-27 Bucket comes to operate slowly in the midst of tilting-back.............................................................................1435 H-28 Bucket cylinder cannot hold down the bucket.............................................................................................1435 H-29 Hydraulic drifts of bucket occur often..................................................................................................1435 H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”).........................................................1435 H-31 During operation of machine, engine speed lowers remarkably or engine stalls............................................................1436 H-32 Large shocks are made when work equipment starts and stops..............................................................................1436 H-33 When work equipment circuit is relieved singly, other work equipment moves..............................................................1436 H-34 ECSS does not operate, and pitching and bouncing occur..................................................................................1437 Troubleshooting of engine (S-mode)...............................................................................................................1439 Method of using troubleshooting chart........................................................................................................1441 S-1 Engine does not start easily.............................................................................................................1444 S-2 Engine does not start....................................................................................................................1445 S-3 Engine does not pick up smoothly.........................................................................................................1448 S-4 Engine stops during operation............................................................................................................1449 S-5 Engine does not rotate smoothly (Engine hunts.)..........................................................................................1450 S-6 Engine lacks output (or lacks power).....................................................................................................1451 S-7 Exhaust smoke is black (Incomplete combustion)...........................................................................................1452 S-8 Oil is consumed much (or exhaust gas color is blue)......................................................................................1453 S-9 Engine oil becomes contaminated quickly..................................................................................................1454 S-10 Fuel consumption is excessive...........................................................................................................1455 S-11 Coolant contains oil (blows back or reduces)............................................................................................1456 S-12 Oil pressure drops......................................................................................................................1457 S-13 Oil level rises (Water, fuel in oil)....................................................................................................1458 S-14 Coolant temperature rises too high (Overheating)........................................................................................1459 S-15 Abnormal noise is made..................................................................................................................1460 S-16 Vibration is excessive..................................................................................................................1461 S-17 Air cannot be bled from fuel circuit....................................................................................................1462 50 Disassembly and assembly.......................................................................................................................... 0 General information on disassembly and assembly..................................................................................................1465 How to read this manual......................................................................................................................1466 Coating materials list.......................................................................................................................1468 Special tool list............................................................................................................................1471 Sketches of special tools....................................................................................................................1475 Engine and cooling system (SAA6D140E-5)..........................................................................................................1483 Removal and installation of engine assembly..................................................................................................1484 Removal and installation of radiator assembly................................................................................................1489 Removal and installation of air aftercooler..................................................................................................1491 Removal and installation of cooling fan and fan motor assembly...............................................................................1492 Removal and installation of radiator guard and cooling fan motor assembly....................................................................1494 Removal and installation of fuel tank assembly...............................................................................................1497 Removal and installation of hood.............................................................................................................1499 Engine (SAA6D140E-5).............................................................................................................................1503 Removal and installation of fuel supply pump assembly........................................................................................1504 Removal and installation of cylinder head assembly...........................................................................................1508 Removal and installation of fuel injector assembly...........................................................................................1519 Removal and installation of engine front seal................................................................................................1522 Removal and installation of engine rear seal.................................................................................................1526 Power train, Part 1..............................................................................................................................1533 Removal and installation of torque converter and transmission assembly.......................................................................1534 Disconnection and connection of power train unit.............................................................................................1540 Disassembly and assembly of input transfer assembly..........................................................................................1544 Disassembly and assembly of torque converter assembly (Lockup specification).................................................................1551 Disassembly and assembly of torque converter assembly (Lockup-less specification)............................................................1564 Power train, Part 2..............................................................................................................................1577 Disassembly and assembly of transmission assembly............................................................................................1578 Disassembly and assembly of transfer and parking brake assembly..............................................................................1608 Removal and installation of front axle assembly..............................................................................................1624 Removal and installation of rear axle assembly...............................................................................................1626 Power train, Part 3..............................................................................................................................1629 Removal and installation of front differential assembly......................................................................................1630 Disassembly and assembly of differential assembly (LSD specification)........................................................................1632 Disassembly and assembly of differential assembly (LSD-less specification)...................................................................1646 Disassembly and assembly of final drive assembly (Front and rear)............................................................................1657 Brake system.....................................................................................................................................1665 Removal and installation of brake assembly (Front and rear)..................................................................................1666 Disassembly and assembly of brake assembly (Front and rear)..................................................................................1668 Disassembly and assembly of slack adjuster assembly..........................................................................................1674 Disassembly and assembly of brake accumulator charge valve assembly..........................................................................1675 Undercarriage and frame..........................................................................................................................1677 Removal and installation of center hinge pin.................................................................................................1678 Removal and installation of large counterweight assembly.....................................................................................1685 Removal and installation of small counterweight assembly.....................................................................................1686 Hydraulic system.................................................................................................................................1689 Removal and installation of hydraulic tank assembly..........................................................................................1690 Removal and installation of cooling pump assembly............................................................................................1693 Removal and installation of fan pump assembly................................................................................................1694 Removal and installation of work equipment pump assembly.....................................................................................1695 Removal and installation of steering, torque converter charge and EPC pump assembly..........................................................1697 Removal and installation of work equipment valve assembly....................................................................................1698 Disassembly and assembly of work equipment control valve assembly............................................................................1701 Disassembly and assembly of steering cylinder assembly.......................................................................................1704 Disassembly and assembly of lift arm and bucket cylinder assembly............................................................................1708 Removal and installation of steering valve assembly..........................................................................................1714 Work equipment...................................................................................................................................1717 Removal and installation of work equipment assembly..........................................................................................1718 Cab and its attachments..........................................................................................................................1723 Removal and installation of operator's cab assembly (Separate cab and floor specification)...................................................1724 Removal and installation of operator's cab and floor frame assembly (Cab-floor unit specification)...........................................1729 Removal and installation of operator's cab glass (Stuck glass)...............................................................................1733 Disassembly and assembly of operator's seat assembly.........................................................................................1742 Electrical system................................................................................................................................1777 Removal and installation of engine controller assembly.......................................................................................1778 Removal and installation of transmission controller assembly.................................................................................1779 Removal and installation of work equipment controller assembly...............................................................................1780 Removal and installation of air conditioner unit assembly....................................................................................1781 90 Diagrams and drawings............................................................................................................................. 0 Hydraulic diagrams and drawings..................................................................................................................1787 Power train hydraulic circuit diagram........................................................................................................1789 Brake hydraulic circuit diagram..............................................................................................................1791 Work equipment hydraulic circuit diagram.....................................................................................................1793 Electrical diagrams and drawings.................................................................................................................1796 Air conditioner electrical circuit diagram...................................................................................................1798 Electrical circuit diagram (1/7).............................................................................................................1799 Electrical circuit diagram (2/7).............................................................................................................1800 Electrical circuit diagram (3/7).............................................................................................................1801 Electrical circuit diagram (4/7).............................................................................................................1802 Electrical circuit diagram (5/7).............................................................................................................1803 Electrical circuit diagram (6/7).............................................................................................................1804 Electrical circuit diagram (7/7).............................................................................................................1805 Connector arrangement diagram................................................................................................................1806
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