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Komatsu WA600-6 Wheel Loader Shop Manual 60001 and up – PDF DOWNLOAD
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Komatsu WA600-6 Wheel Loader Shop Manual
SERIAL NUMBERS : 60001 and up
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Description
Komatsu WA600-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA600-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA600-6
Serial Number: 60001 and up
Book Code: SEN00235-17
Language: English
Pages: 2007
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA600-6 Wheel Loader Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, 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. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains 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.
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.
30. 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. OTHERS (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 WA600-6 Wheel Loader Shop Manual
COVER .................................................................................................................................................................. 1 00 Index and foreword................................................................................................................................................... 0 Index............................................................................................................................................................... 3 Composition of shop manual...................................................................................................................................... 4 Table of contents............................................................................................................................................... 6 01 Specification........................................................................................................................................................ 0 Specification and technical data.................................................................................................................................... 63 Specification and technical data................................................................................................................................ 64 Specification dimension drawing............................................................................................................................. 64 Specifications.............................................................................................................................................. 65 Weight table................................................................................................................................................ 72 Table of fuel, coolant and lubricants....................................................................................................................... 74 10 Structure, function and maintenance standard......................................................................................................................... 0 Engine and cooling system........................................................................................................................................... 77 Engine and cooling system....................................................................................................................................... 78 Engine mount and transmission mount......................................................................................................................... 78 Damper...................................................................................................................................................... 80 Cooling system.............................................................................................................................................. 82 Cooling fan pump............................................................................................................................................ 85 Cooling fan motor........................................................................................................................................... 92 Power train, Part 1................................................................................................................................................. 99 Power train, Part 1............................................................................................................................................. 100 Power train................................................................................................................................................. 100 Power train system diagram.................................................................................................................................. 101 Torque converter and transmission piping diagram............................................................................................................ 102 Torque converter............................................................................................................................................ 103 Modulation clutch........................................................................................................................................... 112 Torque converter regulator valve............................................................................................................................ 113 Transmission................................................................................................................................................ 115 Transfer.................................................................................................................................................... 133 Transmission control valve.................................................................................................................................. 134 ECMV........................................................................................................................................................ 137 Main relief valve and torque converter relief valve......................................................................................................... 144 Lubrication relief valve.................................................................................................................................... 146 Power train, Part 2................................................................................................................................................. 148 Power train, Part 2............................................................................................................................................. 149 Torque converter oil cooler................................................................................................................................. 149 Torque converter oil filter................................................................................................................................. 150 Drive shaft................................................................................................................................................. 152 Center support.............................................................................................................................................. 155 Axle........................................................................................................................................................ 157 Differential................................................................................................................................................ 161 Limited slip differential................................................................................................................................... 170 Final drive................................................................................................................................................. 175 Steering system..................................................................................................................................................... 180 Steering system................................................................................................................................................. 183 Steering piping diagram..................................................................................................................................... 183 Steering column............................................................................................................................................. 185 Joystick steering lever linkage............................................................................................................................. 186 Joystick EPC valve.......................................................................................................................................... 187 Lock valve.................................................................................................................................................. 188 Steering valve.............................................................................................................................................. 189 Rotary valve................................................................................................................................................ 192 Steering control valve...................................................................................................................................... 195 Two-way restrictor valve.................................................................................................................................... 211 Stop valve.................................................................................................................................................. 212 Steering pump............................................................................................................................................... 213 Steering cylinder........................................................................................................................................... 227 Emergency steering piping diagram........................................................................................................................... 229 Diverter valve.............................................................................................................................................. 230 Emergency steering pump..................................................................................................................................... 238 Brake system........................................................................................................................................................ 240 Brake system.................................................................................................................................................... 241 Brake piping diagram........................................................................................................................................ 241 Brake....................................................................................................................................................... 243 Brake valve................................................................................................................................................. 247 Accumulator charge valve.................................................................................................................................... 255 EPC relief valve............................................................................................................................................ 261 Accumulator (for brake)..................................................................................................................................... 263 Slack adjuster.............................................................................................................................................. 265 Parking brake............................................................................................................................................... 269 Parking brake solenoid valve................................................................................................................................ 271 Emergency parking brake release valve....................................................................................................................... 273 Brake cooling pump.......................................................................................................................................... 274 Undercarriage and frame............................................................................................................................................. 276 Undercarriage and frame......................................................................................................................................... 277 Axle mount.................................................................................................................................................. 277 Center hinge pin............................................................................................................................................ 281 Hydraulic system, Part 1............................................................................................................................................ 285 Hydraulic system, Part 1........................................................................................................................................ 286 Hydraulic piping diagram.................................................................................................................................... 286 Work equipment control lever linkage........................................................................................................................ 288 Hydraulic tank.............................................................................................................................................. 289 Work equipment hydraulic pump............................................................................................................................... 291 Hydraulic system, Part 2............................................................................................................................................ 311 Hydraulic system, Part 2........................................................................................................................................ 312 Control valve............................................................................................................................................... 312 CLSS........................................................................................................................................................ 326 Each function and operation of each valve................................................................................................................... 331 Accumulator (for PPC circuit)............................................................................................................................... 350 Accumulator (for ECSS)...................................................................................................................................... 351 Triple pump................................................................................................................................................. 352 Work equipment...................................................................................................................................................... 355 Work equipment.................................................................................................................................................. 372 Work equipment linkage...................................................................................................................................... 372 Bucket...................................................................................................................................................... 376 Bucket positioner and boom kick-out......................................................................................................................... 380 Work equipment lubrication.................................................................................................................................. 381 Work equipment cylinder..................................................................................................................................... 383 Cab and its attachments............................................................................................................................................. 385 Cab and its attachments......................................................................................................................................... 386 ROPS cab.................................................................................................................................................... 386 Air conditioner............................................................................................................................................. 388 Electrical system, Part 1........................................................................................................................................... 393 Electrical system, Part 1....................................................................................................................................... 394 Machine monitor system...................................................................................................................................... 394 Machine monitor............................................................................................................................................. 400 Electrical system, Part 2........................................................................................................................................... 457 Electrical system, Part 2....................................................................................................................................... 458 Work equipment control system............................................................................................................................... 458 Transmission controller system.............................................................................................................................. 493 Electrical system, Part 3........................................................................................................................................... 526 Electrical system, Part 3....................................................................................................................................... 527 Electric transmission control............................................................................................................................... 527 Engine starting/stopping circuit............................................................................................................................ 529 Parking brake circuit....................................................................................................................................... 532 Sensor...................................................................................................................................................... 536 VHMS controller related..................................................................................................................................... 558 Work equipment electric lever............................................................................................................................... 562 20 Standard value table................................................................................................................................................. 0 Standard service value table........................................................................................................................................ 566 Standard service value table for engine......................................................................................................................... 567 Standard service value table for chassis........................................................................................................................ 568 30 Testing and adjusting................................................................................................................................................ 0 Testing and adjusting, Part 1....................................................................................................................................... 578 Tools for testing, adjusting, and troubleshooting............................................................................................................... 580 Sketches of special tools....................................................................................................................................... 586 Measuring engine speed.......................................................................................................................................... 587 Measuring exhaust gas color..................................................................................................................................... 589 Measuring exhaust temperature................................................................................................................................... 590 Adjusting valve clearance....................................................................................................................................... 592 Testing compression pressures................................................................................................................................... 594 Measuring blow-by pressure...................................................................................................................................... 597 Measuring engine oil pressure................................................................................................................................... 598 Testing EGR valve and bypass valve drive oil pressure........................................................................................................... 599 Measuring intake air (boost) pressure........................................................................................................................... 601 Handling fuel system equipment.................................................................................................................................. 602 Releasing residual pressure in fuel system...................................................................................................................... 602 Testing fuel pressures.......................................................................................................................................... 603 Testing return rate and leakage................................................................................................................................. 604 Bleeding air from fuel circuit.................................................................................................................................. 607 Testing leakage in fuel system.................................................................................................................................. 609 Handling reduced cylinder mode operation........................................................................................................................ 610 Handling no-injection cranking operation........................................................................................................................ 610 Handling controller voltage circuit............................................................................................................................. 611 Replacing and adjusting alternator and air conditioner compressor belt tension.................................................................................. 612 Adjusting modulation clutch speed sensor and speed sensor....................................................................................................... 613 Measuring directional lever and gear shift lever (Steering wheel specification)................................................................................. 615 Testing and adjusting power train oil pressure.................................................................................................................. 616 Flushing procedure for torque converter and transmission hydraulic circuit...................................................................................... 630 Method of moving machine when transmission valve is broken...................................................................................................... 632 Adjusting steering stop valve................................................................................................................................... 634 Testing and adjusting, Part 2....................................................................................................................................... 636 Measuring operating effort of AJSS lever (AJSS specification)................................................................................................... 638 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)....................................................................... 639 Testing and adjusting steering stopper bolt (AJSS specification)................................................................................................ 641 Testing and adjusting steering wheel (Steering wheel specification)............................................................................................. 643 Testing steering oil pressure................................................................................................................................... 645 Bleeding air from steering cylinder circuit..................................................................................................................... 649 Testing hydraulic drive fan..................................................................................................................................... 650 Bleeding air from hydraulic drivefan circuit.................................................................................................................... 653 Measuring brake pedal........................................................................................................................................... 655 Measuring brake performance..................................................................................................................................... 656 Testing and adjusting accumulator charge pressure............................................................................................................... 657 Testing wheel brake oil pressure................................................................................................................................ 659 Measuring wear of wheel brake disc.............................................................................................................................. 661 Bleeding air from wheel brake circuit........................................................................................................................... 662 Releasing residual pressure in brake accumulator circuit........................................................................................................ 663 Testing parking brake performance............................................................................................................................... 664 Measuring parking brake oilpressure............................................................................................................................. 665 Testing wear of parking brake disc.............................................................................................................................. 668 Method of releasing parking brake manually...................................................................................................................... 669 Measuring and adjusting worke quipment control lever............................................................................................................ 670 Measuring work equipment oil pressure........................................................................................................................... 671 Bleeding air from work equipment circuit........................................................................................................................ 676 Releasing residual pressure in work equipment circuit........................................................................................................... 677 Testing of accumulator nitrogen gas pressure and procedure for charging ECSS accumulator with nitrogen gas...................................................... 679 Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas..................................................... 685 Moving machine for removing operator cab........................................................................................................................ 690 Testing and adjusting bucket positioner......................................................................................................................... 692 Testing and adjusting lift arm position detecting lever......................................................................................................... 694 Checking proximity switch operation indication lamp............................................................................................................. 695 Preparations for work on troubleshooting of electric system..................................................................................................... 696 Procedure for testing diodes.................................................................................................................................... 700 Testing and adjusting, Part 3....................................................................................................................................... 702 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller........................... 703 Special functions of machine monitor (EMMS)..................................................................................................................... 706 Testing and adjusting, Part 4....................................................................................................................................... 782 VHMS controller initial setting procedure....................................................................................................................... 783 Precautions for replacing VHMS controller....................................................................................................................... 803 Pm-clinic inspection table...................................................................................................................................... 809 40 Troubleshooting...................................................................................................................................................... 0 Failure code table and fuse locations............................................................................................................................... 812 Failure codes list.............................................................................................................................................. 813 Fuse locations.................................................................................................................................................. 826 General information on troubleshooting.............................................................................................................................. 830 Points to remember when troubleshooting......................................................................................................................... 831 Sequence of events in troubleshooting........................................................................................................................... 832 Testing before troubleshooting.................................................................................................................................. 833 Classification and procedures of troubleshooting................................................................................................................ 834 Information contained in troubleshooting table.................................................................................................................. 835 Phenomena looking like troubles and troubleshooting Nos......................................................................................................... 837 Connection table for connector pin numbers...................................................................................................................... 839 T- branch box and T- branch adapter table....................................................................................................................... 874 Troubleshooting by failure code (Display of code), Part 1........................................................................................................... 878 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................................... 880 Failure code [15B0NX] (Transmission filter: Clogged)............................................................................................................ 881 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................................... 883 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................................... 885 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................................... 887 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................................... 889 Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON)................................................................................ 891 Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF)................................................................................ 893 Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON)................................................................................ 895 Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF)................................................................................ 897 Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON)................................................................................ 899 Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF)................................................................................ 901 Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON)................................................................................ 903 Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF)................................................................................ 905 Failure code [15W0NT] (Transmission modulation clutch: Overheating)............................................................................................. 907 Failure code [2F00MA] (Parking brake: Malfunction).............................................................................................................. 908 Failure code [2G42ZG] (Front accumulator: Low oil pressure)..................................................................................................... 911 Troubleshooting by failure code (Display of code), Part 2........................................................................................................... 914 Failure code [2G43ZG] (Rear accumulator: Low oil pressure)...................................................................................................... 917 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree).............................................................................................. 919 Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) (Engine: Overrun)...................................................................................... 921 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................................... 923 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)............................................................................. 925 Failure code [AB00MA] (Alternator: Malfunction)................................................................................................................. 927 Failure code [B@BAZG] (Engine oil pressure: Low error).......................................................................................................... 929 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................................... 930 Failure code [B@BCNS] (Engine coolant temperature: Overheating)................................................................................................. 931 Failure code [B@BCZK] (Coolant: Low level)...................................................................................................................... 933 Failure code [B@C7NS] (Brake oil: Overheating).................................................................................................................. 935 Failure code [b@CENS] (Torque converter oil: Overheating)....................................................................................................... 937 Failure code [B@CENS] (Torque converter oil: Overheating)....................................................................................................... 939 Failure code [B@GAZK] (Battery electrolyte: Low level).......................................................................................................... 941 Failure code [B@HANS] (Hydraulic oil: Overheating).............................................................................................................. 943 Failure code [CA111] (Abnormality in engine controller)......................................................................................................... 945 Failure code [CA115] (Engine Ne or Bkup speed sensor error)..................................................................................................... 947 Failure code [CA122] (Charge (boost) pressure sensor high error)................................................................................................ 949 Failure code [CA123] (Charge (boost) pressure sensor low error)................................................................................................. 951 Failure code [CA131] (Throttle sensor high error)............................................................................................................... 953 Failure code [CA132] (Throttle sensor low error)................................................................................................................ 955 Failure code [CA135] (Engine oil pressure sensor high error).................................................................................................... 957 Failure code [CA141] (Engine oil pressure sensor low error)..................................................................................................... 959 Failure code [CA144] (Coolant temperature sensor high error).................................................................................................... 961 Failure code [CA145] (Coolant temperature sensor low error)..................................................................................................... 963 Failure code [CA153] (Charge (boost) temperature sensor high error)............................................................................................. 965 Failure code [CA154] (Charge (boost) temperature sensor low error).............................................................................................. 967 Failure code [CA187] (Sensor power supply 2 low error).......................................................................................................... 968 Failure code [CA212] (Engine oil temperature sensor high error)................................................................................................. 969 Failure code [CA213] (Engine oil temperature sensor low error).................................................................................................. 971 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................................... 973 Failure code [CA222] (Atmospheric pressure sensor low error).................................................................................................... 975 Failure code [CA227] (Sensor power supply 2 high error)......................................................................................................... 977 Troubleshooting by failure code (Display of code), Part 3........................................................................................................... 980 Failure code [CA234] (Engine overspeed)......................................................................................................................... 982 Failure code [CA238] (Ne speed sensor power supply error)....................................................................................................... 983 Failure code [CA263] (Fuel temperature sensor high error)....................................................................................................... 985 Failure code [CA265] (Fuel temperature sensor low error)........................................................................................................ 987 Failure code [CA271] (PCV1 Short circuit)....................................................................................................................... 989 Failure code [CA272] (PCV1 Disconnection)....................................................................................................................... 991 Failure code [CA273] (PCV2 Short circuit)....................................................................................................................... 993 Failure code [CA274] (PCV2 Disconnection)....................................................................................................................... 995 Failure code [CA322] (Injector #1 open/short error)............................................................................................................. 997 Failure code [CA323] (Injector #5 open/short error)............................................................................................................. 999 Failure code [CA324] (Injector #3 open/short error).............................................................................................................1001 Failure code [CA325] (Injector #6 open/short error).............................................................................................................1003 Failure code [CA331] (Injector #2 open/short error).............................................................................................................1005 Failure code [CA332] (Injector #4 open/short error).............................................................................................................1007 Failure code [CA342] (Calibration code inconsistency)...........................................................................................................1009 Failure code [CA351] (Injectors drive circuit error)............................................................................................................1011 Failure code [CA352] (Sensor power supply 1 low error)..........................................................................................................1013 Failure code [CA386] (Sensor power supply 1 high error).........................................................................................................1015 Failure code [CA431] (Idle validation switch error).............................................................................................................1017 Failure code [CA432] (Idle validation action error).............................................................................................................1020 Failure code [CA441] (Battery voltage low error)................................................................................................................1020 Failure code [CA442] (Battery voltage high error)...............................................................................................................1021 Failure code [CA449] Common rail pressure high error 2..........................................................................................................1021 Failure code [CA451] (Common rail pressure sensor high error)...................................................................................................1023 Failure code [CA452] (Common rail pressure sensor low error)....................................................................................................1025 Failure code [CA553] (Common rail pressure high error 1)........................................................................................................1026 Failure code [CA559] (Supply pump pressure very low error 1)....................................................................................................1027 Failure code [CA689] (Engine Ne speed sensor error).............................................................................................................1031 Failure code [CA731] (Engine Bkup speed sensor phase error).....................................................................................................1033 Failure code [CA757] (All continuous data lost error)...........................................................................................................1034 Failure code [CA778] (Engine Bkup speed sensor error)...........................................................................................................1035 Failure code [CA1228] (EGR valve servo error 1).................................................................................................................1037 Failure code [CA1625] (EGR valve servo error 2).................................................................................................................1038 Failure code [CA1626] (Bypass valve solenoid current high error)................................................................................................1039 Failure code [CA1627] (Bypass valve solenoid current low error).................................................................................................1041 Failure code [CA1628] (Bypass valve servo error 1)..............................................................................................................1042 Failure code [CA1629] (Bypass valve servo error 2)..............................................................................................................1043 Failure code [CA1631] (Bypass valve lift sensor high error).....................................................................................................1045 Failure code [CA1632] (Bypass valve lift sensor low error)......................................................................................................1047 Failure code [CA1633] (KOMNET datalink timeout error)...........................................................................................................1048 Troubleshooting by failure code (Display of code), Part 4...........................................................................................................1050 Failure code [CA2185] (Throttle sensor supply voltage high error)...............................................................................................1053 Failure code [CA2186] (Throttle sensor power supply low error)..................................................................................................1055 Failure code [CA2249] (Supply pump pressure very low error 2)...................................................................................................1056 Failure code [CA2271] (EGR valve lift sensor high error)........................................................................................................1057 Failure code [CA2272] (EGR valve lift sensor low error).........................................................................................................1059 Failure code [CA2351] (EGR valve solenoid operation short circuit)..............................................................................................1061 Failure code [CA2352] (EGR valve solenoid operation disconnect).................................................................................................1063 Failure code [CA2555] (Intake heater relay disconnection error).................................................................................................1064 Failure code [CA2556] (Intake heater relay short circuit error).................................................................................................1065 Failure code [D191KA] (AJSS neutral safety relay: Disconnection)................................................................................................1067 Failure code [D191KB] (AJSS neutral safety relay: Short circuit)................................................................................................1069 Failure code [D192KA] (ECSS solenoid: Disconnection)............................................................................................................1071 Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................................................................1072 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line).....................................................................................1073 Failure code [D198KA] (Transmission oil pressure bypass solenoid: Disconnection)................................................................................1074 Failure code [D198KB] (Transmission oil pressure bypass solenoid: Short circuit)................................................................................1075 Failure code [D198KY] (Transmission oil pressure bypass solenoid: Short circuit with power supply line).........................................................1076 Failure code [D5ZHKA] (Terminal C signal: Disconnection)........................................................................................................1077 Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................................................................1079 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit).......................................................................................1081 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)................................................................1083 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).........................................................................................1085 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).............................................................................................1087 Failure code [DAF5KP] (Machine monitor: Low output voltage).....................................................................................................1089 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))................................1091 Failure code [DAQ0KK] (Transmission controller: Low source voltage).............................................................................................1093 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)......................................................................................1095 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))..............................................................1097 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)........................................................1099 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))........................1101 Failure code [DAQRMA] (Transmission controller CAN communication: Malfunction)..................................................................................1103 Troubleshooting by failure code (Display of code), Part 5...........................................................................................................1106 Failure code [DB2RKR] CAN communication from engine controller: Defective communication (Abnormality in target component system)................................1109 Failure code [DB90KK] Work equipment controller: Low source voltage (input).....................................................................................1111 Failure code [DB90KT] (Work equipment controller: Abnormality in controller)....................................................................................1113 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)..............................................................1115 Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range)................................................................1117 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)......................................................1119 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)........................1121 Failure code [DB9RMA] (Work equipment controller CAN communication: Malfunction)................................................................................1123 Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation).....................................................................1125 Failure code [DBB0KK] (or VHMS_LED display: “n9” → “01”) VHMS controller: Low source voltage (input)............................................................1127 Failure code [DBB0KQ] (or VHMS_LED display: “nF” → “11”) (VHMS controller: Disagreement of model selection signals).............................................1129 Failure code [DBB3KK] (or VHMS_LED display: “n9” → “05”) VHMS controller battery power supply: Low source voltage (input).......................................1131 Failure code [DBB5KP] (or VHMS_LED display: “n9” → “04”) (VHMS controller 5 V power supply output: Low output voltage)..........................................1133 Failure code [DBB6KP] (or VHMS_LED display: “n9” → “02”) (VHMS controller 24 V power supply output: Low output voltage).........................................1135 Failure code [DBB7KP] (or VHMS_LED display: “n9” → “03”) (VHMS controller 12 V power supply output: Low output voltage).........................................1137 Failure code [DBBQKR] (or VHMS_LED display: “n8” → “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system)....1139 Failure code [DD15LD] (■ switch (Panel switch 1): Switch is kept pressed for long time).........................................................................1141 Failure code [DD16LD] (◇ switch (Panel switch 2): Switch is kept pressed for long time).........................................................................1143 Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time).........................................................................1145 Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time).........................................................................1147 Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time)..................................................1149 Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time)..................................................1151 Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time)........................................................................1153 Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time).............................................................1155 Failure code [DD1GLD] (Load meter mode selector switch (+/-): Switch is kept pressed for long time).............................................................1157 Troubleshooting by failure code (Display of code), Part 6...........................................................................................................1160 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)................................................................1163 Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree...........................................................................................1165 Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)...........................................................................1167 Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit).........................................................................1169 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).............................................................................1171 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time).........................................................1175 Failure code [DDDBKA] (Traction adjustment dial: Disconnection).................................................................................................1177 Failure code [DDDBKB] (Traction adjustment dial: Short circuit).................................................................................................1179 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)............................................................................................1181 Failure code [DDK4KA] (AJSS FNR switch: Disconnection)..........................................................................................................1183 Failure code [DDK4KB] (AJSS FNR switch: Short circuit)..........................................................................................................1185 Failure code [DDK5L4] (AJSS shift-up/down switch: ON/OFF signals disagree)......................................................................................1187 Failure code [DDK6KA] (FNR lever switch: Disconnection).........................................................................................................1191 Failure code [DDK6KB] (FNR lever switch: Short circuit).........................................................................................................1193 Failure code [DDP5KA] (Lock detection pressure switch of steering lock lever: Disconnection)....................................................................1195 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).....................................................................................1197 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)..................................................................................1199 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).......................................................................................1201 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)..........................................................................1203 Failure code [DF10KA] (Transmission shift lever switch: Disconnection)..........................................................................................1205 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)..........................................................................................1207 Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) (Atmospheric temperature sensor: Out of input signal range)............................................1209 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)......................................................................................1211 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)......................................................................................1213 Troubleshooting by failure code (Display of code), Part 7...........................................................................................................1216 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).............................................................................1219 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)........................................................................................1221 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)............................................................................1223 Failure code [DGT1KA] (Torque converter oil temperature sensor: Disconnection)..................................................................................1225 Failure code [DGT1KB] (Torque converter oil temperature sensor: Short circuit)..................................................................................1226 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)......................................................................1227 Failure code [DGT4KA] (or VHMS_LED display: “n3” → “12”) (Exhaust gas temperature sensor (F): Disconnection)....................................................1229 Failure code [DGT4KB] (or VHMS_LED display: “n3” → “11”) (Exhaust gas temperature sensor (F): Short circuit)....................................................1231 Failure code [DGT5KA] (or VHMS_LED display: “n3” → “22”) (Exhaust gas temperature sensor (R): Disconnection)....................................................1233 Failure code [DGT5KB] (or VHMS_LED display: “n3” → “21”) (Exhaust gas temperature sensor (R): Short circuit)....................................................1235 Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)..................................................................................1237 Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)..................................................................................1239 Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) (Blow-by pressure sensor: Short circuit)...............................................................1241 Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) (Blow-by pressure sensor: Short circuit with power supply line)........................................1243 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range).....................................................................1245 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).......................................................................1247 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating state of engine)....................................................1249 Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) (Steering oil pressure sensor: Out of input signal range)..............................................1251 Failure code [DHTBKA] (Modulation clutch oil pressure sensor: Disconnection)....................................................................................1253 Failure code [DHTBKB] (Modulation clutch oil pressure sensor: Short circuit)....................................................................................1255 Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) (Front brake oil pressure sensor (F): Out of input signal range).......................................1257 Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) (Rear brake oil pressure sensor (R): Out of input signal range)........................................1259 Failure code [DK30KA] (AJSS lever angle sensor: Disconnection)..................................................................................................1261 Failure code [DK30KY] (AJSS lever angle sensor: Short circuit with power supply line)...........................................................................1263 Troubleshooting by failure code (Display of code), Part 8...........................................................................................................1266 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)..................................................................................1268 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...........................................................1271 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)........................................................................1275 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)...................................................................................1278 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)............................................................1281 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)....................................................................................1284 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line).............................................................1287 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)..........................................................................1289 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection).....................................................................................1292 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)..............................................................1295 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)................................................................1297 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line).........................................1299 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)......................................................1301 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection).................................................................1305 Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line).......................................................1307 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)....................................................................................................1309 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)........................................................................................1311 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line).............................................................................1313 Failure code [DKA0L0] (Lift arm angle sensor: Improper position)................................................................................................1315 Troubleshooting by failure code (Display of code), Part 9...........................................................................................................1318 Failure code [DKD0KA] (Frame angle sensor: Disconnection).......................................................................................................1321 Failure code [DKD0KY] (Frame angle sensor: Short circuit with power supply line)................................................................................1323 Failure code [DKD0KZ] (AJSS lever and frame angle sensor: Disconnection or short circuit).......................................................................1325 Failure code [DLFAKA] (Modulation clutch output shaft speed sensor: Disconnection)..............................................................................1327 Failure code [DLFALC] (Modulation clutch output shaft speed sensor: Speed signals disagree).....................................................................1329 Failure code [DLT3KA] (Transmission output shaft speed sensor (2): Disconnection)...............................................................................1331 Failure code [DLT3LC] (Transmission output shaft speed sensor (2): Speed signals disagree)......................................................................1333 Failure code [DLT4KB] (Transmission output shaft speed sensor (1): Short circuit)...............................................................................1335 Failure code [DLT4KX] (Transmission output shaft speed sensor (1): Out of input signal range)...................................................................1337 Failure code [DUM1KB] (Remote positioner raise indicator lamp: Short circuit)...................................................................................1339 Failure code [DUM2KB] (Remote positioner lower indicator lamp: Short circuit)...................................................................................1341 Failure code [DV00KB] (Alarm buzzer: Short circuit).............................................................................................................1343 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)..............................................................................................1345 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)..............................................................................................1346 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line).......................................................................1347 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)..............................................................................................1349 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)..............................................................................................1350 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line).......................................................................1351 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection).................................................................................................1353 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit).................................................................................................1354 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)..........................................................................1355 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection).................................................................................................1357 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit).................................................................................................1358 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)..........................................................................1359 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).....................................................................................................1361 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).....................................................................................................1363 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)..............................................................................1365 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection).....................................................................................1367 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit).....................................................................................1367 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)..............................................................1368 Troubleshooting by failure code (Display of code), Part 10..........................................................................................................1370 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection).....................................................................................1373 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit).....................................................................................1375 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)..............................................................1377 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)....................................................................................1379 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)....................................................................................1381 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line).............................................................1383 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)....................................................................................1385 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)....................................................................................1387 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line).............................................................1389 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection).......................................................................................1391 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit).......................................................................................1393 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source).......................................................................1395 Failure code [DWNFKA] (Modulation clutch cut-off release solenoid: Disconnection)...............................................................................1397 Failure code [DWNFKB] (Modulation clutch cut-off release solenoid: Short circuit)...............................................................................1399 Failure code [DWNFKY] (Modulation clutch cut-off release solenoid: Short circuit with power source line)........................................................1401 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)....................................................................................................1403 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)....................................................................................................1404 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line).............................................................................1405 Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection).....................................................................................................1406 Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit).....................................................................................................1407 Failure code [DXF0KA] (AJSS EPC solenoid: Disconnection)........................................................................................................1408 Failure code [DXF0KB] (AJSS EPC solenoid: Short circuit)........................................................................................................1409 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).....................................................................................................1410 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).....................................................................................................1411 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)..............................................................................1413 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection).................................................................................................1415 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit).................................................................................................1417 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1419 Troubleshooting by failure code (Display of code), Part 11..........................................................................................................1422 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection).................................................................................................1425 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit).................................................................................................1427 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1429 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection).................................................................................................1431 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).................................................................................................1433 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1435 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...................................................................................................1437 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...................................................................................................1439 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)............................................................................1441 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...................................................................................................1443 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...................................................................................................1445 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)............................................................................1447 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection).................................................................................................1449 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit).................................................................................................1451 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1453 Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection).......................................................................................1455 Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit).......................................................................................1456 Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)................................................................1457 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection).......................................................................................1458 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit).......................................................................................1459 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)................................................................1460 Failure code [DXHPKA] (Modulation clutch solenoid: Disconnection)...............................................................................................1461 Failure code [DXHPKB] (Modulation clutch solenoid: Short circuit)...............................................................................................1463 Failure code [DXHPKY] (Modulation clutch solenoid: Short circuit with power source line)........................................................................1465 Failure code [DXHPMA] (Modulation clutch solenoid: Malfunction).................................................................................................1467 Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) (Blow-by pressure: High error).........................................................................1469 Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) (Exhaust gas temperature (F): Abnormal heat)...........................................................1471 Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) (Exhaust gas temperature (F): Overheat)................................................................1473 Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) (Exhaust gas temperature (R): abnormal heat)...........................................................1475 Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) (Exhaust gas temperature (R): Overheat).................................................................1477 Troubleshooting of electrical system (E-mode).......................................................................................................................1480 Before carrying out troubleshooting of electrical system........................................................................................................1483 Information in troubleshooting table............................................................................................................................1486 E-1 Engine does not start.......................................................................................................................................1487 E-2 Wiper does not operate......................................................................................................................................1497 E-3 Windshield washer does not operate..........................................................................................................................1505 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off.............................................................................1511 E-5 Working lamp does not light up or go off....................................................................................................................1527 E-6 Step lamp does not light up or go off.......................................................................................................................1535 E-7 Turn signal lamp and hazard lamp do not light up or go off..................................................................................................1537 E-8 Brake lamp does not light or it keeps lighting up...........................................................................................................1547 E-9 Backup lamp does not light or it keeps lighting up..........................................................................................................1551 E-10 Backup buzzer does not sound or it keeps sounding..........................................................................................................1555 E-11 Horn does not sound or it keeps sounding...................................................................................................................1559 E-12 Alarm buzzer does not sound or it keeps sounding...........................................................................................................1563 E-13 Air conditioner does not operate or stop...................................................................................................................1565 E-14 Electric priming pump does not operate or does not stop automatically......................................................................................1567 Troubleshooting of hydraulic and mechanical system (H-mode).........................................................................................................1570 Method of using troubleshooting chart...........................................................................................................................1573 Table of failure modes and causes...............................................................................................................................1575 H-1 Machine does not start......................................................................................................................................1579 H-2 Torque converter lockup is not switched (engine stalls).....................................................................................................1581 H-3 Torque converter lockup is not turned on....................................................................................................................1582 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted......................................................1583 H-5 Shocks are large at the times of starting and shifting gear.................................................................................................1585 H-6 Time lag is large at the times of starting and shifting gear................................................................................................1587 H-7 Torque converter oil temperature is high....................................................................................................................1589 H-8 Steering does not turn [machine with steering wheel]........................................................................................................1590 H-9 Steering does not turn [machine with AJSS]..................................................................................................................1591 H-10 Turning, response of steering is poor [machine with steering wheel]........................................................................................1592 H-11 Turning, response of AJSS is poor [machine with AJSS]......................................................................................................1593 H-12 Steering is heavy [machine with steering wheel]............................................................................................................1594 H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel]..........................................................................1595 H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]....................................................................................1596 H-15 Wheel brake does not work or does not work well............................................................................................................1597 H-16 Wheel brake is not released or it drags....................................................................................................................1598 H-17 Parking brake does not work or does not work well..........................................................................................................1599 H-18 Parking brake is not released or it drags (including emergency release system).............................................................................1600 H-19 Lift arm does not rise.....................................................................................................................................1601 H-20 Lift arm speed is low or rising force of lift arm is insuff................................................................................................1602 H-21 When rising, lift arm comes to move slowly at specific height..............................................................................................1603 H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)..................................................................................................1603 H-23 Hydraulic drifts of lift arm occur often...................................................................................................................1603 H-24 Lift arm wobbles during operation..........................................................................................................................1603 H-25 Bucket does not tilt back..................................................................................................................................1604 H-26 Bucket speed is low or tilting back force is insufficient..................................................................................................1605 H-27 Bucket comes to operate slowly in the midst of tilting-back................................................................................................1606 H-28 Bucket cylinder cannot hold down bucket....................................................................................................................1606 H-29 Hydraulic drifts of bucket occur often.....................................................................................................................1606 H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)............................................................................1606 H-31 During operation of machine, engine speed lowers remarkably or engine stalls...............................................................................1607 H-32 Large shocks are made when work equipment starts and stops.................................................................................................1607 H-33 When work equipment circuit is relieved singly, other work equipment moves.................................................................................1607 H-34 ECSS does not operate, and pitching bouncing occurs........................................................................................................1608 H-35 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats)...................................................................1609 Troubleshooting of engine (S-mode)..................................................................................................................................1612 Method of using troubleshooting chart...........................................................................................................................1614 S-1 Engine does not start easily................................................................................................................................1617 S-2 Engine does not start.......................................................................................................................................1619 S-3 Engine does not pick up smoothly............................................................................................................................1623 S-4 Engine stops during operation...............................................................................................................................1624 S-5 Engine does not rotate smoothly (Hunting occurs)............................................................................................................1625 S-6 Engine lacks output (or lacks power)........................................................................................................................1626 S-7 Exhaust smoke is black (Incomplete combustion)..............................................................................................................1627 S-8 Oil is consumed much (or exhaust gas color is blue).........................................................................................................1629 S-9 Engine oil becomes contaminated quickly.....................................................................................................................1630 S-10 Fuel consumption is excessive..............................................................................................................................1631 S-11 Coolant contains oil (blows back or reduces)...............................................................................................................1632 S-12 Oil pressure drops.........................................................................................................................................1633 S-13 Oil level rises (Water, fuel in oil).......................................................................................................................1635 S-14 Coolant temperature rises too high (Overheating)...........................................................................................................1637 S-15 Abnormal noise is made.....................................................................................................................................1638 S-16 Vibration is excessive.....................................................................................................................................1639 S-17 Air cannot be bled from fuel circuit.......................................................................................................................1641 50 Disassembly and assembly............................................................................................................................................. 0 General information on disassembly and assembly.....................................................................................................................1644 How to read this manual.........................................................................................................................................1645 Coating materials list..........................................................................................................................................1647 Special tools list..............................................................................................................................................1650 Sketches of special tools.......................................................................................................................................1654 Engine and cooling system, Part 1...................................................................................................................................1664 Removal and installation of engine assembly.....................................................................................................................1665 Removal and installation of radiator assembly...................................................................................................................1669 Removal and installation of air aftercooler.....................................................................................................................1674 Removal and installation of cooling fan and fan motor assembly..................................................................................................1675 Removal and installation of damper assembly.....................................................................................................................1677 Disassembly and assembly of damper assembly.....................................................................................................................1679 Removal and installation of fuel tank assembly..................................................................................................................1683 Removal and installation of engine hood assembly................................................................................................................1685 Removal and installation of bulkhead assembly...................................................................................................................1687 Engine and cooling system, Part 2...................................................................................................................................1692 Removal and installation of fuel supply pump assembly...........................................................................................................1693 Removal and installation of cylinder head assembly..............................................................................................................1699 Removal and installation of fuel injector assembly..............................................................................................................1715 Removal and installation of engine front seal...................................................................................................................1719 Removal and installation of engine rear seal....................................................................................................................1722 Power train, Part 1.................................................................................................................................................1728 Removal and installation of parking brake assembly..............................................................................................................1729 Removal and installation of torque converter and transmission assembly..........................................................................................1731 Power train, Part 2.................................................................................................................................................1738 Disassembly and assembly of torque converter assembly...........................................................................................................1739 Disassembly and assembly of transmission assembly...............................................................................................................1766 Disassembly and assembly of transfer assembly...................................................................................................................1793 Disassembly and assembly of parking brake assembly..............................................................................................................1808 Power train, Part 3.................................................................................................................................................1816 Removal and installation of front axle assembly.................................................................................................................1817 Removal and installation of rear axle assembly..................................................................................................................1819 Removal and installation of center support assembly.............................................................................................................1821 Disassembly and assembly of center support assembly.............................................................................................................1823 Disassembly and assembly of differential assembly...............................................................................................................1827 Power train, Part 4.................................................................................................................................................1842 Removal and installation of final drive carrier assembly........................................................................................................1843 Disassembly and assembly of final drive carrier assembly........................................................................................................1845 Removal and installation of front final drive brake assembly....................................................................................................1846 Disassembly and assembly of final drive assembly................................................................................................................1848 Brake system........................................................................................................................................................1852 Disassembly and assembly of brake assembly......................................................................................................................1853 Removal and installation of brake valve assembly................................................................................................................1861 Disassembly and assembly of accumulator and charge valve assembly...............................................................................................1862 Disassembly and assembly of slack adjustor assembly.............................................................................................................1865 Undercarriage and frame.............................................................................................................................................1868 Removal and installation of center hinge pin....................................................................................................................1869 Removal and installation of counterweight assembly..............................................................................................................1876 Hydraulic system....................................................................................................................................................1878 Removal and installation of hydraulic tank assembly.............................................................................................................1879 Removal and installation of hydraulic pump assembly.............................................................................................................1881 Removal and installation of control valve assembly..............................................................................................................1885 Disassembly and assembly of control valve assembly..............................................................................................................1887 Removal and installation of steering valve assembly.............................................................................................................1892 Removal and installation of ECSS accumulator assembly...........................................................................................................1893 Disassembly and assembly of hydraulic cylinder assembly.........................................................................................................1894 Work equipment......................................................................................................................................................1900 Removal and installation of work equipment assembly.............................................................................................................1901 Cab and its attachments.............................................................................................................................................1908 Removal and installation of operator's cab assembly.............................................................................................................1909 Removal and installation of operator's cab glass (stuck glass)..................................................................................................1913 Removal and installation of floor frame assembly................................................................................................................1921 Disassembly and assembly of operator’s seat assembly............................................................................................................1924 Removal and installation of air conditioner unit assembly.......................................................................................................1957 Electrical system...................................................................................................................................................1962 Removal and installation of engine controller assembly..........................................................................................................1963 Removal and installation of transmission controller assembly....................................................................................................1965 Removal and installation of loader controller assembly..........................................................................................................1966 Removal and installation of VHMS controller assembly............................................................................................................1967 Removal and installation of monitor assembly....................................................................................................................1968 90 Diagrams and drawings................................................................................................................................................ 0 Hydraulic diagrams and drawings.....................................................................................................................................1972 Hydraulic diagrams and drawings.................................................................................................................................1973 Power train hydraulic circuit diagram.......................................................................................................................1973 Brake hydraulic circuit diagram.............................................................................................................................1974 Work equipment hydraulic circuit diagram....................................................................................................................1976 Steering wheel specification............................................................................................................................1976 Steering wheel specification with ECSS..................................................................................................................1977 AJSS (Advanced Joystick Steering System) specification..................................................................................................1978 AJSS (Advanced Joystick Steering System) specification with ECSS........................................................................................1979 Electrical diagrams and drawings....................................................................................................................................1982 Air conditioner electrical circuit diagram......................................................................................................................1984 Steering wheel specification....................................................................................................................................1985 Electrical circuit diagram (1/10)...........................................................................................................................1985 Electrical circuit diagram (2/10)...........................................................................................................................1986 Electrical circuit diagram (3/10)...........................................................................................................................1987 Electrical circuit diagram (4/10)...........................................................................................................................1988 Electrical circuit diagram (5/10)...........................................................................................................................1989 Electrical circuit diagram (6/10)...........................................................................................................................1990 Electrical circuit diagram (7/10)...........................................................................................................................1991 Electrical circuit diagram (8/10)...........................................................................................................................1992 Electrical circuit diagram (9/10)...........................................................................................................................1993 Electrical circuit diagram (10/10)..........................................................................................................................1994 AJSS (Advanced Joystick Steering System) specification..........................................................................................................1995 Electrical circuit diagram (1/10)...........................................................................................................................1995 Electrical circuit diagram (2/10)...........................................................................................................................1996 Electrical circuit diagram (3/10)...........................................................................................................................1997 Electrical circuit diagram (4/10)...........................................................................................................................1998 Electrical circuit diagram (5/10)...........................................................................................................................1999 Electrical circuit diagram (6/10)...........................................................................................................................2000 Electrical circuit diagram (7/10)...........................................................................................................................2001 Electrical circuit diagram (8/10)...........................................................................................................................2002 Electrical circuit diagram (9/10)...........................................................................................................................2003 Electrical circuit diagram (10/10)..........................................................................................................................2004 Connector arrangement diagram...................................................................................................................................2005
KOMATSU WA600-6 WHEEL LOADER SHOP MANUAL 60001 AND UP – PDF DOWNLOAD:
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