Komatsu Wheel Loader WA430-6 Shop Manual SEN00823-22 – PDF DOWNLOAD

Description

Komatsu Wheel Loader WA430-6 Shop Manual SEN00823-22 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Wheel Loader WA430-6 Shop Manual SEN00823-22 – PDF DOWNLOAD

Language : English
Pages :1842
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Wheel Loader WA430-6 Shop Manual SEN00823-22 – PDF DOWNLOAD

SERIAL NUMBERS 65001 and up

1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu Wheel Loader WA430-6 Shop Manual SEN00823-22 – PDF DOWNLOAD

SERIAL NUMBERS 65001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 21
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of electric equipment and hydraulic component 31
Handling of connectors newly used for engines 40
How to read electric wire code 43
Precautions when carrying out operation 46
Method of disassembling and connecting push-pull type coupler 49
Standard tightening torque table 52
Conversion table 56
01 Specification 63
Specification and technical data 63
Specification dimension drawing 65
Specifications 66
Weight table 70
Table of fuel, coolant and lubricants 72
10 Structure, function and maintenance standard 75
Engine and cooling system 75
Engine mount and transmission mount 76
Cooling system 77
Cooling fan pump 78
Cooling fan motor 86
Power train 93
Power train 95
Power train system diagram 96
Drive shaft 98
Power train piping diagram 99
Torque converter 100
Transmission 108
Flow control valve 125
Transmission control valve 128
ECMV 132
Main relief valve and torque converter relief valve 138
Axle 140
Differential 142
Limited slip differential 148
Final drive 154
Steering system 161
Steering piping diagram 163
Steering column 164
Steering pump 165
Steering valve 177
Orbit-roll valve 192
Stop valve 196
Steering relief valve 197
Steering cylinder 198
Emergency steering motor 200
Emergency steering pump 201
Joystick steering lever linkage 202
Steering electric lever 203
Joystick EPC valve 204
Brake system 207
Brake piping diagram 208
Charge valve 209
Brake valve 216
Accumulator (for brake) 221
Brake 222
Parking brake control 227
Parking brake 228
Parking brake solenoid valve 230
Emergency parking brake release valve 232
Undercarriage and frame 235
Axle mount and center hinge pin 236
Tires 240
Hydraulic system, Part 1 243
Hydraulic piping diagram 244
Work equipment control lever linkage 247
Hydraulic tank 250
Power train pump 252
Work equipment pump 253
Work equipment control valve 264
CLSS 278
Each function and operation of each valve 282
Hydraulic system, Part 2 305
PPC valve 306
Stabilizer valve 314
Accumulator (for PPC circuit) 320
Accumulator (for ECSS) 321
Work equipment PPC cut-off solenoid valve 322
Work equipment 325
Work equipment linkage 326
Bucket 328
Bucket positioner and boom kick-out 329
Work equipment cylinder 335
Cab and its attachments 337
Cab 339
Air conditioner 340
Electrical system, Part 1 359
Machine monitor system 360
Machine monitor 364
Electrical system, Part 2 397
Electrical system (Transmission controller system) 398
Transmission controller 440
Electrical system (Work equipment controller system) 442
Work equipment controller 448
Electrical system, Part 3 451
Electric transmission control 452
Kickdown switch and hold switch 456
Load meter cancel switch and load meter subtotal switch 456
Multi-function knob 457
Joystick steering knob 458
KOMTRAX system 460
Engine starting circuit 462
Engine stopping circuit 464
Preheating circuit 465
Engine power mode selector circuit 466
Engine output derating function 467
Automatic warm-up function 467
Parking brake circuit 468
Sensor 470
20 Standard value table 481
Standard service value table 481
Standard value table for engine 482
Standard value table for chassis 483
30 Testing and adjusting 491
Testing and adjusting, Part 1 491
Precautions before work 493
Tools for testing, adjusting, and troubleshooting 494
Sketch of special tool 499
Testing engine speed 500
Testing exhaust gas color 502
Testing exhaust temperature 503
Adjusting valve clearance 505
Testing compression pressure 507
Testing blow-by pressure 511
Testing engine oil pressure 512
Testing intake air (boost) pressure 513
Handling fuel system equipment 514
Releasing residual pressure in fuel system 514
Testing fuel pressure 515
Testing fuel return and leak amount 521
Bleeding air from fuel circuit 523
Testing leakage in fuel system 524
Handling reduced cylinder mode operation 525
Handling no-injection cranking operation 525
Handling controller voltage circuit 526
Check of muffler and muffler stack for looseness and damage 527
Check of muffler function 527
Check of installed condition of cylinder head and manifolds 528
Check of engine piping for damage and looseness 528
Checking and replacing alternator belt 529
Checking and replacing auto- tensioner 531
Adjusting transmission speed sensor 533
Adjusting directional lever length 534
Adjusting gear shift lever length 534
Testing directional lever 535
Testing and adjusting power train oil pressure 536
Procedure for flushing torque converter and transmission hydraulic circuit 550
Method of moving machine when transmission valve is broken 551
Checking axle final drive for oil leakage 553
Checking drive shafts for looseness, play and damage 553
Testing and adjusting steering stop valve 554
Testing and adjusting steering wheel 556
Testing and adjusting steering oil pressure 558
Bleeding air from steering circuit 561
Testing and adjusting, Part 2 563
Testing hydraulic drive fan 565
Bleeding air from hydraulic drive fan circuit 567
Testing brake pedal 569
Testing and adjusting brake pedal linkage 570
Testing brake performance 571
Measuring accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas 572
Testing and adjusting accumulator charge pressure 578
Testing wheel brake oil pressure 579
Testing wear of wheel brake disc 581
Bleeding air from wheel brake circuit 582
Releasing residual pressure in brake accumulator circuit 583
Testing parking brake performance 584
Testing parking brake oil pressure 585
Testing wear of parking brake disc 587
Method of releasing parking brake manually 588
Testing and adjusting work equipment control lever 589
Testing and adjusting work equipment PPC oil pressure 590
Testing and adjusting work equipment oil pressure 593
Bleeding air from work equipment circuit 597
Releasing residual pressure in work equipment circuit 598
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator 599
Testing and adjusting bucket positioner 603
Testing and adjusting boom kick- out 605
Checking proximity switch operation pilot lamp 606
Procedure for testing diodes 607
Preparation work for troubleshooting for electrical system 608
Starting KOMTRAX terminal operations 613
Indicator lamps of KOMTRAX terminal 618
Testing and adjusting, Part 3 623
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 624
Special functions of machine monitor (EMMS) 627
Pm-clinic inspection table 695
40 Troubleshooting 699
Failure code table and fuse locations 699
Precautions before work 700
Failure code table 701
Fuse locations 712
General information on troubleshooting 717
Points to remember when troubleshooting 718
Sequence of events in troubleshooting 719
Testing before troubleshooting 720
Classification and procedures of troubleshooting 721
Information contained in troubleshooting table 724
Connection table for connector pin numbers 726
T- branch box and T- branch adapter table 762
Troubleshooting by failure code (Display of code), Part 1 767
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 769
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 770
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 772
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 774
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 776
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 778
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 780
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 782
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 784
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 786
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 788
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 790
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 792
Failure code [2F00MA] (Parking brake: Malfunction) 794
Failure code [2G43ZG] (Accumulator: Low oil pressure) 796
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 798
Troubleshooting by failure code (Display of code), Part 2 803
Failure code [AA1ANX] (Air cleaner: Clogging) 806
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 808
Failure code [AB00MA] (Alternator: Malfunction) 810
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 812
Failure code [B@BAZK] (Engine oil: Low level) 813
Failure code [B@BCNS] (Coolant: Overheating) 814
Failure code [B@BCZK] (Coolant: Low level) 816
Failure code [B@BEBF] (Water in fuel error) 818
Failure code [B@C7NS] (Brake oil: Overheating) 820
Failure code [b@CENS] (Torque converter oil: Overheating) 822
Failure code [B@CENS] (Torque converter oil: Overheating) 824
Failure code [B@HANS] (Hydraulic oil: Overheating) 826
Failure code [CA111] (Abnormality in engine controller) 828
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 829
Failure code [CA122] (Charge pressure sensor high error) 830
Failure code [CA123] (Charge pressure sensor low error) 832
Failure code [CA131] (Throttle sensor high error) 834
Failure code [CA132] (Throttle sensor low error) 836
Failure code [CA144] (Coolant sensor high error) 838
Failure code [CA145] (Coolant sensor low error) 840
Failure code [CA153] (Charge temperature sensor high error) 842
Failure code [CA154] (Charge temperature sensor low error) 844
Failure code [CA155] (Derating of speed by abnormally high charge temperature) 846
Failure code [CA187] (Sensor power supply 2 low error) 848
Failure code [CA221] (Atmospheric pressure sensor high error) 850
Failure code [CA222] (Atmospheric sensor low error) 852
Failure code [CA227] (Sensor power supply 2 high error) 854
Failure code [CA234] (Engine overspeed) 855
Failure code [CA238] (Ne speed sensor power supply error) 856
Troubleshooting by failure code (Display of code), Part 3 859
Failure code [CA271] (IMV/PCV1 Short circuit) 861
Failure code [CA272] (IMV/PCV1 Disconnection) 862
Failure code [CA281] High pressure pump error 864
Failure code [CA322] (Injector #1 open/short error) 866
Failure code [CA323] (Injector #5 open/short error) 868
Failure code [CA324] (Injector #3 open/short error) 870
Failure code [CA325] (Injector #6 open/short error) 872
Failure code [CA331] (Injector #2 open/short error) 874
Failure code [CA332] (Injector #4 open/short error) 876
Failure code [CA342] (Calibration code inconsistency) 878
Failure code [CA351] (Injectors drive circuit error) 880
Failure code [CA352] (Sensor power supply 1 low error) 882
Failure code [CA386] (Sensor power supply 1 high error) 884
Failure code [CA428] (Abnormally high level in water sensor) 885
Failure code [CA429] (Abnormally low level in water sensor) 886
Failure code [CA431] (Idle validation switch error) 888
Failure code [CA432] (Idle validation action error) 890
Failure code [CA435] (Engine oil pressure switch error) 892
Failure code [CA441] (Battery voltage low error) 893
Failure code [CA442] (Battery voltage high error) 896
Failure code [CA449] Common rail pressure high error 2 898
Failure code [CA451] (Common rail pressure sensor high error) 902
Failure code [CA452] (Common rail pressure sensor low error) 904
Failure code [CA488] (Derating of torque by abnormally high charge temperature) 906
Failure code [CA553] (Common rail pressure high error 1) 907
Failure code [CA559] (Supply pump pressure very low error) 908
Failure code [CA689] (Engine Ne speed sensor error) 910
Failure code [CA731] (Engine Bkup speed sensor phase error) 912
Failure code [CA757] (All continuous data lost error) 913
Failure code [CA778] (Engine Bkup speed sensor error) 916
Failure code [CA1633] (KOMNET datalink timeout error) 918
Failure code [CA2185] (Throttle sensor power supply voltage high error) 920
Failure code [CA2186] (Throttle sensor power supply voltage low error) 921
Troubleshooting by failure code (Display of code), Part 4 923
Failure code [CA2249] (Supply pump pressure very low error 2) 925
Failure code [CA2265] (Abnormally high level in electric lift pump) 926
Failure code [CA2266] (Abnormally low level in electric lift pump) 928
Failure code [CA2311] (Abnormality in IMV solenoid) 930
Failure code [CA2555] (Intake heater relay disconnection error) 932
Failure code [CA2556] (Intake heater relay short circuit error) 934
Failure code [D150KA] (Emergency steering relay: Disconnection) 936
Failure code [D150KB] (Emergency steering relay: Short circuit) 938
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 940
Failure code [D160KA] (Backup lamp relay: Disconnection) 942
Failure code [D160KB] (Backup lamp relay: Short circuit) 944
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) 946
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 948
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 950
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) 952
Failure code [D192KA] (ECSS solenoid: Disconnection) 954
Failure code [D192KB] (ECSS solenoid: Short circuit) 955
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 956
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 958
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 960
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) 962
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 965
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 969
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 972
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 977
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 980
Failure code [DAF3KK] (Machine monitor: Low source voltage (input) 982
Failure code [DAF5KP] (Machine monitor: Low output voltage) 984
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system) 988
Troubleshooting by failure code (Display of code), Part 5 991
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 994
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 996
Failure code [DAQ1KA] (Terminal ACC input: Disconnection) 997
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)1000
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)1002
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)1003
Failure code [DAQRMA] (Transmission controller option setting: Disagreement of option selection)1006
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)1008
Failure code [DB90KK] Work equipment controller: Low source voltage (input)1010
Failure code [DB90KT] Work equipment controller: Abnormality in controller1012
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)1014
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range1016
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)1019
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)1020
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)1022
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)1023
Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time1026
Failure code [DD16LD] ◇ switch (Panel switch 2): Switch is kept pressed for long time1028
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time1030
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time1032
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time1034
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time1036
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time1038
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time1040
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time1042
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)1044
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)1046
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)1048
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)1050
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)1054
Troubleshooting by failure code (Display of code), Part 61057
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)1060
Failure code [DDK3KA] (Right FNR switch: Disconnection)1062
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)1065
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)1068
Failure code [DDK6KA] (FNR lever switch: Disconnection)1070
Failure code [DDK6KB] (FNR lever switch: Short circuit)1074
Failure code [DDS5KA] (Steering pressure switch: Disconnected)1076
Failure code [DDS5KB] (Steering pressure switch: Short-circuit)1078
Failure code [DDS5L6] (Steering: Low oil pressure)1080
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)1082
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)1084
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)1086
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)1088
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)1090
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)1092
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)1096
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)1098
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)1100
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)1102
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)1104
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)1106
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)1108
Troubleshooting by failure code (Display of code), Part 71111
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)1114
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)1116
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)1118
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)1120
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)1122
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)1124
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)1126
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)1128
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)1131
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)1134
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)1137
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)1140
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)1143
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)1146
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)1149
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)1152
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)1155
Troubleshooting by failure code (Display of code), Part 81159
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)1161
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)1164
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)1166
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)1170
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)1172
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)1176
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)1178
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)1180
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)1182
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)1184
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)1186
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)1188
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)1190
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)1192
Failure code [DV00KB] (Alarm buzzer: Short circuit)1194
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)1196
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)1198
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)1200
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)1202
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)1203
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)1204
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)1206
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)1207
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)1208
Troubleshooting by failure code (Display of code), Part 91211
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)1213
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)1214
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)1216
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)1218
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)1219
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)1220
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)1221
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)1222
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)1223
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)1224
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)1226
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)1228
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)1230
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)1232
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)1234
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)1236
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)1238
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)1240
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)1242
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1244
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)1246
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)1248
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)1249
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)1250
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)1252
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)1254
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)1256
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)1258
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)1260
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)1262
Troubleshooting by failure code (Display of code), Part 101265
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)1268
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)1270
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)1272
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)1274
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)1276
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)1278
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)1280
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)1282
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)1284
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)1286
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)1288
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)1290
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)1292
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)1294
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)1296
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)1298
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)1300
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)1302
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)1304
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)1306
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)1308
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)1310
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)1313
Failure code [DY30ME] Emergency steering: Operating for more than 1 minute1316
Troubleshooting of electrical system (E-mode)1321
Installing positions of fuses1323
Information in troubleshooting table1326
E-1 Engine does not start1328
E-2 Wiper does not operate1334
E-3 Windshield washer does not operate1338
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off1341
E-5 Working lamp does not light up or go off1349
E-6 Turn signal lamp and hazard lamp do not light up or go off1354
E-7 Brake lamp does not light or it keeps lighting up1360
E-8 Backup lamp does not light or it keeps lighting up1362
E-9 Backup buzzer does not sound or it keeps sounding1364
E-10 Horn does not sound or it keeps sounding1366
E-11 Alarm buzzer does not sound or it keeps sounding1368
E-12 Air conditioner does not operate or stop1370
E-13 The KOMTRAX system does not work properly1373
E-14 When kick-down switch is turned ON, kick-down operation does not start1376
E-15 When hold switch is pressed, holding operation does not start1378
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied1380
E-17 Transmission cut-off mode cannot be set or reset1382
E-18 Transmission cut-off set cannot be reset1384
E-19 FNR switch mode cannot be set or reset1386
E-20 Fan reverse function cannot be used or reset1388
E-21 Discharge from loader pump does not rise from minimum level1390
E-22 ECSS function cannot be used or reset1392
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up1394
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate1398
E-25 Air cleaner clogging indicator lamp does not light up1400
E-26 Radiator coolant level caution lamp does not light up1402
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up1403
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up1404
E-29 Steering oil pressure caution lamp does not light up1406
E-30 Abnormality in ■ switch (panel switch 1) input1408
E-31 Abnormality in ◇ switch (panel switch 2) input1410
E-32 Abnormality in < switch (panel switch 3) input1412
E-33 Abnormality in > switch (panel switch 4) input1414
E-34 Air conditioner does not operate1416
E-35 Air is not cooled1420
E-36 No air comes out or air flow is abnormal1424
E-37 Temperature cannot be controlled1430
E-38 Spurting out mode cannot be switched1434
E-39 Recirc/Fresh cannot be changed over1438
Troubleshooting of hydraulic and mechanical system (H-mode)1441
Method of using troubleshooting chart1443
Table of failure modes and causes1446
H-1 The machine does not start1450
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]1452
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]1453
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted1454
H-5 Shocks are large at the times of starting and shifting gear1456
H-6 Time lag is large at the times of starting and shifting gear1458
H-7 The torque converter oil temperature is high1460
H-8 Steering does not turn1461
H-9 Steering does not turn [Machine with joystick steering (if equipped)]1462
H-10 Steering response is low1463
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]1464
H-12 Steering is heavy1465
H-13 When machine turns, it shakes or makes large shocks1466
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]1467
H-15 The wheel brake does not work or does not work well1468
H-16 The wheel brake is not released or it drags1469
H-17 The parking brake does not work or does not work well1470
H-18 The parking brake is not released or it drags (including emergency release system)1471
H-19 Lift arm does not rise1472
H-20 Lift arm speed is low or rising force of lift arm is insufficient1473
H-21 When rising, the lift arm comes to move slowly at specific height1474
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)1474
H-23 Hydraulic drifts of the lift arm is large1474
H-24 The lift arm wobbles during operation1474
H-25 Bucket does not tilt back1475
H-26 Bucket speed is low or tilting back force is insufficient1476
H-27 The bucket comes to operate slowly in the midst of tilting-back1477
H-28 The bucket cylinder cannot hold down the bucket1477
H-29 Hydraulic drifts of the bucket is large1477
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)1477
H-31 Lift arm and bucket control levers do not move smoothly and are heavy1478
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls1479
H-33 Large shock is made when work equipment starts and stops1479
H-34 When work equipment circuit is relieved singly, other work equipment moves1479
H-35 ECSS does not operate, and pitching, bouncing occur1480
Troubleshooting of engine (S-mode)1483
Method of using troubleshooting charts1485
S-1 Engine does not start easily1488
S-2 Engine does not start1489
S-3 Engine does not pick up smoothly1492
S-4 Engine stops during operations1493
S-5 Engine does not rotate smoothly1494
S-6 Engine lacks output (or lacks power)1495
S-7 Exhaust smoke is black (Incomplete combustion)1496
S-8 Oil consumption is excessive (or exhaust smoke is blue)1497
S-9 Engine oil becomes contaminated quickly1498
S-10 Fuel consumption is excessive1499
S-11 Coolant contains oil (blows back or reduces)1500
S-12 Oil pressure drops1501
S-13 Oil level rises (Water, fuel in oil)1502
S-14 Coolant temperature rises too high (Overheating)1503
S-15 Abnormal noise is made1504
S-16 Vibration is excessive1505
50 Disassembly and assembly1507
General information on disassembly and assembly1507
Precautions before work1508
How to read this manual1509
Coating materials list1511
Special tools list1514
Sketches of special tools1517
Engine and cooling system1531
Removal and installation of fuel supply pump assembly1532
Removal and installation of fuel injector assembly1535
Removal and installation of cylinder head assembly1544
Removal and installation of engine hood and radiator guard assembly1557
Removal and installation of radiator assembly1559
Removal and installation of air aftercooler assembly1561
Removal and installation of hydraulic oil cooler assembly1563
Removal and installation of engine assembly1564
Removal and installation of front seal assembly1569
Removal and installation of rear oil seal assembly1571
Removal and installation of cooling fan and fan motor assembly1576
Removal and installation of fuel tank assembly1579
Power train, Part 11583
Removal and installation of torque converter and transmission assembly1584
Disassembly and assembly of torque converter assembly (Standard specification)1589
Disassembly and assembly of torque converter assembly (Lock-up specification)1593
Disassembly and assembly of transmission assembly1600
Disassembly and assembly of transmission clutch pack assembly1615
Disassembly and assembly of parking brake assembly1631
Power train, Part 21641
Removal and installation of front axle assembly1642
Removal and installation of rear axle assembly1644
Disassembly and assembly of axle housing1648
Disassembly and assembly of differential assembly1657
Steering system1681
Removal and installation of steering demand valve assembly1682
Removal and installation of steering valve oil seal1684
Brake system1687
Removal and installation of parking brake disc and plate1688
Undercarriage and frame1693
Removal and installation of center hinge pin1694
Removal and installation of counterweight1702
Hydraulic system1705
Removal and installation of work equipment control valve assembly1706
Removal and installation of power train pump and work equipment pump assembly1709
Removal and installation of steering pump and cooling fan pump assembly1710
Removal and installation of hydraulic tank assembly1711
Work equipment1715
Removal and installation of work equipment assembly1716
Disassembly and assembly of hydraulic cylinder assembly1721
Cab and its attachments1729
Removal and installation of operator’s cab and floor frame assembly1730
Removal and installation of operator’s cab glass (stuck glass)1734
Disassembly and assembly of operator’s seat assembly (Standard specification)1742
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER)1751
Removal and installation of air conditioner unit assembly1784
Electrical system1791
Removal and installation of engine controller assembly1792
Removal and installation of KOMTRAX terminal assembly1793
90 Diagrams and drawings1795
Hydraulic diagrams and drawings1795
Power train hydraulic circuit diagram1796
Automatic greasing circuit diagram1800
Hydraulic circuit diagram1803
Electrical diagrams and drawings1807
Electrical circuit diagram1809
Work equipment controller system electrical circuit diagram1837
Connector list and sterogram1839

S.M 29/12/24