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Komatsu WD600-6 Wheel Dozer Shop Manual SEN04979-06 – PDF DOWNLOAD
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Komatsu WD600-6 Wheel Dozer Shop Manual
SERIAL NUMBERS : 55001 and up
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Description
Komatsu WD600-6 Wheel Dozer Shop Manual SEN04979-06
FILE DETAILS:
Komatsu WD600-6 Wheel Dozer Shop Manual
Brands: Komatsu
Equipment Type: Wheel Dozer
Manuals Type: Shop Manual
Machine Model: WD600-6
Serial Number: 55001 and up
Book Code: SEN04979-06
Language: English
Pages: 1860
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WD600-6 Wheel Dozer Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu WD600-6 Wheel Dozer Shop Manual
COVER .................................................................................................................................................................. 1 00 Index and foreword................................................................................................................................................... 0 100 Index........................................................................................................................................................... 3 Composition of shop manual...................................................................................................................................... 4 Table of contents............................................................................................................................................... 6 200 Foreword and general information................................................................................................................................ 19 Safety notice................................................................................................................................................... 20 How to read the shop manual..................................................................................................................................... 25 Explanation of terms for maintenance standard................................................................................................................... 27 Handling of electric equipment and hydraulic component.......................................................................................................... 29 Handling of connectors newly used for engines................................................................................................................... 38 How to read electric wire code.................................................................................................................................. 41 Precautions when carrying out operation......................................................................................................................... 44 Method of disassembling and connecting push-pull type coupler................................................................................................... 47 Standard tightening torque table................................................................................................................................ 50 Conversion table................................................................................................................................................ 54 01 Specification........................................................................................................................................................ 0 100 Specification and technical data................................................................................................................................ 61 Specification dimension drawing................................................................................................................................. 62 Specifications.................................................................................................................................................. 63 Weight table.................................................................................................................................................... 66 Table of fuel, coolant and lubricants........................................................................................................................... 68 10 Structure, function and maintenance standard......................................................................................................................... 0 100 Engine and cooling system....................................................................................................................................... 71 Engine mount and transmission mount............................................................................................................................. 72 Damper.......................................................................................................................................................... 74 Cooling system.................................................................................................................................................. 76 Cooling fan pump................................................................................................................................................ 80 Cooling fan motor............................................................................................................................................... 88 201 Power train, Part 1............................................................................................................................................. 95 Power train..................................................................................................................................................... 96 Power train system diagram...................................................................................................................................... 97 Torque converter and transmission piping diagram................................................................................................................ 98 Torque converter................................................................................................................................................ 100 Modulation clutch............................................................................................................................................... 109 Torque converter regulator valve................................................................................................................................ 110 Transmission.................................................................................................................................................... 112 Transfer........................................................................................................................................................ 132 Transmission control valve...................................................................................................................................... 134 ECMV............................................................................................................................................................ 136 Main relief valve and torque converter relief valve............................................................................................................. 143 Lubrication relief valve........................................................................................................................................ 145 202 Power train, Part 2............................................................................................................................................. 147 Torque converter oil cooler..................................................................................................................................... 148 Torque converter oil filter..................................................................................................................................... 149 Drive shaft..................................................................................................................................................... 151 Center support.................................................................................................................................................. 154 Axle............................................................................................................................................................ 156 Differential.................................................................................................................................................... 160 Limited slip differential....................................................................................................................................... 169 Final drive..................................................................................................................................................... 174 300 Steering system................................................................................................................................................. 179 Steering piping diagram......................................................................................................................................... 180 Steering column................................................................................................................................................. 182 Joystick steering lever linkage................................................................................................................................. 183 Joystick EPC valve.............................................................................................................................................. 184 Lock valve...................................................................................................................................................... 185 Steering valve.................................................................................................................................................. 186 Rotary valve.................................................................................................................................................... 189 Steering control valve.......................................................................................................................................... 192 Two-way restrictor valve........................................................................................................................................ 208 Stop valve...................................................................................................................................................... 209 Steering pump................................................................................................................................................... 210 Steering cylinder............................................................................................................................................... 224 Emergency steering piping diagram............................................................................................................................... 225 Diverter valve.................................................................................................................................................. 226 Emergency steering pump......................................................................................................................................... 234 400 Brake system.................................................................................................................................................... 237 Brake piping diagram............................................................................................................................................ 238 Brake........................................................................................................................................................... 240 Brake valve..................................................................................................................................................... 244 Accumulator charge valve........................................................................................................................................ 252 EPC relief valve................................................................................................................................................ 258 Accumulator (for brake)......................................................................................................................................... 260 Slack adjuster.................................................................................................................................................. 262 Parking brake................................................................................................................................................... 266 Parking brake solenoid valve.................................................................................................................................... 268 Emergency parking brake release valve........................................................................................................................... 270 Brake cooling pump.............................................................................................................................................. 271 500 Undercarriage and frame......................................................................................................................................... 273 Axle mount...................................................................................................................................................... 274 Center hinge pin................................................................................................................................................ 279 601 Hydraulic system, Part 1........................................................................................................................................ 283 Hydraulic piping diagram........................................................................................................................................ 284 Work equipment control lever linkage............................................................................................................................ 286 Hydraulic tank.................................................................................................................................................. 288 Work equipment pump............................................................................................................................................. 290 602 Hydraulic system, Part 2........................................................................................................................................ 311 Control valve................................................................................................................................................... 312 CLSS............................................................................................................................................................ 326 Functions and operation by valve................................................................................................................................ 330 Accumulator (for PPC circuit)................................................................................................................................... 340 Triple pump..................................................................................................................................................... 341 700 Work equipment.................................................................................................................................................. 343 Work equipment linkage.......................................................................................................................................... 344 Cutting edge and end bit........................................................................................................................................ 347 Work equipment lubrication...................................................................................................................................... 349 Hydraulic cylinder.............................................................................................................................................. 352 800 Cab and its attachments......................................................................................................................................... 355 ROPS cab........................................................................................................................................................ 356 Air conditioner................................................................................................................................................. 358 901 Electrical system, Part 1....................................................................................................................................... 363 Machine monitor system.......................................................................................................................................... 364 Machine monitor................................................................................................................................................. 370 902 Electrical system, Part 2....................................................................................................................................... 419 Work equipment control system................................................................................................................................... 420 Transmission controller system.................................................................................................................................. 446 903 Electrical system, Part 3....................................................................................................................................... 479 Electric transmission control................................................................................................................................... 480 Engine starting/stopping circuit................................................................................................................................ 482 Parking brake circuit........................................................................................................................................... 485 Sensor.......................................................................................................................................................... 489 VHMS controller related......................................................................................................................................... 509 Electric lever (Work equipment)................................................................................................................................. 515 20 Standard value table................................................................................................................................................. 0 100 Standard service value table.................................................................................................................................... 519 Standard service value table for engine......................................................................................................................... 520 Standard service value table for chassis........................................................................................................................ 521 30 Testing and adjusting................................................................................................................................................ 0 101 Testing and adjusting, Part 1................................................................................................................................... 531 Tools for testing, adjusting, and troubleshooting............................................................................................................... 533 Sketches of special tools....................................................................................................................................... 538 Measuring engine speed.......................................................................................................................................... 539 Measuring exhaust gas color..................................................................................................................................... 541 Measuring exhaust temperature................................................................................................................................... 542 Adjusting valve clearance....................................................................................................................................... 544 Testing compression pressures................................................................................................................................... 546 Measuring blow-by pressure...................................................................................................................................... 549 Measuring engine oil pressure................................................................................................................................... 550 Testing EGR valve and bypass valve drive oil pressure........................................................................................................... 551 Measuring intake air (boost) pressure........................................................................................................................... 553 Handling fuel system equipment.................................................................................................................................. 554 Releasing residual pressure in fuel system...................................................................................................................... 554 Testing fuel pressures.......................................................................................................................................... 555 Testing return rate and leakage................................................................................................................................. 556 Bleeding air from fuel circuit.................................................................................................................................. 559 Testing leakage in fuel system.................................................................................................................................. 561 Handling reduced cylinder mode operation........................................................................................................................ 562 Handling no-injection cranking operation........................................................................................................................ 562 Handling controller voltage circuit............................................................................................................................. 563 Replacing and adjusting alternator and air conditioner compressor belt tension.................................................................................. 564 Adjusting modulation clutch speed sensor and speed sensor....................................................................................................... 565 Measuring directional lever and gear shift lever (Steering wheel specification)................................................................................. 567 Testing and adjusting power train oil pressure.................................................................................................................. 568 Flushing procedure for torque converter and transmission hydraulic circuit...................................................................................... 582 Method of moving machine when transmission valve is broken...................................................................................................... 584 Moving method of machine disabled by short-to-power failure in work equipment potentiometer..................................................................... 586 Adjusting steering stop valve................................................................................................................................... 588 102 Testing and adjusting, Part 2................................................................................................................................... 591 Measuring operating effort of AJSS lever (AJSS specification)................................................................................................... 593 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)....................................................................... 594 Testing and adjusting steering stopper bolt (AJSS specification)................................................................................................ 596 Testing and adjusting steering wheel (Steering wheel specification)............................................................................................. 598 Testing steering oil pressure................................................................................................................................... 600 Bleeding air from steering cylinder circuit..................................................................................................................... 604 Testing hydraulic drive fan..................................................................................................................................... 605 Bleeding air from hydraulic drive fan circuit................................................................................................................... 608 Measuring brake pedal........................................................................................................................................... 610 Measuring brake performance..................................................................................................................................... 611 Testing and adjusting accumulator charge pressure............................................................................................................... 612 Testing wheel brake oil pressure................................................................................................................................ 614 Measuring wear of wheel brake disc.............................................................................................................................. 616 Bleeding air from wheel brake circuit........................................................................................................................... 617 Releasing residual pressure in brake accumulator circuit........................................................................................................ 618 Testing parking brake performance............................................................................................................................... 619 Measuring parking brake oil pressure............................................................................................................................ 620 Testing wear of parking brake disc.............................................................................................................................. 623 Method of releasing parking brake manually...................................................................................................................... 624 Measuring and adjusting work equipment control lever............................................................................................................ 625 Measuring work equipment oil pressure........................................................................................................................... 626 Bleeding air from work equipment circuit........................................................................................................................ 631 Moving machine for removing operator cab........................................................................................................................ 632 Preparations for work on troubleshooting of electric system..................................................................................................... 634 Procedure for testing diodes.................................................................................................................................... 638 103 Testing and adjusting, Part 3................................................................................................................................... 641 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller........................... 642 Special functions of machine monitor (EMMS)..................................................................................................................... 645 104 Testing and adjusting, Part 4................................................................................................................................... 715 VHMS controller initial setting procedure....................................................................................................................... 716 Precautions for replacing VHMS controller....................................................................................................................... 738 Pm-clinic inspection table...................................................................................................................................... 744 40 Troubleshooting...................................................................................................................................................... 0 100 Failure code table and fuse locations........................................................................................................................... 747 Failure codes list.............................................................................................................................................. 748 Fuse locations.................................................................................................................................................. 760 200 General information on troubleshooting.......................................................................................................................... 763 Points to remember when troubleshooting......................................................................................................................... 764 Sequence of events in troubleshooting........................................................................................................................... 765 Testing before troubleshooting.................................................................................................................................. 766 Classification and procedures of troubleshooting................................................................................................................ 767 Information contained in troubleshooting table.................................................................................................................. 768 Phenomena looking like troubles and troubleshooting Nos......................................................................................................... 770 Connection table for connector pin numbers...................................................................................................................... 772 T- branch box and T- branch adapter table....................................................................................................................... 808 301 Troubleshooting by failure code (Display of code), Part 1....................................................................................................... 813 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................................... 814 Failure code [15B0NX] (Transmission filter: Clogged)............................................................................................................ 816 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................................... 818 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................................... 820 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................................... 822 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................................... 824 Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON)................................................................................ 826 Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF)................................................................................ 828 Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON)................................................................................ 830 Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF)................................................................................ 832 Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON)................................................................................ 834 Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF)................................................................................ 836 Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON)................................................................................ 838 Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF)................................................................................ 840 Failure code [15W0NT] (Transmission modulation clutch: Overheating)............................................................................................. 842 Failure code [2F00MA] (Parking brake: Malfunction).............................................................................................................. 843 Failure code [2G42ZG] (Front accumulator: Low oil pressure)..................................................................................................... 846 302 Troubleshooting by failure code (Display of code), Part 2....................................................................................................... 849 Failure code [2G43ZG] (Rear accumulator: Low oil pressure)...................................................................................................... 852 Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) (Engine: Overrun)...................................................................................... 854 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................................... 856 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)............................................................................. 858 Failure code [AB00MA] (Alternator: Malfunction)................................................................................................................. 860 Failure code [B@BAZG] (Engine oil pressure: Low error).......................................................................................................... 862 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................................... 863 Failure code [B@BCNS] (Engine coolant temperature: Overheating)................................................................................................. 864 Failure code [B@BCZK] (Coolant: Low level)...................................................................................................................... 866 Failure code [B@C7NS] (Brake oil: Overheating).................................................................................................................. 868 Failure code [b@CENS] (Torque converter oil: Overheating)....................................................................................................... 870 Failure code [B@CENS] (Torque converter oil: Overheating)....................................................................................................... 872 Failure code [B@GAZK] (Battery electrolyte: Low level).......................................................................................................... 874 Failure code [B@HANS] (Hydraulic oil: Overheating).............................................................................................................. 876 Failure code [CA111] (Abnormality in engine controller)......................................................................................................... 878 Failure code [CA115] (Engine Ne or Bkup speed sensor error)..................................................................................................... 880 Failure code [CA122] (Charge (boost) pressure sensor high error)................................................................................................ 882 Failure code [CA123] (Charge (boost) pressure sensor low error)................................................................................................. 884 Failure code [CA131] (Throttle sensor high error)............................................................................................................... 886 Failure code [CA132] (Throttle sensor low error)................................................................................................................ 888 Failure code [CA135] (Engine oil pressure sensor high error).................................................................................................... 890 Failure code [CA141] (Engine oil pressure sensor low error)..................................................................................................... 892 Failure code [CA144] (Coolant temperature sensor high error).................................................................................................... 894 Failure code [CA145] (Coolant temperature sensor low error)..................................................................................................... 896 Failure code [CA153] (Charge (boost) temperature sensor high error)............................................................................................. 898 Failure code [CA154] (Charge (boost) temperature sensor low error).............................................................................................. 900 Failure code [CA187] (Sensor power supply 2 low error).......................................................................................................... 901 Failure code [CA212] (Engine oil temperature sensor high error)................................................................................................. 902 Failure code [CA213] (Engine oil temperature sensor low error).................................................................................................. 904 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................................... 906 Failure code [CA222] (Atmospheric pressure sensor low error).................................................................................................... 908 Failure code [CA227] (Sensor power supply 2 high error)......................................................................................................... 910 303 Troubleshooting by failure code (Display of code), Part 3....................................................................................................... 913 Failure code [CA234] (Engine overspeed)......................................................................................................................... 915 Failure code [CA238] (Ne speed sensor power supply error)....................................................................................................... 916 Failure code [CA263] (Fuel temperature sensor high error)....................................................................................................... 918 Failure code [CA265] (Fuel temperature sensor low error)........................................................................................................ 920 Failure code [CA271] (PCV1 Short circuit)....................................................................................................................... 922 Failure code [CA272] (PCV1 Disconnection)....................................................................................................................... 924 Failure code [CA273] (PCV2 Short circuit)....................................................................................................................... 926 Failure code [CA274] (PCV2 Disconnection)....................................................................................................................... 928 Failure code [CA322] (Injector #1 open/short error)............................................................................................................. 930 Failure code [CA323] (Injector #5 open/short error)............................................................................................................. 932 Failure code [CA324] (Injector #3 open/short error)............................................................................................................. 934 Failure code [CA325] (Injector #6 open/short error)............................................................................................................. 936 Failure code [CA331] (Injector #2 open/short error)............................................................................................................. 938 Failure code [CA332] (Injector #4 open/short error)............................................................................................................. 940 Failure code [CA342] (Calibration code inconsistency)........................................................................................................... 942 Failure code [CA351] (Injectors drive circuit error)............................................................................................................ 944 Failure code [CA352] (Sensor power supply 1 low error).......................................................................................................... 946 Failure code [CA386] (Sensor power supply 1 high error)......................................................................................................... 948 Failure code [CA431] (Idle validation switch error)............................................................................................................. 950 Failure code [CA432] (Idle validation action error)............................................................................................................. 952 Failure code [CA441] (Battery voltage low error)................................................................................................................ 952 Failure code [CA442] (Battery voltage high error)............................................................................................................... 953 Failure code [CA449] Common rail pressure high error 2.......................................................................................................... 953 Failure code [CA451] (Common rail pressure sensor high error)................................................................................................... 954 Failure code [CA452] (Common rail pressure sensor low error).................................................................................................... 956 Failure code [CA553] (Common rail pressure high error 1)........................................................................................................ 957 Failure code [CA554] (Common rail pressure sensor in range error)............................................................................................... 958 Failure code [CA559] (Supply pump pressure very low error 1).................................................................................................... 960 Failure code [CA689] (Engine Ne speed sensor error)............................................................................................................. 964 Failure code [CA731] (Engine Bkup speed sensor phase error)..................................................................................................... 966 Failure code [CA757] (All continuous data lost error)........................................................................................................... 967 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................................... 968 Failure code [CA1228] (EGR valve servo error 1)................................................................................................................. 970 Failure code [CA1625] (EGR valve servo error 2)................................................................................................................. 971 Failure code [CA1626] (Bypass valve solenoid current high error)................................................................................................ 972 Failure code [CA1627] (Bypass valve solenoid current low error)................................................................................................. 974 Failure code [CA1628] (Bypass valve servo error 1).............................................................................................................. 975 Failure code [CA1629] (Bypass valve servo error 2).............................................................................................................. 976 Failure code [CA1631] (Bypass valve lift sensor high error)..................................................................................................... 978 Failure code [CA1632] (Bypass valve lift sensor low error)...................................................................................................... 980 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................................... 981 304 Troubleshooting by failure code (Display of code), Part 4....................................................................................................... 983 Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................................................... 986 Failure code [CA2186] (Throttle sensor power supply low error).................................................................................................. 988 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................................... 989 Failure code [CA2271] (EGR valve lift sensor high error)........................................................................................................ 990 Failure code [CA2272] (EGR valve lift sensor low error)......................................................................................................... 992 Failure code [CA2351] (EGR valve solenoid operation short circuit).............................................................................................. 994 Failure code [CA2352] (EGR valve solenoid operation disconnect)................................................................................................. 996 Failure code [CA2555] (Intake heater relay disconnection error)................................................................................................. 997 Failure code [CA2556] (Intake heater relay short circuit error)................................................................................................. 998 Failure code [D191KA] (AJSS neutral safety relay: Disconnection)................................................................................................1000 Failure code [D191KB] (AJSS neutral safety relay: Short circuit)................................................................................................1002 Failure code [D198KA] (Transmission oil pressure bypass solenoid: Disconnection)................................................................................1004 Failure code [D198KB] (Transmission oil pressure bypass solenoid: Short circuit)................................................................................1005 Failure code [D198KY] (Transmission oil pressure bypass solenoid: Short circuit with power supply line).........................................................1006 Failure code [D5ZHKA] (Terminal C signal: Disconnection)........................................................................................................1008 Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................................................................1010 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit).......................................................................................1012 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)................................................................1014 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).........................................................................................1016 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).............................................................................................1018 Failure code [DAF5KP] (5V power source output voltage defective)................................................................................................1020 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))................................1022 Failure code [DAQ0KK] (Transmission controller: Low source voltage).............................................................................................1024 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)......................................................................................1026 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))..............................................................1028 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)........................................................1030 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))........................1032 Failure code [DAQRMA] (Transmission controller CAN communication: Malfunction)..................................................................................1034 305 Troubleshooting by failure code (Display of code), Part 5.......................................................................................................1037 Failure code [DB2RKR] CAN communication from engine controller: Defective communication (Abnormality in target component system)................................1040 Failure code [DB90KK] Work equipment controller: Low source voltage (input).....................................................................................1042 Failure code [DB90KT] (Work equipment controller: Abnormality in controller)....................................................................................1044 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)..............................................................1046 Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range)................................................................1048 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)......................................................1050 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)........................1052 Failure code [DB9RMA] (Work equipment controller CAN communication: Malfunction)................................................................................1054 Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation).....................................................................1056 Failure code [DBB0KK] (or VHMS_LED display: “n9” → “01”) VHMS controller: Low source voltage (input)............................................................1058 Failure code [DBB0KQ] (or VHMS_LED display: “nF” → “11”) (VHMS controller: Disagreement of model selection signals).............................................1060 Failure code [DBB3KK] (or VHMS_LED display: “n9” → “05”) VHMS controller battery power supply: Low source voltage (input).......................................1062 Failure code [DBB5KP] (or VHMS_LED display: “n9” → “04”) (VHMS controller 5 V power supply output: Low output voltage)..........................................1064 Failure code [DBB6KP] (or VHMS_LED display: “n9” → “02”) (VHMS controller 24 V power supply output: Low output voltage).........................................1066 Failure code [DBB7KP] (or VHMS_LED display: “n9” → “03”) (VHMS controller 12 V power supply output: Low output voltage).........................................1068 Failure code [DBBQKR] (or VHMS_LED display: “n8” → “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system)....1070 Failure code [DD15LD] (■ switch (Panel switch 1): Switch is kept pressed for long time).........................................................................1072 Failure code [DD16LD] (◇ switch (Panel switch 2): Switch is kept pressed for long time).........................................................................1074 Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time).........................................................................1076 Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time).........................................................................1078 306 Troubleshooting by failure code (Display of code), Part 6.......................................................................................................1081 Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree...........................................................................................1084 Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)...........................................................................1086 Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit).........................................................................1088 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).............................................................................1090 Failure code [DDD1LD] (Pitch operation switch: Switch is kept pressed for long time)............................................................................1094 Failure code [DDDBKA] (Traction adjustment dial: Disconnection).................................................................................................1096 Failure code [DDDBKB] (Traction adjustment dial: Short circuit).................................................................................................1098 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)............................................................................................1100 Failure code [DDK4KA] (AJSS FNR switch: Disconnection)..........................................................................................................1102 Failure code [DDK4KB] (AJSS FNR switch: Short circuit)..........................................................................................................1104 Failure code [DDK5L4] (AJSS shift-up/down switch: ON/OFF signals disagree)......................................................................................1106 Failure code [DDK6KA] (FNR lever switch: Disconnection).........................................................................................................1110 Failure code [DDK6KB] (FNR lever switch: Short circuit).........................................................................................................1112 Failure code [DDP5KA] (Lock detection pressure switch of steering lock lever: Disconnection)....................................................................1114 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).....................................................................................1116 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)..................................................................................1118 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).......................................................................................1120 Failure code [DF10KA] (Transmission shift lever switch: Disconnection)..........................................................................................1122 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)..........................................................................................1124 Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) (Atmospheric temperature sensor: Out of input signal range)............................................1126 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)......................................................................................1128 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)......................................................................................1130 307 Troubleshooting by failure code (Display of code), Part 7.......................................................................................................1133 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).............................................................................1136 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)........................................................................................1138 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)............................................................................1140 Failure code [DGT1KA] (Torque converter oil temperature sensor: Disconnection)..................................................................................1142 Failure code [DGT1KB] (Torque converter oil temperature sensor: Short circuit)..................................................................................1143 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)......................................................................1144 Failure code [DGT4KA] (or VHMS_LED display: “n3” → “12”) (Exhaust gas temperature sensor (F): Disconnection)....................................................1146 Failure code [DGT4KB] (or VHMS_LED display: “n3” → “11”) (Exhaust gas temperature sensor (F): Short circuit)....................................................1148 Failure code [DGT5KA] (or VHMS_LED display: “n3” → “22”) (Exhaust gas temperature sensor (R): Disconnection)....................................................1150 Failure code [DGT5KB] (or VHMS_LED display: “n3” → “21”) (Exhaust gas temperature sensor (R): Short circuit)....................................................1152 Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)..................................................................................1154 Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)..................................................................................1156 Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) (Blow-by pressure sensor: Short circuit)...............................................................1158 Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) (Blow-by pressure sensor: Short circuit with power supply line)........................................1160 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating state of engine)....................................................1162 Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) (Steering oil pressure sensor: Out of input signal range)..............................................1164 Failure code [DHTBKA] (Modulation clutch oil pressure sensor: Disconnection)....................................................................................1166 Failure code [DHTBKB] (Modulation clutch oil pressure sensor: Short circuit)....................................................................................1168 Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) (Front brake oil pressure sensor (F): Out of input signal range).......................................1170 Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) (Rear brake oil pressure sensor (R): Out of input signal range)........................................1172 Failure code [DK30KA] (AJSS lever angle sensor: Disconnection)..................................................................................................1174 Failure code [DK30KY] (AJSS lever angle sensor: Short circuit with power supply line)...........................................................................1176 308 Troubleshooting by failure code (Display of code), Part 8.......................................................................................................1179 Failure code [DK59KA] (Lift EPC lever potentiometer (Main): Disconnection)......................................................................................1181 Failure code [DK59KY] (Lift EPC lever potentiometer (Main): Short circuit with power supply line)...............................................................1184 Failure code [DK59L8] (Lift EPC lever potentiometer (Main): Analog signals disagree)............................................................................1188 Failure code [DK5AKA] (Lift EPC lever potentiometer (Sub): Disconnection).......................................................................................1191 Failure code [DK5AKY] (Lift EPC lever potentiometer (Sub): Short circuit with power supply line)................................................................1194 Failure code [DK5BKA] (Tilt & pitch EPC lever potentiometer (Main): Disconnection)..............................................................................1197 Failure code [DK5BKY] (Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply line).......................................................1200 Failure code [DK5BL8] (Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree)....................................................................1202 Failure code [DK5CKA] (Tilt & pitch EPC lever potentiometer (Sub): Disconnection)...............................................................................1205 Failure code [DK5CKY] (Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply line)........................................................1208 Failure code [DKD0KA] (Frame angle sensor: Disconnection).......................................................................................................1210 Failure code [DKD0KY] (Frame angle sensor: Short circuit with power supply line)................................................................................1212 Failure code [DKD0KZ] (AJSS lever and frame angle sensor: Disconnection or short circuit).......................................................................1214 Failure code [DLFAKA] (Modulation clutch output shaft speed sensor: Disconnection)..............................................................................1216 Failure code [DLFALC] (Modulation clutch output shaft speed sensor: Speed signals disagree).....................................................................1218 Failure code [DLT3KA] (Transmission output shaft speed sensor (2): Disconnection)...............................................................................1220 Failure code [DLT3LC] (Transmission output shaft speed sensor (2): Speed signals disagree)......................................................................1222 Failure code [DLT4KB] (Transmission output shaft speed sensor (1): Short circuit)...............................................................................1224 Failure code [DLT4KX] (Transmission output shaft speed sensor (1): Out of input signal range)...................................................................1226 Failure code [DV00KB] (Alarm buzzer: Short circuit).............................................................................................................1228 Failure code [DW4PKA] (Blade raise EPC solenoid: Disconnection).................................................................................................1230 Failure code [DW4PKB] (Blade raise EPC solenoid: Short circuit).................................................................................................1231 Failure code [DW4PKY] (Blade raise EPC solenoid: Short circuit with power supply line)..........................................................................1232 Failure code [DW4QKA] (Blade lower EPC solenoid: Disconnection).................................................................................................1234 Failure code [DW4QKB] (Blade lower EPC solenoid: Short circuit).................................................................................................1235 Failure code [DW4QKY] (Blade lower EPC solenoid: Short circuit with power supply line)..........................................................................1236 Failure code [DW4RKA] (Tilt & pitch EPC solenoid: Disconnection)................................................................................................1238 Failure code [DW4RKB] (Tilt & pitch EPC solenoid: Short circuit)................................................................................................1239 Failure code [DW4RKY] (Tilt & pitch EPC solenoid: Short circuit with power supply line).........................................................................1240 Failure code [DW4SKA] (Tilt & pitch EPC solenoid: Disconnection)................................................................................................1242 Failure code [DW4SKB] (Tilt & pitch EPC solenoid: Short circuit)................................................................................................1243 Failure code [DW4SKY] (Tilt & pitch EPC solenoid: Short circuit with power supply line).........................................................................1244 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).....................................................................................................1246 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).....................................................................................................1248 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)..............................................................................1250 309 Troubleshooting by failure code (Display of code), Part 9.......................................................................................................1253 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection).....................................................................................1256 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit).....................................................................................1258 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)..............................................................1260 Failure code [DWN7KA] (Blade float magnet detent solenoid: Disconnection).......................................................................................1262 Failure code [DWN7KB] (Blade float magnet detent solenoid: Short circuit).......................................................................................1264 Failure code [DWN7KY] (Blade float magnet detent solenoid: Short circuit with power supply line)................................................................1266 Failure code [DWNFKA] (Modulation clutch cut-off release solenoid: Disconnection)...............................................................................1268 Failure code [DWNFKB] (Modulation clutch cut-off release solenoid: Short circuit)...............................................................................1270 Failure code [DWNFKY] (Modulation clutch cut-off release solenoid: Short circuit with power source line)........................................................1272 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)....................................................................................................1274 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)....................................................................................................1275 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line).............................................................................1276 Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection).....................................................................................................1277 Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit).....................................................................................................1278 Failure code [DXF0KA] (AJSS EPC solenoid: Disconnection)........................................................................................................1279 Failure code [DXF0KB] (AJSS EPC solenoid: Short circuit)........................................................................................................1280 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).....................................................................................................1281 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).....................................................................................................1282 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)..............................................................................1284 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection).................................................................................................1286 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit).................................................................................................1288 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1290 310 Troubleshooting by failure code (Display of code), Part 10......................................................................................................1293 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection).................................................................................................1296 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit).................................................................................................1298 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1300 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection).................................................................................................1302 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).................................................................................................1304 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1306 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...................................................................................................1308 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...................................................................................................1310 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)............................................................................1312 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...................................................................................................1314 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...................................................................................................1316 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)............................................................................1318 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection).................................................................................................1320 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit).................................................................................................1322 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)..........................................................................1324 Failure code [DXHJKA] (RH pitch REAR EPC solenoid: Disconnection)...............................................................................................1326 Failure code [DXHJKB] (RH pitch REAR EPC solenoid: Short circuit)...............................................................................................1327 Failure code [DXHJKY] (RH pitch REAR EPC solenoid: Short circuit with power supply line)........................................................................1328 Failure code [DXHKKA] (RH pitch FORWARD EPC solenoid: Disconnection)............................................................................................1329 Failure code [DXHKKB] (RH pitch FORWARD EPC solenoid: Short circuit)............................................................................................1330 Failure code [DXHKKY] (RH pitch FORWARD EPC solenoid: Short circuit with power supply line).....................................................................1331 Failure code [DXHPKA] (Modulation clutch solenoid: Disconnection)...............................................................................................1332 Failure code [DXHPKB] (Modulation clutch solenoid: Short circuit)...............................................................................................1334 Failure code [DXHPKY] (Modulation clutch solenoid: Short circuit with power source line)........................................................................1336 Failure code [DXHPMA] (Modulation clutch solenoid: Malfunction).................................................................................................1338 Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) (Blow-by pressure: High error).........................................................................1340 Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) (Exhaust gas temperature (F): Abnormal heat)...........................................................1342 Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) (Exhaust gas temperature (F): Overheat)................................................................1344 Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) (Exhaust gas temperature (R): abnormal heat)...........................................................1346 Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) (Exhaust gas temperature (R): Overheat).................................................................1348 400 Troubleshooting of electrical system (E-mode)...................................................................................................................1351 Before carrying out troubleshooting of electrical system........................................................................................................1352 Information in troubleshooting table............................................................................................................................1355 E-1 Engine does not start.......................................................................................................................................1356 E-2 Wiper does not operate......................................................................................................................................1366 E-3 Windshield washer does not operate..........................................................................................................................1374 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off.............................................................................1380 E-5 Working lamp does not light up or go off....................................................................................................................1396 E-6 Step lamp does not light up or go off.......................................................................................................................1404 E-7 Turn signal lamp and hazard lamp do not light up or go off..................................................................................................1406 E-8 Brake lamp does not light or it keeps lighting up...........................................................................................................1416 E-9 Backup lamp does not light or it keeps lighting up..........................................................................................................1420 E-10 Backup buzzer does not sound or it keeps sounding..........................................................................................................1424 E-11 Horn does not sound or it keeps sounding...................................................................................................................1428 E-12 Alarm buzzer does not sound or it keeps sounding...........................................................................................................1432 E-13 Air conditioner does not operate or stop...................................................................................................................1434 E-14 Electric priming pump does not operate or does not stop automatically......................................................................................1436 500 Troubleshooting of hydraulic and mechanical system (H-mode).....................................................................................................1439 Method of using troubleshooting chart...........................................................................................................................1442 Table of failure modes and causes...............................................................................................................................1444 H-1 Machine does not start......................................................................................................................................1448 H-2 Torque converter lockup is not switched (engine stalls).....................................................................................................1450 H-3 Torque converter lockup is not turned on....................................................................................................................1451 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted......................................................1452 H-5 Shocks are large at the times of starting and shifting gear.................................................................................................1454 H-6 Time lag is large at the times of starting and shifting gear................................................................................................1456 H-7 Torque converter oil temperature is high....................................................................................................................1458 H-8 Steering does not turn [machine with steering wheel]........................................................................................................1459 H-9 Steering does not turn [machine with AJSS]..................................................................................................................1460 H-10 Turning, response of steering is poor [machine with steering wheel]........................................................................................1461 H-11 Turning, response of AJSS is poor [machine with AJSS]......................................................................................................1462 H-12 Steering is heavy [machine with steering wheel]............................................................................................................1463 H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel]..........................................................................1464 H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]....................................................................................1465 H-15 Wheel brake does not work or does not work well............................................................................................................1466 H-16 Wheel brake is not released or it drags....................................................................................................................1467 H-17 Parking brake does not work or does not work well..........................................................................................................1468 H-18 Parking brake is not released or it drags (including emergency release system).............................................................................1469 H-19 Blade does not rise........................................................................................................................................1470 H-20 Blade speed is low or rising force of lift is insufficient.................................................................................................1471 H-21 When rising, blade comes to move slowly at specific height.................................................................................................1472 H-22 Lift cylinder cannot hold down blade (Blade floats)........................................................................................................1472 H-23 Hydraulic drifts of blade occur often......................................................................................................................1472 H-24 Blade wobbles during operation.............................................................................................................................1472 H-25 Blade does not tilt and pitch..............................................................................................................................1473 H-26 Blade speed is low or tilt and pitch force is insufficient.................................................................................................1474 H-27 Bucket comes to operate slowly in the midst of tilt and pitch..............................................................................................1475 H-28 Tilt & pitch cylinder cannot hold down blade...............................................................................................................1475 H-29 Hydraulic drifts of blade occur often......................................................................................................................1475 H-30 Blade wobbles during travel when loaded (Work equipment valve is set to “HOLD”)............................................................................1475 H-31 During operation of machine, engine speed lowers remarkably or engine stalls...............................................................................1476 H-32 Large shocks are made when work equipment starts and stops.................................................................................................1476 H-33 When work equipment circuit is relieved singly, other work equipment moves.................................................................................1476 H-34 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats)...................................................................1477 600 Troubleshooting of engine (S-mode)..............................................................................................................................1479 Method of using troubleshooting chart...........................................................................................................................1480 S-1 Engine does not start easily................................................................................................................................1484 S-2 Engine does not start.......................................................................................................................................1486 S-3 Engine does not pick up smoothly............................................................................................................................1490 S-4 Engine stops during operation...............................................................................................................................1491 S-5 Engine does not rotate smoothly (Hunting occurs)............................................................................................................1492 S-6 Engine lacks output (or lacks power)........................................................................................................................1493 S-7 Exhaust smoke is black (Incomplete combustion)..............................................................................................................1494 S-8 Oil is consumed much (or exhaust gas color is blue).........................................................................................................1496 S-9 Engine oil becomes contaminated quickly.....................................................................................................................1497 S-10 Fuel consumption is excessive..............................................................................................................................1498 S-11 Coolant contains oil (blows back or reduces)...............................................................................................................1499 S-12 Oil pressure drops.........................................................................................................................................1500 S-13 Oil level rises (Water, fuel in oil).......................................................................................................................1502 S-14 Coolant temperature rises too high (Overheating)...........................................................................................................1504 S-15 Abnormal noise is made.....................................................................................................................................1505 S-16 Vibration is excessive.....................................................................................................................................1506 S-17 Air cannot be bled from fuel circuit.......................................................................................................................1508 50 Disassembly and assembly............................................................................................................................................. 0 100 General information on disassembly and assembly.................................................................................................................1511 How to read this manual.........................................................................................................................................1512 Coating materials list..........................................................................................................................................1514 Special tools list..............................................................................................................................................1517 Sketches of special tools.......................................................................................................................................1521 201 Engine and cooling system, Part 1...............................................................................................................................1531 Removal and installation of engine assembly.....................................................................................................................1532 Removal and installation of radiator assembly...................................................................................................................1536 Removal and installation of air aftercooler.....................................................................................................................1541 Removal and installation of cooling fan and fan motor assembly..................................................................................................1542 Removal and installation of damper assembly.....................................................................................................................1544 Disassembly and assembly of damper assembly.....................................................................................................................1546 Removal and installation of fuel tank assembly..................................................................................................................1550 Removal and installation of engine hood assembly................................................................................................................1552 Removal and installation of bulkhead assembly...................................................................................................................1554 202 Engine and cooling system, Part 2...............................................................................................................................1559 Removal and installation of fuel supply pump assembly...........................................................................................................1560 Removal and installation of cylinder head assembly..............................................................................................................1566 Removal and installation of fuel injector assembly..............................................................................................................1582 Removal and installation of engine front seal...................................................................................................................1586 Removal and installation of engine rear seal....................................................................................................................1589 301 Power train, Part 1.............................................................................................................................................1595 Removal and installation of parking brake assembly..............................................................................................................1596 Removal and installation of torque converter and transmission assembly..........................................................................................1598 302 Power train, Part 2.............................................................................................................................................1605 Disassembly and assembly of torque converter assembly...........................................................................................................1606 Disassembly and assembly of transmission assembly...............................................................................................................1633 Disassembly and assembly of transfer assembly...................................................................................................................1660 Disassembly and assembly of parking brake assembly..............................................................................................................1675 303 Power train, Part 3.............................................................................................................................................1683 Removal and installation of front axle assembly.................................................................................................................1684 Removal and installation of rear axle assembly..................................................................................................................1686 Removal and installation of center support assembly.............................................................................................................1688 Disassembly and assembly of center support assembly.............................................................................................................1690 Disassembly and assembly of differential assembly...............................................................................................................1694 304 Power train, Part 4.............................................................................................................................................1709 Removal and installation of final drive carrier assembly........................................................................................................1710 Disassembly and assembly of final drive carrier assembly........................................................................................................1712 Removal and installation of front final drive brake assembly....................................................................................................1713 Disassembly and assembly of final drive assembly................................................................................................................1715 400 Brake system....................................................................................................................................................1719 Disassembly and assembly of brake assembly......................................................................................................................1720 Removal and installation of brake valve assembly................................................................................................................1728 Disassembly and assembly of accumulator and charge valve assembly...............................................................................................1729 Disassembly and assembly of slack adjustor assembly.............................................................................................................1732 500 Undercarriage and frame.........................................................................................................................................1735 Removal and installation of center hinge pin....................................................................................................................1736 Removal and installation of counterweight assembly..............................................................................................................1743 600 Hydraulic system................................................................................................................................................1745 Removal and installation of hydraulic tank assembly.............................................................................................................1746 Removal and installation of hydraulic pump assembly.............................................................................................................1748 Removal and installation of control valve assembly..............................................................................................................1752 Disassembly and assembly of control valve assembly..............................................................................................................1754 Removal and installation of steering valve assembly.............................................................................................................1759 Disassembly and assembly of hydraulic cylinder assembly.........................................................................................................1760 700 Work equipment..................................................................................................................................................1767 Removal and installation of work equipment assembly.............................................................................................................1769 800 Cab and its attachments.........................................................................................................................................1774 Removal and installation of operator's cab assembly.............................................................................................................1775 Removal and installation of operator's cab glass (stuck glass)..................................................................................................1779 Removal and installation of floor frame assembly................................................................................................................1787 Disassembly and assembly of operator’s seat assembly............................................................................................................1790 Removal and installation of air conditioner unit assembly.......................................................................................................1823 900 Electrical system...............................................................................................................................................1828 Removal and installation of engine controller assembly..........................................................................................................1829 Removal and installation of transmission controller assembly....................................................................................................1831 Removal and installation of loader controller assembly..........................................................................................................1831 Removal and installation of VHMS controller assembly............................................................................................................1832 Removal and installation of machine monitor assembly............................................................................................................1833 90 Diagrams and drawings................................................................................................................................................ 0 100 Hydraulic diagrams and drawings.................................................................................................................................1838 Power train hydraulic circuit diagram...........................................................................................................................1839 Brake hydraulic circuit diagram.................................................................................................................................1840 Work equipment hydraulic circuit diagram........................................................................................................................1842 200 Electrical diagrams and drawings................................................................................................................................1845 Air conditioner electrical circuit diagram......................................................................................................................1847 Electrical circuit diagram (1/10)...............................................................................................................................1848 Electrical circuit diagram (2/10)...............................................................................................................................1849 Electrical circuit diagram (3/10)...............................................................................................................................1850 Electrical circuit diagram (4/10)...............................................................................................................................1851 Electrical circuit diagram (5/10)...............................................................................................................................1852 Electrical circuit diagram (6/10)...............................................................................................................................1853 Electrical circuit diagram (7/10)...............................................................................................................................1854 Electrical circuit diagram (8/10)...............................................................................................................................1855 Electrical circuit diagram (9/10)...............................................................................................................................1856 Electrical circuit diagram (10/10)..............................................................................................................................1857 Connector list and stereogram...................................................................................................................................1858
KOMATSU WD600-6 WHEEL DOZER SHOP MANUAL SEN04979-06 – PDF DOWNLOAD:
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