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KOMATSU WA600-6R WHEEL LOADER SHOP MANUAL SEN02211-21 – PDF DOWNLOAD
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Description
KOMATSU WA600-6R WHEEL LOADER SHOP MANUAL SEN02211-21 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA600-6R WHEEL LOADER SHOP MANUAL SEN02211-21 – PDF DOWNLOAD
Language : English
Pages : 2034
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA600-6R WHEEL LOADER SHOP MANUAL SEN02211-21 – PDF DOWNLOAD
Cover..................................................................................................................................................................................... 1 00 INDEX AND FOREWORD................................................................................................................................................................. 3 INDEX............................................................................................................................................................................. 3 Composition of shop manual.................................................................................................................................................... 4 Table of contents............................................................................................................................................................. 6 FOREWORD AND GENERAL INFORMATION.................................................................................................................................................. 21 SAFETY NOTICE................................................................................................................................................................. 22 HOW TO READ THE SHOP MANUAL................................................................................................................................................... 27 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................................................................. 29 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT........................................................................................................................ 31 HANDLING OF CONNECTORS NEWLY USED FOR ENGINES................................................................................................................................. 40 HOW TO READ ELECTRIC WIRE CODE................................................................................................................................................ 43 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................................................... 46 METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER................................................................................................................. 49 STANDARD TIGHTENING TORQUE TABLE.............................................................................................................................................. 52 CONVERSION TABLE.............................................................................................................................................................. 56 01 SPECIFICATION...................................................................................................................................................................... 63 SPECIFICATION AND TECHNICAL DATA.................................................................................................................................................. 63 SPECIFICATION DIMENSION DRAWING............................................................................................................................................... 64 SPECIFICATIONS................................................................................................................................................................ 65 WEIGHT TABLE.................................................................................................................................................................. 72 TABLE OF FUEL, COOLANT AND LUBRICANTS......................................................................................................................................... 74 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....................................................................................................................................... 77 ENGINE AND COOLING SYSTEM......................................................................................................................................................... 77 ENGINE MOUNT AND TRANSMISSION MOUNT........................................................................................................................................... 78 DAMPER........................................................................................................................................................................ 80 COOLING SYSTEM................................................................................................................................................................ 82 COOLING FAN PUMP.............................................................................................................................................................. 86 COOLING FAN MOTOR............................................................................................................................................................. 94 POWER TRAIN, PART 1............................................................................................................................................................... 101 POWER TRAIN .................................................................................................................................................................. 102 POWER TRAIN SYSTEM DIAGRAM.................................................................................................................................................... 103 TORQUE CONVERTER AND TRANSMISSION PIPING DIAGRAM.............................................................................................................................. 104 TORQUE CONVERTER.............................................................................................................................................................. 106 MODULATION CLUTCH............................................................................................................................................................. 115 TORQUE CONVERTER REGULATOR VALVE.............................................................................................................................................. 116 TRANSMISSION.................................................................................................................................................................. 118 TRANSFER...................................................................................................................................................................... 138 TRANSMISSION CONTROL VALVE.................................................................................................................................................... 140 ECMV.......................................................................................................................................................................... 142 MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE........................................................................................................................... 149 LUBRICATION RELIEF VALVE...................................................................................................................................................... 151 POWER TRAIN, PART 2............................................................................................................................................................... 153 TORQUE CONVERTER OIL COOLER................................................................................................................................................... 154 TORQUE CONVERTER OIL FILTER................................................................................................................................................... 155 DRIVE SHAFT................................................................................................................................................................... 157 CENTER SUPPORT................................................................................................................................................................ 160 AXLE.......................................................................................................................................................................... 162 DIFFERENTIAL.................................................................................................................................................................. 166 LIMITED SLIP DIFFERENTIAL..................................................................................................................................................... 175 FINAL DRIVE................................................................................................................................................................... 180 STEERING SYSTEM................................................................................................................................................................... 185 Steering piping diagram....................................................................................................................................................... 188 Steering column............................................................................................................................................................... 190 Joystick steering lever linkage............................................................................................................................................... 191 Joystick EPC valve............................................................................................................................................................ 192 Lock valve.................................................................................................................................................................... 193 Steering valve................................................................................................................................................................ 194 Rotary valve.................................................................................................................................................................. 197 Steering control valve........................................................................................................................................................ 200 Two-way restrictor valve...................................................................................................................................................... 216 Stop valve.................................................................................................................................................................... 217 Steering pump................................................................................................................................................................. 218 Steering cylinder............................................................................................................................................................. 232 Emergency steering piping diagram............................................................................................................................................. 234 Diverter valve................................................................................................................................................................ 235 Emergency steering pump....................................................................................................................................................... 243 BRAKE SYSTEM...................................................................................................................................................................... 245 Brake piping diagram.......................................................................................................................................................... 246 Brake......................................................................................................................................................................... 248 Brake valve................................................................................................................................................................... 252 Accumulator charge valve...................................................................................................................................................... 260 EPC relief valve.............................................................................................................................................................. 266 Accumulator (for brake)....................................................................................................................................................... 268 Slack adjuster................................................................................................................................................................ 270 Parking brake................................................................................................................................................................. 274 Parking brake solenoid valve.................................................................................................................................................. 276 Emergency parking brake release valve......................................................................................................................................... 278 Brake cooling pump............................................................................................................................................................ 279 UNDERCARRIAGE AND FRAME........................................................................................................................................................... 281 AXLE MOUNT.................................................................................................................................................................... 282 CENTER HINGE PIN.............................................................................................................................................................. 287 HYDRAULIC SYSTEM, PART 1.......................................................................................................................................................... 291 HYDRAULIC PIPING DIAGRAM...................................................................................................................................................... 292 WORK EQUIPMENT CONTROL LEVER LINKAGE.......................................................................................................................................... 294 HYDRAULIC TANK................................................................................................................................................................ 296 WORK EQUIPMENT HYDRAULIC PUMP................................................................................................................................................. 298 HYDRAULIC SYSTEM, PART 2.......................................................................................................................................................... 319 Control valve................................................................................................................................................................. 320 CLSS.......................................................................................................................................................................... 334 Each function and operation of each valve..................................................................................................................................... 339 Accumulator (for PPC circuit)................................................................................................................................................. 358 Accumulator (for ECSS)........................................................................................................................................................ 359 Triple pump................................................................................................................................................................... 360 WORK EQUIPMENT.................................................................................................................................................................... 363 Work equipment linkage........................................................................................................................................................ 364 Bucket........................................................................................................................................................................ 368 Bucket positioner and boom kick-out........................................................................................................................................... 372 Work equipment lubrication.................................................................................................................................................... 373 Work equipment cylinder....................................................................................................................................................... 375 CAB AND ITS ATTACHMENTS........................................................................................................................................................... 379 ROPS CAB...................................................................................................................................................................... 380 AIR CONDITIONER............................................................................................................................................................... 382 ELECTRICAL SYSTEM, PART 1......................................................................................................................................................... 387 Machine monitor system........................................................................................................................................................ 388 Machine monitor............................................................................................................................................................... 394 ELECTRICAL SYSTEM, PART 2......................................................................................................................................................... 451 WORK EQUIPMENT CONTROL SYSTEM ................................................................................................................................................ 452 TRANSMISSION CONTROLLER SYSTEM................................................................................................................................................ 488 ELECTRICAL SYSTEM, PART 3......................................................................................................................................................... 521 Electric transmission control................................................................................................................................................. 522 Engine starting/stopping circuit.............................................................................................................................................. 524 Parking brake circuit......................................................................................................................................................... 527 Sensor........................................................................................................................................................................ 531 VHMS controller related....................................................................................................................................................... 554 VHMS controller and wireless LAN system....................................................................................................................................... 555 Work equipment electric lever................................................................................................................................................. 561 20 STANDARD VALUE TABLE............................................................................................................................................................... 565 STANDARD SERVICE VALUE TABLE...................................................................................................................................................... 565 Standard service value table for engine....................................................................................................................................... 566 Standard service value table for chassis...................................................................................................................................... 567 30 TESTING AND ADJUSTING.............................................................................................................................................................. 577 TESTING AND ADJUSTING, PART 1..................................................................................................................................................... 577 Precautions before work....................................................................................................................................................... 579 Tools for testing, adjusting, and troubleshooting............................................................................................................................. 580 Measuring engine speed........................................................................................................................................................ 586 Measuring exhaust gas color................................................................................................................................................... 588 Measuring exhaust temperature................................................................................................................................................. 589 Adjusting valve clearance..................................................................................................................................................... 591 Testing compression pressures................................................................................................................................................. 593 Measuring blow-by pressure.................................................................................................................................................... 596 Measuring engine oil pressure................................................................................................................................................. 597 Measuring intake air (boost) pressure......................................................................................................................................... 598 Handling fuel system equipment................................................................................................................................................ 599 Releasing residual pressure in fuel system.................................................................................................................................... 599 Testing fuel pressures........................................................................................................................................................ 600 Testing return rate and leakage............................................................................................................................................... 601 Bleeding air from fuel circuit................................................................................................................................................ 604 Testing leakage in fuel system................................................................................................................................................ 606 Handling reduced cylinder mode operation...................................................................................................................................... 607 Handling no-injection cranking operation...................................................................................................................................... 607 Handling controller voltage circuit........................................................................................................................................... 608 Replacing and adjusting alternator and air conditioner compressor belt tension................................................................................................ 609 Adjusting modulation clutch speed sensor and speed sensor..................................................................................................................... 610 Measuring directional lever (Steering wheel specification).................................................................................................................... 612 Testing and adjusting power train oil pressure................................................................................................................................ 613 Flushing procedure for torque converter and transmission hydraulic circuit.................................................................................................... 627 Method of moving machine when transmission valve is broken.................................................................................................................... 629 Adjusting steering stop valve................................................................................................................................................. 631 TESTING AND ADJUSTING, PART 2..................................................................................................................................................... 633 Measuring operating effort of AJSS lever (AJSS specification)................................................................................................................. 635 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)..................................................................................... 636 Testing and adjusting steering stopper bolt (AJSS specification).............................................................................................................. 638 Testing and adjusting steering wheel (Steering wheel specification)........................................................................................................... 640 Testing steering oil pressure................................................................................................................................................. 642 Bleeding air from steering cylinder circuit................................................................................................................................... 646 Testing hydraulic drive fan................................................................................................................................................... 647 Bleeding air from hydraulic drive fan circuit................................................................................................................................. 650 Measuring brake pedal......................................................................................................................................................... 652 Measuring brake performance................................................................................................................................................... 653 Testing and adjusting accumulator charge pressure............................................................................................................................. 654 Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas................................................................... 656 Testing wheel brake oil pressure.............................................................................................................................................. 664 Measuring wear of wheel brake disc............................................................................................................................................ 666 Bleeding air from wheel brake circuit......................................................................................................................................... 667 Releasing residual pressure in brake accumulator circuit...................................................................................................................... 668 Testing parking brake performance............................................................................................................................................. 669 Measuring parking brake oil pressure.......................................................................................................................................... 670 Testing wear of parking brake disc............................................................................................................................................ 673 Method of releasing parking brake manually.................................................................................................................................... 674 Measuring and adjusting work equipment control lever.......................................................................................................................... 675 Measuring work equipment oil pressure......................................................................................................................................... 676 Bleeding air from work equipment circuit...................................................................................................................................... 681 Releasing residual pressure in work equipment circuit......................................................................................................................... 682 Testing of accumulator nitrogen gas pressure and procedure for charging ECSS accumulator with nitrogen gas.................................................................... 684 Moving machine for removing operator cab...................................................................................................................................... 692 Testing and adjusting bucket positioner....................................................................................................................................... 694 Testing and adjusting lift arm position detecting lever....................................................................................................................... 696 Checking proximity switch operation indication lamp........................................................................................................................... 697 Preparations for work on troubleshooting of electric system................................................................................................................... 698 Procedure for testing diodes.................................................................................................................................................. 702 TESTING AND ADJUSTING, PART 3..................................................................................................................................................... 705 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller......................................... 706 Special functions of machine monitor (EMMS)................................................................................................................................... 709 TESTING AND ADJUSTING, PART 4..................................................................................................................................................... 785 VHMS controller initial setting procedure (ORBCOMM installation specification)................................................................................................ 786 VHMS controller initial setting procedure (IRIDIUM installation specification)................................................................................................ 808 Precautions for replacing VHMS controller..................................................................................................................................... 830 Initialization of VHMS wireless LAN modem and downloading of data............................................................................................................. 836 Pm-clinic inspection table.................................................................................................................................................... 843 40 TROUBLESHOOTING.................................................................................................................................................................... 847 FAILURE CODE TABLE AND FUSE LOCATIONS............................................................................................................................................. 847 Failure codes list............................................................................................................................................................ 848 Fuse locations................................................................................................................................................................ 860 GENERAL INFORMATION ON TROUBLESHOOTING............................................................................................................................................ 863 Precautions before work....................................................................................................................................................... 864 Points to remember when performing troubleshooting............................................................................................................................ 865 How to proceed in troubleshooting............................................................................................................................................. 867 Testing before troubleshooting................................................................................................................................................ 869 Classification and procedures of troubleshooting.............................................................................................................................. 870 Information in troubleshooting table.......................................................................................................................................... 874 Troubleshooting method for disconnecting wiring harness of pressure sensor system............................................................................................. 876 Phenomena looking like troubles and troubleshooting Nos....................................................................................................................... 879 Connection table for connector pin numbers.................................................................................................................................... 881 T- branch box and T- branch adapter table..................................................................................................................................... 916 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1......................................................................................................................... 921 Failure code [1500L0] TORQFLOW transmission: Double meshing................................................................................................................... 923 Failure code [15B0NX] Transmission Oil Filter Clogging........................................................................................................................ 924 Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON........................................................................................... 926 Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF........................................................................................... 928 Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON........................................................................................... 930 Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF........................................................................................... 932 Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON................................................................................................ 934 Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF................................................................................................ 936 Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON................................................................................................ 938 Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF................................................................................................ 940 Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON................................................................................................ 942 Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF................................................................................................ 944 Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON................................................................................................ 946 Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF................................................................................................ 948 Failure code [15W0NT] Transmission modulation clutch: Overheating............................................................................................................. 950 Failure code [2F00MA] Parking brake: Malfunction.............................................................................................................................. 951 Failure code [2G42ZG] Front Accumulator Oil Pressure Low...................................................................................................................... 954 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2......................................................................................................................... 957 Failure code [2G43ZG] Rear Accumulator Oil Pressure Low....................................................................................................................... 960 Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree.............................................................................................................. 962 Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine: Overrun...................................................................................................... 965 Failure code [AA1ANX] Air Cleaner Clogging.................................................................................................................................... 966 Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine................................................................................................ 968 Failure code [AB00MA] Alternator: Malfunction................................................................................................................................. 970 Failure code [B@BAZG] Engine oil pressure: Low error.......................................................................................................................... 972 Failure code [B@BAZK] Eng Oil Level Low....................................................................................................................................... 973 Failure code [B@BCNS] Engine coolant temperature: Overheating................................................................................................................. 974 Failure code [B@BCZK] Engine coolant level low................................................................................................................................ 976 Failure code [B@C7NS] Brake oil overheating................................................................................................................................... 978 Failure code [b@CENS] Torque converter oil overheating........................................................................................................................ 979 Failure code [B@CENS] Torque converter oil overheating........................................................................................................................ 980 Failure code [B@GAZK] Low Battery Fluid Level................................................................................................................................. 981 Failure code [B@HANS] Hyd Oil Overheat........................................................................................................................................ 983 Failure code [CA111] Abnormality in engine controller......................................................................................................................... 984 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................................................................... 987 Failure code [CA122] Charge (boost) pressure sensor high error................................................................................................................ 988 Failure code [CA123] Charge (boost) pressure sensor low error................................................................................................................. 990 Failure code [CA131] Throttle sensor high error............................................................................................................................... 992 Failure code [CA132] Throttle sensor low error................................................................................................................................ 995 Failure code [CA135] Engine oil pressure sensor high error.................................................................................................................... 998 Failure code [CA141] Engine oil pressure sensor low error.....................................................................................................................1000 Failure code [CA144] Coolant temperature sensor high error....................................................................................................................1002 Failure code [CA145] Coolant temperature sensor low error.....................................................................................................................1004 Failure code [CA153] Charge (boost) temperature sensor high error.............................................................................................................1006 Failure code [CA154] Charge (boost) temperature sensor low error..............................................................................................................1008 Failure code [CA187] Sensor power supply 2 low error..........................................................................................................................1010 Failure code [CA212] Engine oil temperature sensor high error.................................................................................................................1012 Failure code [CA213] Engine oil temperature sensor low error..................................................................................................................1014 Failure code [CA221] Atmospheric pressure sensor high error...................................................................................................................1016 Failure code [CA222] Atmospheric pressure sensor low error....................................................................................................................1018 Failure code [CA227] Sensor power supply 2 high error.........................................................................................................................1020 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3.........................................................................................................................1023 Failure code [CA234] Engine overspeed.........................................................................................................................................1025 Failure code [CA238] Ne speed sensor power supply error.......................................................................................................................1026 Failure code [CA263] Fuel temperature sensor high error.......................................................................................................................1028 Failure code [CA265] Fuel temperature sensor low error........................................................................................................................1030 Failure code [CA271] PCV1 Short circuit.......................................................................................................................................1032 Failure code [CA272] PCV1 Disconnection.......................................................................................................................................1033 Failure code [CA273] PCV2 Short circuit.......................................................................................................................................1034 Failure code [CA274] PCV2 Disconnection.......................................................................................................................................1035 Failure code [CA322] Injector #1 open/short error.............................................................................................................................1036 Failure code [CA323] Injector #5 open/short error.............................................................................................................................1038 Failure code [CA324] Injector #3 open/short error.............................................................................................................................1040 Failure code [CA325] Injector #6 open/short error.............................................................................................................................1042 Failure code [CA331] Injector #2 open/short error.............................................................................................................................1044 Failure code [CA332] Injector #4 open/short error.............................................................................................................................1046 Failure code [CA342] Calibration code inconsistency...........................................................................................................................1048 Failure code [CA351] Injectors drive circuit error............................................................................................................................1049 Failure code [CA352] Sensor power supply 1 low error..........................................................................................................................1050 Failure code [CA386] Sensor power supply 1 high error.........................................................................................................................1052 Failure code [CA431] Idle validation switch error.............................................................................................................................1053 Failure code [CA432] Idle validation action error.............................................................................................................................1056 Failure code [CA441] Battery voltage low error................................................................................................................................1059 Failure code [CA442] Battery voltage high error...............................................................................................................................1060 Failure code [CA449] Common rail pressure high error 2........................................................................................................................1061 Failure code [CA451] Common rail pressure sensor high error...................................................................................................................1062 Failure code [CA452] Common rail pressure sensor low error....................................................................................................................1064 Failure code [CA553] Common rail pressure high error 1........................................................................................................................1066 Failure code [CA554] Common rail pressure sensor in range error...............................................................................................................1067 Failure code [CA559] Supply pump pressure very low error 1....................................................................................................................1068 Failure code [CA689] Engine Ne speed sensor error.............................................................................................................................1072 Failure code [CA731] Engine Bkup speed sensor phase error.....................................................................................................................1074 Failure code [CA757] All continuous data lost error...........................................................................................................................1075 Failure code [CA778] Engine Bkup speed sensor error...........................................................................................................................1076 Failure code [CA1633] KOMNET datalink timeout error...........................................................................................................................1078 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4.........................................................................................................................1081 Failure code [CA2185] Throttle sensor supply voltage high error...............................................................................................................1084 Failure code [CA2186] Throttle sensor power supply low error..................................................................................................................1086 Failure code [CA2249] Supply pump pressure very low error 2...................................................................................................................1088 Failure code [CA2555] Intake air heater relay open circuit error..............................................................................................................1090 Failure code [CA2556] Intake air heater relay short circuit error.............................................................................................................1092 Failure code [D191KA] AJSS neutral safety relay open circuit..................................................................................................................1094 Failure code [D191KB] AJSS neutral safety relay short circuit.................................................................................................................1096 Failure code [D192KA] ECSS solenoid: Disconnection............................................................................................................................1098 Failure code [D192KB] ECSS solenoid: Short circuit............................................................................................................................1099 Failure code [D192KY] ECSS solenoid: Short circuit with power supply line.....................................................................................................1100 Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection................................................................................................1101 Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit................................................................................................1102 Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply line.........................................................................1103 Failure code [D5ZHKA] Terminal C signal open circuit..........................................................................................................................1104 Failure code [D5ZHKB] Terminal C signal short circuit.........................................................................................................................1106 Failure code [D5ZHKZ] Terminal C signal open or short circuit.................................................................................................................1108 Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine.................................................................................................1110 Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal...................................................................................................1112 Failure code [DAF3KK] Machine monitor: Source voltage low (input).............................................................................................................1114 Failure code [DAF5KP] Machine monitor: Output voltage low.....................................................................................................................1116 Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system)....................................................1118 Failure code [DAQ0KK] Transmission controller: Source voltage low.............................................................................................................1119 Failure code [DAQ0KT] Transmission controller: Defect in controller...........................................................................................................1122 Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)..............................................................................1123 Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement............................................................................1126 Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system)............................................1127 Failure code [DAQRMA] Transmission controller (Option setting): Malfunction...................................................................................................1132 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5.........................................................................................................................1135 Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system)..................................................1138 Failure code [DB90KK] Work equipment controller: Source voltage low (input)...................................................................................................1141 Failure code [DB90KT] Work equipment controller: Defect in controller.........................................................................................................1144 Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input)............................................................................1145 Failure code [DB95KX] Work equipment controller power supply output: Out of range.............................................................................................1148 Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement..........................................................................1150 Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system)..........................................1151 Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction.................................................................................................1152 Failure code [DB9RMC] CAN communication with transmission controller: Malfunction.............................................................................................1153 Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source voltage low (input))...........................................................1154 Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller: Disagreement of model selection signals)..............................................1156 Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery power supply: Source voltage low (input))......................................1158 Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V power supply output: Output voltage low)...........................................1160 Failure code [DBB6KP] or change of VHMS_LED display from "n9" to "02" (VHMS controller 24V power supply output: Output voltage low)...........................................1162 Failure code [DBB7KP] or change of VHMS_LED display from "n9" to "03" (VHMS controller 12V power supply output: Output voltage low)...........................................1164 Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of VHMS controller: Communication error (Abnormality in target component system))....1166 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time.........................................................................................1168 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time.........................................................................................1170 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time.........................................................................................1172 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time.........................................................................................1174 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time..................................................................1176 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time..................................................................1178 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................................................................................1180 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time.............................................................................1182 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time.............................................................................1184 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6.........................................................................................................................1187 Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time................................................................................1190 Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree..........................................................................................................1192 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit...........................................................................................1194 Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit.........................................................................................1197 Failure code [DDD1LD] Remote positioner bucket angle set switch: Switch is kept pressed for long time.........................................................................1200 Failure code [DDDBKA] Traction adjustment dial: Disconnection.................................................................................................................1204 Failure code [DDDBKB] Traction adjustment dial: Short circuit.................................................................................................................1206 Failure code [DDE5MA] Emergency steering drive switch: Malfunction............................................................................................................1208 Failure code [DDK4KA] AJSS FNR switch: Disconnection..........................................................................................................................1210 Failure code [DDK4KB] AJSS FNR switch: Short circuit..........................................................................................................................1212 Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree......................................................................................................1214 Failure code [DDK6KA] FNR lever switch: Disconnection.........................................................................................................................1217 Failure code [DDK6KB] FNR lever switch: Short circuit.........................................................................................................................1220 Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection....................................................................................1222 Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree.....................................................................................................1224 Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time..................................................................................................1226 Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time.......................................................................................................1228 Failure code [DDY0LD] Load meter cancel switch: Switch is kept pressed for long time..........................................................................................1230 Failure code [DF10KA] Transmission shift lever switch: Disconnection..........................................................................................................1232 Failure code [DF10KB] Transmission shift lever switch: Short circuit..........................................................................................................1236 Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor: Out of input signal range............................................................1238 Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection......................................................................................................1240 Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit......................................................................................................1242 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 7.........................................................................................................................1245 Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range.............................................................................................1248 Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection........................................................................................................1250 Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range............................................................................................1252 Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection..................................................................................................1254 Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit..................................................................................................1255 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range......................................................................................1256 Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12") Exhaust gas temperature sensor (F): Disconnection....................................................................1258 Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11") Exhaust gas temperature sensor (F): Short circuit....................................................................1261 Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22") Exhaust gas temperature sensor (R): Disconnection....................................................................1264 Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21") Exhaust gas temperature sensor (R): Short circuit....................................................................1267 Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection..................................................................................................1270 Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit..................................................................................................1272 Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit...............................................................................1274 Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with power supply line........................................................1276 Failure code [DHPCKX] Lift arm cylinder bottom pressure sensor: Out of input signal range.....................................................................................1278 Failure code [DHPDKX] Lift arm cylinder head pressure sensor: Out of input signal range.......................................................................................1281 Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine....................................................................1284 Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input signal range..............................................................1286 Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection....................................................................................................1290 Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit....................................................................................................1292 Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of input signal range.......................................................1294 Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of input signal range........................................................1296 Failure code [DK30KA] AJSS lever angle sensor: Disconnection..................................................................................................................1298 Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line...........................................................................................1300 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 8.........................................................................................................................1303 Failure code [DK59KA] Lift arm EPC lever potentiometer (Main): Disconnection..................................................................................................1305 Failure code [DK59KY] Lift arm EPC lever potentiometer (Main): Short circuit with power supply line...........................................................................1308 Failure code [DK59L8] Lift arm EPC lever potentiometer (Main): Analog signals disagree........................................................................................1310 Failure code [DK5AKA] Lift arm EPC lever potentiometer (Sub): Disconnection...................................................................................................1314 Failure code [DK5AKY] Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line............................................................................1317 Failure code [DK5BKA] Bucket EPC lever potentiometer (Main): Disconnection....................................................................................................1320 Failure code [DK5BKY] Bucket EPC lever potentiometer (Main): Short circuit with power supply line.............................................................................1323 Failure code [DK5BL8] Bucket EPC lever potentiometer (Main): Analog signals disagree..........................................................................................1325 Failure code [DK5CKA] Bucket EPC lever potentiometer (Sub): Disconnection.....................................................................................................1329 Failure code [DK5CKY] Bucket EPC lever potentiometer (Sub): Short circuit with power supply line..............................................................................1332 Failure code [DK5DKA] 3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection................................................................................1335 Failure code [DK5DKY] 3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line.........................................................1338 Failure code [DK5DL8] 3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree......................................................................1340 Failure code [DK5EKA] 3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection.................................................................................1343 Failure code [DK5EKY] 3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line.......................................................................1346 Failure code [DKA0KA] Lift arm angle sensor: Disconnection....................................................................................................................1348 Failure code [DKA0KX] Lift arm angle sensor: Out of input signal range........................................................................................................1351 Failure code [DKA0KY] Lift arm angle sensor: Short circuit with power supply line.............................................................................................1352 Failure code [DKA0L0] Lift arm angle sensor: Improper position................................................................................................................1354 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 9.........................................................................................................................1357 Failure code [DKD0KA] Frame angle sensor: Disconnection.......................................................................................................................1360 Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line................................................................................................1362 Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit.......................................................................................1364 Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection..............................................................................................1368 Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree.....................................................................................1370 Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection...............................................................................................1372 Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree......................................................................................1374 Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit...............................................................................................1376 Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range...................................................................................1378 Failure code [DUM1KB] Remote positioner raise indicator lamp: Short circuit...................................................................................................1380 Failure code [DUM2KB] Remote positioner lower indicator lamp: Short circuit...................................................................................................1382 Failure code [DV00KB] Alarm buzzer: Short circuit.............................................................................................................................1384 Failure code [DW4PKA] Lift arm raise EPC solenoid: Disconnection..............................................................................................................1386 Failure code [DW4PKB] Lift arm raise EPC solenoid: Short circuit..............................................................................................................1388 Failure code [DW4PKY] Lift arm raise EPC solenoid: Short circuit with power supply line.......................................................................................1389 Failure code [DW4QKA] Lift arm lower EPC solenoid: Disconnection..............................................................................................................1390 Failure code [DW4QKB] Lift arm lower EPC solenoid: Short circuit..............................................................................................................1391 Failure code [DW4QKY] Lift arm lower EPC solenoid: Short circuit with power supply line.......................................................................................1392 Failure code [DW4RKA] Bucket tilt EPC solenoid: Disconnection.................................................................................................................1393 Failure code [DW4RKB] Bucket tilt EPC solenoid: Short circuit.................................................................................................................1394 Failure code [DW4RKY] Bucket tilt EPC solenoid: Short circuit with power supply line..........................................................................................1395 Failure code [DW4SKA] Bucket dump EPC solenoid: Disconnection.................................................................................................................1396 Failure code [DW4SKB] Bucket dump EPC solenoid: Short circuit.................................................................................................................1397 Failure code [DW4SKY] Bucket dump EPC solenoid: Short circuit with power supply line..........................................................................................1398 Failure code [DW7BKA] Fan reverse solenoid: Disconnection.....................................................................................................................1400 Failure code [DW7BKB] Fan reverse solenoid: Short circuit.....................................................................................................................1402 Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line..............................................................................................1404 Failure code [DW7DKA] Hydraulic drive fan neutral solenoid: Disconnection.....................................................................................................1405 Failure code [DW7DKB] Hydraulic drive fan neutral solenoid: Short circuit.....................................................................................................1406 Failure code [DW7DKY] Hydraulic drive fan neutral solenoid: Short circuit with power supply line..............................................................................1407 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 10........................................................................................................................1409 Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection.....................................................................................................1412 Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit.....................................................................................................1414 Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line..............................................................................1416 Failure code [DWN6KA] Lift arm raise magnet detent solenoid: Disconnection....................................................................................................1418 Failure code [DWN6KB] Lift arm raise magnet detent solenoid: Short circuit....................................................................................................1420 Failure code [DWN6KY] Lift arm raise magnet detent solenoid: Short circuit with power supply line.............................................................................1422 Failure code [DWN7KA] Lift arm float magnet detent solenoid: Disconnection....................................................................................................1424 Failure code [DWN7KB] Lift arm float magnet detent solenoid: Short circuit....................................................................................................1426 Failure code [DWN7KY] Lift arm float magnet detent solenoid: Short circuit with power supply line.............................................................................1428 Failure code [DWN8KA] Bucket tilt magnet detent solenoid: Disconnection.......................................................................................................1430 Failure code [DWN8KB] Bucket tilt magnet detent solenoid: Short circuit.......................................................................................................1432 Failure code [DWN8KY] Bucket tilt magnet detent solenoid: Shorted with the power source.......................................................................................1434 Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection...............................................................................................1436 Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit...............................................................................................1438 Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source line........................................................................1440 Failure code [DX16KA] Fan pump EPC solenoid: Disconnection....................................................................................................................1442 Failure code [DX16KB] Fan pump EPC solenoid: Short circuit....................................................................................................................1443 Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line.............................................................................................1444 Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection.....................................................................................................................1445 Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit.....................................................................................................................1446 Failure code [DXF0KA] AJSS EPC solenoid: Disconnection........................................................................................................................1447 Failure code [DXF0KB] AJSS EPC solenoid: Short circuit........................................................................................................................1448 Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection.....................................................................................................................1450 Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit.....................................................................................................................1452 Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line..............................................................................................1454 Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection.................................................................................................................1456 Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit.................................................................................................................1458 Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1460 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 11........................................................................................................................1463 Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection.................................................................................................................1466 Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.................................................................................................................1468 Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1470 Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection.................................................................................................................1472 Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit.................................................................................................................1474 Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1476 Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection...................................................................................................................1478 Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit...................................................................................................................1480 Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line............................................................................................1482 Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection...................................................................................................................1484 Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit...................................................................................................................1486 Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line............................................................................................1488 Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection.................................................................................................................1490 Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit.................................................................................................................1492 Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1494 Failure code [DXHJKA] 3-spool valve extract EPC solenoid: Disconnection.......................................................................................................1496 Failure code [DXHJKB] 3-spool valve extract EPC solenoid: Short circuit.......................................................................................................1498 Failure code [DXHJKY] 3-spool valve extract EPC solenoid: Short circuit with power supply line................................................................................1499 Failure code [DXHKKA] 3-spool valve retract EPC solenoid: Disconnection.......................................................................................................1500 Failure code [DXHKKB] 3-spool valve retract EPC solenoid: Short circuit.......................................................................................................1502 Failure code [DXHKKY] 3-spool valve retract EPC solenoid: Short circuit with power supply line................................................................................1503 Failure code [DXHPKA] Modulation clutch solenoid: Disconnection...............................................................................................................1504 Failure code [DXHPKB] Modulation clutch solenoid: Short circuit...............................................................................................................1506 Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line........................................................................................1508 Failure code [DXHPMA] Modulation clutch solenoid: Malfunction.................................................................................................................1510 Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) Blow-by pressure: High error.........................................................................................1512 Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust gas temperature (F): Abnormal heat...........................................................................1514 Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F): Overheat................................................................................1516 Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust gas temperature (R): abnormal heat...........................................................................1518 Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat.................................................................................1520 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).....................................................................................................................................1523 Before carrying out troubleshooting of electrical system......................................................................................................................1526 Information in troubleshooting table..........................................................................................................................................1529 E-1 Engine does not start.....................................................................................................................................................1530 E-2 Wiper does not operate....................................................................................................................................................1540 E-3 Windshield washer does not operate........................................................................................................................................1548 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...........................................................................................1554 E-5 Working lamp does not light up or go off..................................................................................................................................1568 E-6 Step lamp does not light up or go off.....................................................................................................................................1574 E-7 Turn signal lamp and hazard lamp do not light up or go off................................................................................................................1576 E-8 Brake lamp does not light or it keeps lighting up.........................................................................................................................1586 E-9 Backup lamp does not light or it keeps lighting up........................................................................................................................1588 E-10 Backup buzzer does not sound or it keeps sounding........................................................................................................................1592 E-11 Horn does not sound or it keeps sounding.................................................................................................................................1596 E-12 Alarm buzzer does not sound or it keeps sounding.........................................................................................................................1600 E-13 Air conditioner does not operate or stop.................................................................................................................................1602 E-14 Electric priming pump does not operate or does not stop automatically....................................................................................................1604 E-15 When starting switch is turned to ON position, machine monitor displays nothing..........................................................................................1606 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).......................................................................................................................1611 METHOD OF USING TROUBLESHOOTING CHART.........................................................................................................................................1614 TABLE OF FAILURE MODES AND CAUSES.............................................................................................................................................1616 H-1 MACHINE DOES NOT START....................................................................................................................................................1620 H-2 TORQUE CONVERTER LOCKUP IS NOT SWITCHED (ENGINE STALLS)...................................................................................................................1622 H-3 TORQUE CONVERTER LOCKUP IS NOT TURNED ON..................................................................................................................................1623 H-4 TRAVEL SPEED IS SLOW, THRUSTING FORCE IS WEAK, UPHILL TRAVELING POWER IS WEAK, AND GEAR IS NOT SHIFTED....................................................................1624 H-5 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR...............................................................................................................1626 H-6 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR..............................................................................................................1628 H-7 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................................................................1630 H-8 STEERING DOES NOT TURN [MACHINE WITH STEERING WHEEL] .....................................................................................................................1631 H-9 STEERING DOES NOT TURN [MACHINE WITH AJSS]................................................................................................................................1632 H-10 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH STEERING WHEEL]......................................................................................................1633 H-11 TURNING, RESPONSE OF AJSS IS POOR [MACHINE WITH AJSS]....................................................................................................................1634 H-12 STEERING IS HEAVY [MACHINE WITH STEERING WHEEL]..........................................................................................................................1635 H-13 WHEN MACHINE TURNS, IT SHAKES OR MAKES LARGE SHOCKS [MACHINE WITH STEERING WHEEL]........................................................................................1636 H-14 WHEN MACHINE TURNS, IT SHAKES OR MAKES LARGE SHOCKS [MACHINE WITH AJSS]..................................................................................................1637 H-15 WHEEL BRAKE DOES NOT WORK OR DOES NOT WORK WELL..........................................................................................................................1638 H-16 WHEEL BRAKE IS NOT RELEASED OR IT DRAGS..................................................................................................................................1639 H-17 PARKING BRAKE DOES NOT WORK OR DOES NOT WORK WELL........................................................................................................................1640 H-18 PARKING BRAKE IS NOT RELEASED OR IT DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM) ..........................................................................................1641 H-19 LIFT ARM DOES NOT RISE...................................................................................................................................................1642 H-20 LIFT ARM SPEED IS LOW OR RISING FORCE OF LIFT ARM IS INSUFFICIENT........................................................................................................1643 H-21 WHEN RISING, LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT............................................................................................................1644 H-22 LIFT ARM CYLINDER CANNOT HOLD DOWN BUCKET (BUCKET FLOATS)................................................................................................................1644 H-23 HYDRAULIC DRIFTS OF LIFT ARM OCCUR OFTEN ................................................................................................................................1644 H-24 LIFT ARM WOBBLES DURING OPERATION........................................................................................................................................1644 H-25 BUCKET DOES NOT TILT BACK................................................................................................................................................1645 H-26 BUCKET SPEED IS LOW OR TILTING BACK FORCE IS INSUFFICIENT ...............................................................................................................1646 H-27 BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK..............................................................................................................1647 H-28 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET..................................................................................................................................1647 H-29 HYDRAULIC DRIFTS OF BUCKET OCCUR OFTEN...................................................................................................................................1647 H-30 BUCKET WOBBLES DURING TRAVEL WITH CARGO (WORK EQUIPMENT VALVE IS SET TO "HOLD")..........................................................................................1647 H-31 DURING OPERATION OF MACHINE, ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS.............................................................................................1648 H-32 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS AND STOPS ..............................................................................................................1648 H-33 WHEN WORK EQUIPMENT CIRCUIT IS RELIEVED SINGLY, OTHER WORK EQUIPMENT MOVES...............................................................................................1648 H-34 ECSS DOES NOT OPERATE, AND PITCHING BOUNCING OCCURS......................................................................................................................1649 H-35 FAN SPEED IS ABNORMAL (FAN SOUND AND VIBRATION ARE ABNORMALLY LARGE OR ENGINE OVERHEATS).................................................................................1650 TROUBLESHOOTING OF ENGINE (S-MODE)................................................................................................................................................1653 METHOD OF USING TROUBLESHOOTING CHART.........................................................................................................................................1655 S-1 ENGINE DOES NOT START EASILY..............................................................................................................................................1658 S-2 ENGINE DOES NOT START.....................................................................................................................................................1659 S-3 ENGINE DOES NOT PICK UP SMOOTHLY..........................................................................................................................................1662 S-4 ENGINE STOPS DURING OPERATION.............................................................................................................................................1663 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING OCCURS)..........................................................................................................................1664 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)......................................................................................................................................1665 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................................................................1666 S-8 OIL IS CONSUMED MUCH (OR EXHAUST GAS COLOR IS BLUE).......................................................................................................................1667 S-9 ENGINE OIL BECOMES CONTAMINATED QUICKLY...................................................................................................................................1668 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................................................1669 S-11 COOLANT CONTAINS OIL (BLOWS BACK OR REDUCES).............................................................................................................................1670 S-12 OIL PRESSURE DROPS.......................................................................................................................................................1671 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).....................................................................................................................................1672 S-14 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING).........................................................................................................................1673 S-15 ABNORMAL NOISE IS MADE...................................................................................................................................................1674 S-16 VIBRATION IS EXCESSIVE...................................................................................................................................................1675 S-17 AIR CANNOT BE BLED FROM FUEL CIRCUIT.....................................................................................................................................1676 50 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................................1679 GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY...................................................................................................................................1679 PRECAUTIONS BEFORE WORK.......................................................................................................................................................1680 HOW TO READ THIS MANUAL.......................................................................................................................................................1681 COATING MATERIALS LIST........................................................................................................................................................1683 SPECIAL TOOL LIST.............................................................................................................................................................1686 SKETCHES OF SPECIAL TOOLS.....................................................................................................................................................1690 ENGINE AND COOLING SYSTEM, PART 1 ................................................................................................................................................1699 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY ..................................................................................................................................1700 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ................................................................................................................................1703 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER...................................................................................................................................1708 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY ...............................................................................................................1709 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY...................................................................................................................................1711 DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY ..................................................................................................................................1713 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY................................................................................................................................1717 REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY..............................................................................................................................1719 REMOVAL AND INSTALLATION OF BULKHEAD ASSEMBLY.................................................................................................................................1721 ENGINE AND COOLING SYSTEM, PART 2.................................................................................................................................................1725 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY.........................................................................................................................1726 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY............................................................................................................................1732 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY............................................................................................................................1747 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.................................................................................................................................1751 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL..................................................................................................................................1754 POWER TRAIN, PART 1...............................................................................................................................................................1759 Removal and installation of parking brake assembly............................................................................................................................1760 Removal and installation of torque converter and transmission assembly........................................................................................................1762 POWER TRAIN, PART 2 ..............................................................................................................................................................1769 Disassembly and assembly of torque converter assembly.........................................................................................................................1770 Disassembly and assembly of transmission assembly.............................................................................................................................1797 Disassembly and assembly of transfer assembly.................................................................................................................................1824 Disassembly and assembly of parking brake assembly............................................................................................................................1840 POWER TRAIN, PART 3 ..............................................................................................................................................................1849 Removal and installation of front axle assembly...............................................................................................................................1850 Removal and installation of rear axle assembly................................................................................................................................1852 Removal and installation of center support assembly...........................................................................................................................1854 Disassembly and assembly of center support assembly...........................................................................................................................1856 Disassembly and assembly of differential assembly.............................................................................................................................1860 POWER TRAIN, PART 4 ..............................................................................................................................................................1875 REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY......................................................................................................................1876 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE CARRIER ASSEMBLY......................................................................................................................1878 REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE BRAKE ASSEMBLY .................................................................................................................1879 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY..............................................................................................................................1881 BRAKE SYSTEM .....................................................................................................................................................................1885 Disassembly and assembly of brake assembly....................................................................................................................................1886 Removal and installation of brake valve assembly..............................................................................................................................1894 Disassembly and assembly of accumulator and charge valve assembly.............................................................................................................1895 Disassembly and assembly of slack adjustor assembly...........................................................................................................................1898 UNDERCARRIAGE AND FRAME...........................................................................................................................................................1901 REMOVAL AND INSTALLATION OF CENTER HINGE PIN..................................................................................................................................1902 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY............................................................................................................................1909 HYDRAULIC SYSTEM..................................................................................................................................................................1911 Removal and installation of hydraulic tank assembly...........................................................................................................................1912 Removal and installation of hydraulic pump assembly...........................................................................................................................1914 Removal and installation of control valve assembly............................................................................................................................1918 Disassembly and assembly of control valve assembly............................................................................................................................1920 Removal and installation of steering valve assembly...........................................................................................................................1925 Removal and installation of ECSS accumulator assembly.........................................................................................................................1926 Disassembly and assembly of hydraulic cylinder assembly.......................................................................................................................1927 WORK EQUIPMENT ...................................................................................................................................................................1933 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...........................................................................................................................1934 CAB AND ITS ATTACHMENTS ..........................................................................................................................................................1941 Removal and installation of operator's cab assembly...........................................................................................................................1942 Removal and installation of operator's cab glass (stuck glass)................................................................................................................1946 Removal and installation of floor frame assembly..............................................................................................................................1954 Removal and installation of AJSS lever switch assembly........................................................................................................................1957 ELECTRICAL SYSTEM.................................................................................................................................................................1963 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY........................................................................................................................1964 REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY..................................................................................................................1966 REMOVAL AND INSTALLATION OF LOADER CONTROLLER ASSEMBLY........................................................................................................................1966 REMOVAL AND INSTALLATION OF VHMS CONTROLLER ASSEMBLY..........................................................................................................................1967 REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY..................................................................................................................................1968 REMOVAL AND INSTALLATION OF PRINTER ASSEMBLY..................................................................................................................................1971 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.....................................................................................................................1972 90 DIAGRAMS AND DRAWINGS..............................................................................................................................................................1977 Hydraulic diagrams and drawings...................................................................................................................................................1977 Power train hydraulic circuit diagram.........................................................................................................................................1978 Brake hydraulic circuit diagram...............................................................................................................................................1979 Work equipment hydraulic circuit diagram......................................................................................................................................1981 Electrical diagrams and drawings..................................................................................................................................................1987 Air conditioner electrical circuit diagram....................................................................................................................................1989 Electrical circuit diagram (1/10).............................................................................................................................................1991 Electrical circuit diagram (2/10).............................................................................................................................................1993 Electrical circuit diagram (3/10).............................................................................................................................................1995 Electrical circuit diagram (4/10).............................................................................................................................................1997 Electrical circuit diagram (5/10).............................................................................................................................................1999 Electrical circuit diagram (6/10).............................................................................................................................................2001 Electrical circuit diagram (7/10).............................................................................................................................................2003 Electrical circuit diagram (8/10).............................................................................................................................................2005 Electrical circuit diagram (9/10).............................................................................................................................................2007 Electrical circuit diagram (10/10)............................................................................................................................................2009 Electrical circuit diagram (1/10).............................................................................................................................................2011 Electrical circuit diagram (2/10).............................................................................................................................................2013 Electrical circuit diagram (3/10).............................................................................................................................................2015 Electrical circuit diagram (4/10).............................................................................................................................................2017 Electrical circuit diagram (5/10).............................................................................................................................................2019 Electrical circuit diagram (6/10).............................................................................................................................................2021 Electrical circuit diagram (7/10).............................................................................................................................................2023 Electrical circuit diagram (8/10).............................................................................................................................................2025 Electrical circuit diagram (9/10).............................................................................................................................................2027 Electrical circuit diagram (10/10)............................................................................................................................................2029 Connector arrangement diagram.................................................................................................................................................2031
DESCRIPTION:
KOMATSU WA600-6R WHEEL LOADER SHOP MANUAL SEN02211-21 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only the approved personnel can do the work in a closed environment or in a prohibited area.
6) Only qualified workers must carry out work and operation which require license or qualification.
7) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
8) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
9) Before starting work, warm up your body thoroughly to start work under good condition.
10) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
11) When you work in high places, use a platform.
12) Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
13) Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
14) Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
15) When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
S.S 30/12/24
