Komatsu Wheel Loader WA500-6H Shop Manual VEBM430100 -PDF DOWNLOAD

Description

Komatsu Wheel Loader WA500-6H Shop Manual VEBM430100 -PDF DOWNLOAD

FILE DETAILS:

Komatsu Wheel Loader WA500-6H Shop Manual VEBM430100 -PDF DOWNLOAD

Language : English
Pages :1452
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Wheel Loader WA500-6H Shop Manual VEBM430100 -PDF DOWNLOAD

WA500-6H H60051 and up

1. General precautions

TABLE OF CONTENTS:

Komatsu Wheel Loader WA500-6H Shop Manual VEBM430100 -PDF DOWNLOAD

WA500-6H H60051 and up

VEBM430100 WA500-6 1
00 Index and foreword 3
Foreword and general information 20
Safety notice 20
How to read the shop manual 24
Explanation of terms for maintenance standard 26
Handling electric equipment and hydraulic component 28
How to read electric wire code 36
Method of disassembling and connecting push-pull type coupler 39
Standard tightening torque table 42
Conversion table 46
Organization list of the shop manual 4
Table of contents 6
01 Specification 51
Specification and technical data 52
Specification dimension drawing 52
Specifications 53
Weight table 56
Table of fuel, coolant and lubricants 58
10 Structure, function and maintenance standard 59
Power train, Part 1 67
Power train 67
Power train system diagram 68
Joint 70
Drive shaft 71
Power train piping diagram 72
Torque converter 74
Torque converter regulator valve 92
Transmission 94
Transfer 110
Transmission control valve 112
ECMV 116
Main relief valve and torque converter relief valve 123
Lubrication relief valve 125
Engine and cooling system 60
Cooling system 60
Engine mount and transmission mount 63
Power train, Part 2 128
Torque converter oil cooler 128
Torque converter oil filter 129
Center support 132
Axle 134
Differential 136
Limited slip differential 145
Final drive 150
Steering system 156
Steering piping diagram 156
Steering column 157
Steering demand valve 158
Steering valve 169
Stop valve 173
Joystick steering lever linkage 174
Steering cylinder 175
Emergency steering piping diagram 176
Diverter valve 177
Brake system 184
Brake piping diagram 184
Brake valve 186
Slack adjuster 191
Accumulator charge valve 194
PPC relief valve 198
Accumulator (for brake) 200
Brake 202
Parking brake control 205
Parking brake 206
Parking brake solenoid valve 208
Emergency parking brake release valve 210
Undercarriage and frame 212
Axle mount 212
Center hinge pin 217
Hydraulic system, Part 1 222
Hydraulic piping diagram 222
Work equipment control lever linkage 224
Hydraulic tank 225
Cooling fan motor 227
Cooling fan pump 234
Steering pump 241
Work equipment hydraulic pump 252
Hydraulic system, Part 2 272
Control valve 272
CLSS 286
Each function and operation of each valve 291
Accumulator (for PPC circuit) 302
Work equipment electric lever 303
Work equipment 308
Work equipment linkage 308
Bucket 312
Bucket positioner and boom kick-out 314
Work equipment lubrication 315
Cab and its attachments 318
ROPS cab 318
Air conditioner 320
Electrical system, Part 1 328
Machine monitor system 328
Machine monitor 336
Electrical system, Part 2 390
Work equipment control system 390
Transmission controller system 424
Electrical system, Part 3 458
Electric transmission control 458
Engine starting circuit 462
Engine stopping circuit 464
Preheating circuit 465
Parking brake circuit 467
Backup and stop lamp circuits 472
Small lamp and head lamp circuits 474
Working lamp circuit 475
Horn circuit 476
Wiper and window washer circuits 477
Sensor 480
KOMTRAX terminal system 499
20 Standard value table 501
Standard service value table 502
Standard service value table for engine 502
Standard service value table for chassis 503
30 Testing and adjusting 511
Testing and adjusting, Part 1 513
Tools for testing, adjusting, and troubleshooting 513
Measuring engine speed 516
Measuring exhaust gas color 518
Measuring exhaust temperature 520
Adjusting valve clearance 522
Testing compression pressure 523
Measuring blow-by pressure 525
Measuring engine oil pressure 526
Measuring intake air (boost) pressure 527
Handling fuel system equipment 529
Releasing residual pressure in fuel system 529
Testing fuel pressure 530
Testing return rate and leakage 531
Bleeding air from fuel circuit 534
Testing leakage in fuel system 536
Handling reduced cylinder mode operation 537
Handling no injection cranking operation 537
Handling controller voltage circuit 538
Testing and adjusting alternator belt tension 539
Testing and adjusting air conditioner compressor belt tension 540
Adjusting transmission speed sensor 541
Measuring directional lever (Steering wheel specification) 543
Testing and adjusting power train oil pressure 544
Flushing procedure for torque converter and transmission hydraulic circuit 557
Method of moving machine when transmission valve is broken 560
Testing and adjusting, Part 2 565
Testing and adjusting steering stop valve 565
Testing and adjusting steering wheel 567
Testing steering oil pressure 569
Bleeding air from steering cylinder circuit 572
Testing hydraulic drive fan 573
Bleeding air from hydraulic drive fan circuit 576
Measuring brake pedal 578
Measuring brake performance 579
Testing and adjusting accumulator charge pressure 580
Testing wheel brake oil pressure 582
Measuring wear of wheel brake disc 584
Bleeding air from brake circuit 585
Releasing residual pressure in brake accumulator circuit 587
Testing parking brake performance 588
Measuring parking brake oil pressure 589
Testing wear of parking brake disc 592
Method of releasing parking brake manually 593
Measuring and adjusting work equipment control lever 594
Testing and adjusting work equipment PPC oil pressure 595
Measuring work equipment oil pressure 597
Bleeding air from work equipment circuit 603
Releasing residual pressure in work equipment circuit 604
Method of moving machine when removing operator cab (when splittable cab is used) 605
Testing and adjusting bucket positioner 606
Testing and adjusting lift arm position detecting lever 608
Checking proximity switch operation indication lamp 609
Procedure for testing diodes 610
Preparations for work on troubleshooting of electrical system 611
Testing and adjusting, Part 3 616
Starting KOMTRAX terminal operations 616
Indicator lamps of KOMTRAX terminal 622
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller 625
Special functions of machine monitor (EMMS) 627
Testing and adjusting, Part 4 667
Special functions of machine monitor (EMMS) 668
Pm click inspection table 706
40 Troubleshooting 709
Troubleshooting by failure code (Display of code), Part 1 745
Failure codes list 745
Before carrying out troubleshooting for electrical system 756
Information contained in troubleshooting table 758
Failure code [1500L0] (TORQFLOW transmission : Double meshing) 760
Failure code [15B0NX] (Transmission filter: Clogged) 762
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 764
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 766
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 768
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 770
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 772
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 774
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 776
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 778
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 780
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 782
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 784
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 786
Failure code [2F00MA] (Parking brake: Malfunction) 788
Failure code [2G42ZG] (Front accumulator: Low oil pressure) 790
Troubleshooting by failure code (Display of code), Part 2 796
Failure code [2G43ZG] (Rear accumulator: Low oil pressure) 796
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 798
Failure code [AA1ANX] (Air cleaner: Clogging) 800
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 802
Failure code [AB00MA] (Alternator: Malfunction) 804
Failure code [B@BAZG] (Low engine oil pressure) 806
Failure code [B@BAZK] (Engine oil: Low level) 808
Failure code [B@BCNS] (Coolant: Overheating) 810
Failure code [B@BCZK] (Coolant: Low level) 812
Failure code [B@C7NS] (Brake oil: Overheating) 814
Failure code [b@CENS] (Torque converter oil: Overheating) 816
Failure code [B@CENS] (Torque converter oil: Overheating) 818
Failure code [B@GAZK] (Battery electrolyte: Low level) 820
Failure code [B@HANS] (Hydraulic oil: Overheating) 822
Failure code [CA111] (Abnormality in engine controller) 824
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 827
Failure code [CA122] (Charge pressure sensor high error) 828
Failure code [CA123] (Charge pressure sensor low error) 830
Failure code [CA131] (Throttle sensor high error) 831
Failure code [CA132] (Throttle sensor low error) 833
Failure code [CA135] (Engine oil pressure sensor high error) 834
Failure code [CA141] (Engine oil pressure sensor low error) 836
Failure code [CA144] (Coolant temperature sensor high error) 837
Failure code [CA145] (Coolant temperature sensor low error) 839
Failure code [CA153] (Charge temperature sensor high error) 840
Failure code [CA154] (Charge temperature sensor low error) 842
Failure code [CA187] (Sensor power supply 2 low error) 842
Failure code [CA221] (Atmospheric pressure sensor high error) 843
Failure code [CA222] (Atmospheric pressure sensor low error) 845
Failure code [CA227] (Sensor power supply 2 high error) 846
Troubleshooting by failure code (Display of code), Part 3 851
Failure code [CA234] (Engine overspeed) 851
Failure code [CA238] (Ne speed sensor power supply error) 852
Failure code [CA263] (Fuel temperature sensor high error) 854
Failure code [CA265] (Fuel temperature sensor low error) 856
Failure code [CA271] (PCV1 Short circuit) 858
Failure code [CA272] (PCV1 Disconnection) 860
Failure code [CA273] (PCV2 Short circuit) 862
Failure code [CA274] (PCV2 Disconnection) 864
Failure code [CA322] (Injector #1 (L/B #1) open/short error) 866
Failure code [CA323] (Injector #5 (L/B #5) open/short error) 868
Failure code [CA324] (Injector #3 (L/B #3) open/short error) 870
Failure code [CA325] (Injector #6 (L/B #6) open/short error) 872
Failure code [CA331] (Injector #2 (L/B #2) open/short error) 874
Failure code [CA332] (Injector #4 (L/B #4) open/short error) 876
Failure code [CA342] (Calibration code inconsistency) 878
Failure code [CA351] (Injector drive circuit error) 879
Failure code [CA352] (Sensor power supply 1 low error) 882
Failure code [CA386] (Sensor power supply 1 high error) 884
Failure code [CA431] (Idle validation switch error) 886
Failure code [CA432] (Idle validation action error) 888
Failure code [CA441] (Battery voltage low error) 888
Failure code [CA442] (Battery voltage high error) 889
Failure code [CA449] Common rail pressure high error 2 889
Failure code [CA451] (Common rail pressure sensor high error) 890
Failure code [CA452] (Common rail pressure sensor low error) 892
Failure code [CA553] (Common rail pressure high error 1) 893
Failure code [CA554] (Common rail pressure sensor in-range error) 894
Failure code [CA559] (Supply pump pressure very low error) 895
Failure code [CA689] (Engine Ne speed sensor error) 898
Failure code [CA731] (Engine Bkup speed sensor phase error) 900
Failure code [CA757] (All continuous data lost error) 900
Failure code [CA778] (Engine Bkup speed sensor error) 902
Failure code [CA1228] (EGR valve servo error 1) 904
Failure code [CA1625] (EGR valve servo error 2) 905
Failure code [CA1626] (Bypass valve solenoid current high error) 906
Failure code [CA1627] (Bypass valve solenoid current low error) 908
Failure code [CA1628] (Bypass valve servo error 1) 909
Failure code [CA1629] (Bypass valve servo error 2) 910
Failure code [CA1631] (Bypass valve lift sensor high error) 911
Failure code [CA1632] (Bypass valve lift sensor low error) 913
Failure code [CA1633] (KOMNET datalink timeout error) 913
Troubleshooting by failure code (Display of code), Part 4 917
Failure code [CA1642] (EGR inlet pressure sensor low error) 917
Failure code [CA1653] (EGR inlet pressure sensor high error) 918
Failure code [CA2185] (Throttle sensor supply voltage high error) 920
Failure code [CA2186] (Throttle sensor power supply low error) 922
Failure code [CA2249] (Supply pump pressure very low error 2) 922
Failure code [CA2271] (EGR valve lift sensor high error) 923
Failure code [CA2272] (EGR valve lift sensor low error) 925
Failure code [CA2351] (EGR valve solenoid operation short circuit) 926
Failure code [CA2352] (EGR valve solenoid operation disconnect) 928
Failure code [CA2555] (Intake heater relay disconnection error) 928
Failure code [CA2556] (Intake heater relay short circuit error) 930
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) 932
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 934
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 936
Failure code [D192KA] (ECSS solenoid: Disconnection) 938
Failure code [D192KB] (ECSS solenoid: Short circuit) 939
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 940
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 942
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 944
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) 946
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 948
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 950
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 952
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 954
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 956
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 958
Failure code [DAF5KP] (Machine monitor: Low output voltage) 960
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)) 962
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 964
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 966
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)) 968
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals) 970
Troubleshooting by failure code (Display of code), Part 5 974
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)) 974
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) 976
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) 978
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 980
Failure code [DB90KT] (Work equipment controller: Abnormality in controller) 982
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) 984
Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range) 986
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals) 988
Failure code [DB9RKR] (CAN communication with work equipment controller: Defective communication (Abnormality in target component system)) 990
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) 992
Failure code [DB9RMC] (CAN communication with work equipment controller: Defective operation) 994
Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept pressed for long time) 996
Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept pressed for long time) 998
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)1000
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)1002
Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time)1004
Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time)1006
Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time)1008
Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time)1010
Failure code [DD1GLD] (Load meter mode selector switch (+/-): Switch is kept pressed for long time)1012
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)1014
Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree)1016
Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)1018
Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit)1020
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)1022
Troubleshooting by failure code (Display of code), Part 61028
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)1028
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)1030
Failure code [DDK3KA] (Right FNR switch: Disconnection)1032
Failure code [DDK3KB] (Right FNR switch: Short circuit)1034
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)1036
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)1038
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)1040
Failure code [DDK6KA] (FNR lever switch: Disconnection)1042
Failure code [DDK6KB] (FNR lever switch: Short circuit)1046
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)1048
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)1050
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)1052
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)1054
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)1056
Failure code [DF10KA] (Transmission shift lever switch: Disconnection)1058
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)1062
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)1064
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)1066
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)1068
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)1070
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)1072
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)1074
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)1076
Troubleshooting by failure code (Display of code), Part 71082
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)1082
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)1084
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)1086
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range)1088
Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine)1090
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)1092
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)1096
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)1099
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)1102
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)1105
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)1108
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)1111
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)1114
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)1117
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)1120
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)1123
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)1125
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)1127
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)1130
Troubleshooting by failure code (Display of code), Part 81136
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)1136
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)1138
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)1140
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)1142
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)1144
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)1146
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)1150
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)1152
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)1154
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)1156
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)1158
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)1160
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)1162
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range)1164
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)1166
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)1168
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)1170
Failure code [DV00KB] (Alarm buzzer: Short circuit)1172
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)1174
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)1175
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)1176
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)1178
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)1179
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)1180
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)1182
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)1184
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)1186
Troubleshooting by failure code (Display of code), Part 91191
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)1191
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)1192
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)1194
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)1196
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)1198
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)1200
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)1202
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)1202
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)1203
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)1204
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)1206
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)1208
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)1210
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)1212
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)1214
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)1216
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)1218
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)1220
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)1222
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1224
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)1226
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)1228
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)1229
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)1230
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)1231
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)1232
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)1233
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)1234
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)1236
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)1238
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)1240
Troubleshooting by failure code (Display of code), Part 101246
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)1246
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)1248
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)1250
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)1252
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)1254
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)1256
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)1258
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)1260
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)1262
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)1264
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)1266
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)1268
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)1270
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)1272
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)1274
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)1276
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)1278
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)1279
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)1280
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)1281
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)1282
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)1283
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)1284
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)1286
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)1288
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)1290
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)1292
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)1294
Troubleshooting of electrical system (E-mode)1299
Before carrying out troubleshooting of electrical system1299
Information in troubleshooting table1302
E-1 Engine does not start1303
E-2 Wiper does not operate1308
E-3 Windshield washer does not operate1312
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off1315
E-5 Working lamp does not light up or go off1323
E-6 Turn signal lamp and hazard lamp do not light up or go off1328
E-7 Brake lamp does not light or it keeps lighting up1334
E-8 Backup lamp does not light or it keeps lighting up1336
E-9 Backup buzzer does not sound or it keeps sounding1338
E-10 Horn does not sound or it keeps sounding1340
E-11 Alarm buzzer does not sound or it keeps sounding1343
E-12 Air conditioner does not operate or stop1345
E-13 KOMTRAX system does not work properly1348
Troubleshooting of hydraulic and mechanical system (H-mode)1353
Method of using troubleshooting chart1353
Table of failure modes and causes1356
H-1 Machine does not start1360
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]1362
H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)]1363
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted1364
H-5 Shocks are large at the times of starting and shifting gear1366
H-6 Time lag is large at the times of starting and shifting gear1368
H-7 Torque converter oil temperature is high1370
H-8 Steering does not turn1371
H-9 Steering does not turn [Machine with joystick steering (if equipped)]1372
H-10 Steering response is low1373
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)]1374
H-12 Steering is heavy1375
H-13 When machine turns, it shakes or makes large shocks1376
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]1377
H-15 Wheel brake does not work or does not work well1378
H-16 Wheel brake is not released or it drags1379
H-17 Parking brake does not work or does not work well1380
H-18 Parking brake is not released or it drags (including emergency release system)1381
H-19 Lift arm does not rise1382
H-20 Lift arm speed is low or rising force of lift arm is insufficient1383
H-21 When rising, lift arm comes to move slowly at specific height1384
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)1384
H-23 Hydraulic drifts of lift arm occur often1384
H-24 Lift arm wobbles during operation1384
H-25 Bucket does not tilt back1385
H-26 Bucket speed is low or tilting back force is insufficient1386
H-27 Bucket comes to operate slowly in the midst of tilting-back1387
H-28 Bucket cylinder cannot hold down the bucket1387
H-29 Hydraulic drifts of bucket occur often1387
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)1387
H-31 During operation of machine, engine speed lowers remarkably or engine stalls1388
H-32 Large shocks are made when work equipment starts and stops1388
H-33 When work equipment circuit is relieved singly, other work equipment moves1388
H-34 ECSS does not operate, and pitching and bouncing occur1389
Troubleshooting of engine (S-mode)1393
Method of using troubleshooting chart1393
S-1 Engine does not start easily1396
S-2 Engine does not start1398
S-3 Engine does not pick up smoothly1402
S-4 Engine stops during operation1403
S-5 Engine does not rotate smoothly (Engine hunts)1404
S-6 Engine lacks output (or lacks power)1405
S-7 Exhaust smoke is black (Incomplete combustion)1406
S-8 Oil is consumed much (or exhaust gas color is blue)1408
S-9 Engine oil becomes contaminated quickly1409
S-10 Fuel consumption is excessive1410
S-11 Coolant contains oil (blows back or reduces)1411
S-12 Oil pressure drops1412
S-13 Oil level rises (Water, fuel in oil)1413
S-14 Coolant temperature rises too high (Overheating)1415
S-15 Abnormal noise is made1416
S-16 Vibration is excessive1417
General information on troubleshooting 710
Points to remember when troubleshooting 710
Sequence of events in troubleshooting 711
Testing before troubleshooting 712
Classification and procedures of troubleshooting 713
Connection table for connector pin numbers 716
T-branch box and T-branch adapter table 739
90 Diagrams and drawings1419
Hydraulic diagrams and drawings1419
Power train hydraulic circuit diagram1421
Brake hydraulic circuit diagram1425
Work equipment hydraulic circuit diagram1429
Electrical diagrams and drawings1431
Air conditioner electrical circuit diagram1433
Electrical circuit diagram (1/7)1435
Electrical circuit diagram (2/7)1437
Electrical circuit diagram (3/7)1439
Electrical circuit diagram (4/7)1441
Electrical circuit diagram (5/7)1443
Electrical circuit diagram (6/7)1445
Electrical circuit diagram (7/7)1447
Connector arrangement diagram1449

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24