Komatsu Wheel Loader WA600-6R Shop Manual SEN02211-14 – PDF DOWNLOAD

Description

Komatsu Wheel Loader WA600-6R Shop Manual SEN02211-14 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Wheel Loader WA600-6R Shop Manual SEN02211-14 – PDF DOWNLOAD

Language : English
Pages :2004
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Wheel Loader WA600-6R Shop Manual SEN02211-14 – PDF DOWNLOAD

SERIAL NUMBERS 65001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

2. Preparations for work

TABLE OF CONTENTS:

Komatsu Wheel Loader WA600-6R Shop Manual SEN02211-14 – 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 64
SPECIFICATIONS 65
WEIGHT TABLE 72
TABLE OF FUEL, COOLANT AND LUBRICANTS 74
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 77
ENGINE AND COOLING SYSTEM 77
ENGINE MOUNT AND TRANSMISSION MOUNT 78
DAMPER 80
COOLING SYSTEM 82
COOLING FAN PUMP 86
COOLING FAN MOTOR 94
POWER TRAIN, PART 1 101
POWER TRAIN 102
POWER TRAIN SYSTEM DIAGRAM 103
TORQUE CONVERTER AND TRANSMISSION PIPING DIAGRAM 104
TORQUE CONVERTER 106
MODULATION CLUTCH 115
TORQUE CONVERTER REGULATOR VALVE 116
TRANSMISSION 118
TRANSFER 138
TRANSMISSION CONTROL VALVE 140
ECMV 142
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 149
LUBRICATION RELIEF VALVE 151
POWER TRAIN, PART 2 153
TORQUE CONVERTER OIL COOLER 154
TORQUE CONVERTER OIL FILTER 155
DRIVE SHAFT 157
CENTER SUPPORT 160
AXLE 162
DIFFERENTIAL 166
LIMITED SLIP DIFFERENTIAL 175
FINAL DRIVE 180
STEERING SYSTEM 185
STEERING PIPING DIAGRAM 188
STEERING COLUMN 190
JOYSTICK STEERING LEVER LINKAGE 191
JOYSTICK EPC VALVE 192
LOCK VALVE 193
STEERING VALVE 194
ROTARY VALVE 197
STEERING CONTROL VALVE 200
TWO-WAY RESTRICTOR VALVE 216
STOP VALVE 217
STEERING PUMP 218
STEERING CYLINDER 232
Emergency steering piping diagram 234
Diverter valve 235
Emergency steering pump 243
BRAKE SYSTEM 245
Brake piping diagram 246
Brake 248
Brake valve 252
Accumulator charge valve 260
EPC relief valve 266
Accumulator (for brake) 268
Slack adjuster 270
Parking brake 274
Parking brake solenoid valve 276
Emergency parking brake release valve 278
Brake cooling pump 279
UNDERCARRIAGE AND FRAME 281
AXLE MOUNT 282
CENTER HINGE PIN 287
HYDRAULIC SYSTEM, PART 1 291
HYDRAULIC PIPING DIAGRAM 292
WORK EQUIPMENT CONTROL LEVER LINKAGE 294
HYDRAULIC TANK 296
WORK EQUIPMENT HYDRAULIC PUMP 298
HYDRAULIC SYSTEM, PART 2 319
Control valve 320
CLSS 334
Each function and operation of each valve 339
Accumulator (for PPC circuit) 358
Accumulator (for ECSS) 359
Triple pump 360
WORK EQUIPMENT 363
Work equipment linkage 364
Bucket 368
Bucket positioner and boom kick-out 372
Work equipment lubrication 373
Work equipment cylinder 375
CAB AND ITS ATTACHMENTS 379
ROPS CAB 380
AIR CONDITIONER 382
ELECTRICAL SYSTEM, PART 1 387
MACHINE MONITOR SYSTEM 388
MACHINE MONITOR 394
ELECTRICAL SYSTEM, PART 2 451
WORK EQUIPMENT CONTROL SYSTEM 452
TRANSMISSION CONTROLLER SYSTEM 488
ELECTRICAL SYSTEM, PART 3 521
ELECTRIC TRANSMISSION CONTROL 522
ENGINE STARTING/STOPPING CIRCUIT 524
PARKING BRAKE CIRCUIT 527
SENSOR 531
VHMS CONTROLLER RELATED 553
WORK EQUIPMENT ELECTRIC LEVER 557
20 STANDARD VALUE TABLE 561
STANDARD SERVICE VALUE TABLE 561
Standard service value table for engine 562
Standard service value table for chassis 563
30 TESTING AND ADJUSTING 573
TESTING AND ADJUSTING, PART 1 573
Tools for testing, adjusting, and troubleshooting 575
Measuring engine speed 581
Measuring exhaust gas color 583
Measuring exhaust temperature 584
Adjusting valve clearance 586
Testing compression pressures 588
Measuring blow-by pressure 591
Measuring engine oil pressure 592
Measuring intake air (boost) pressure 593
Handling fuel system equipment 594
Releasing residual pressure in fuel system 594
Testing fuel pressures 595
Testing return rate and leakage 596
Bleeding air from fuel circuit 599
Testing leakage in fuel system 601
Handling reduced cylinder mode operation 602
Handling no-injection cranking operation 602
Handling controller voltage circuit 603
Replacing and adjusting alternator and air conditioner compressor belt tension 604
Adjusting modulation clutch speed sensor and speed sensor 605
Measuring directional lever (Steering wheel specification) 607
Testing and adjusting power train oil pressure 608
Flushing procedure for torque converter and transmission hydraulic circuit 622
Method of moving machine when transmission valve is broken 624
Adjusting steering stop valve 626
TESTING AND ADJUSTING, PART 2 629
Measuring operating effort of AJSS lever (AJSS specification) 631
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) 632
Testing and adjusting steering stopper bolt (AJSS specification) 634
Testing and adjusting steering wheel (Steering wheel specification) 636
Testing steering oil pressure 638
Bleeding air from steering cylinder circuit 642
Testing hydraulic drive fan 643
Bleeding air from hydraulic drive fan circuit 646
Measuring brake pedal 648
Measuring brake performance 649
Testing and adjusting accumulator charge pressure 650
Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas 652
Testing wheel brake oil pressure 660
Measuring wear of wheel brake disc 662
Bleeding air from wheel brake circuit 663
Releasing residual pressure in brake accumulator circuit 664
Testing parking brake performance 665
Measuring parking brake oil pressure 666
Testing wear of parking brake disc 669
Method of releasing parking brake manually 670
Measuring and adjusting work equipment control lever 671
Measuring work equipment oil pressure 672
Bleeding air from work equipment circuit 677
Releasing residual pressure in work equipment circuit 678
Testing of accumulator nitrogen gas pressure and procedure for charging ECSS accumulator with nitrogen gas 680
Moving machine for removing operator cab 688
Testing and adjusting bucket positioner 690
Testing and adjusting lift arm position detecting lever 692
Checking proximity switch operation indication lamp 693
Preparations for work on troubleshooting of electric system 694
Procedure for testing diodes 698
TESTING AND ADJUSTING, PART 3 701
MACHINE MONITOR-BASED ADJUSTMENT AT REPLACEMENT, DISASSEMBLY AND ASSEMBLY, AND ADDITIONAL INSTALLATION FOR EACH SENSOR AND CONTROLLER 702
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) 705
TESTING AND ADJUSTING, PART 4 781
VHMS controller initial setting procedure 782
Precautions for replacing VHMS controller 804
Pm-clinic inspection table 810
40 TROUBLESHOOTING 815
FAILURE CODE TABLE AND FUSE LOCATIONS 815
Failure codes list 816
Fuse locations 828
GENERAL INFORMATION ON TROUBLESHOOTING 831
Points to remember when performing troubleshooting 832
How to proceed in troubleshooting 834
Testing before troubleshooting 836
Classification and procedures of troubleshooting 837
Information in troubleshooting table 841
Troubleshooting method for disconnecting wiring harness of pressure sensor system 843
Phenomena looking like troubles and troubleshooting Nos 846
Connection table for connector pin numbers 848
T- branch box and T- branch adapter table 883
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1 887
Failure code [1500L0] TORQFLOW transmission: Double meshing 889
Failure code [15B0NX] Transmission Oil Filter Clogging 890
Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON 892
Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF 894
Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON 896
Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF 898
Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON 900
Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF 902
Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON 904
Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF 906
Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON 908
Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF 910
Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON 912
Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF 914
Failure code [15W0NT] Transmission modulation clutch: Overheating 916
Failure code [2F00MA] Parking brake: Malfunction 917
Failure code [2G42ZG] Front Accumulator Oil Pressure Low 920
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2 923
Failure code [2G43ZG] Rear Accumulator Oil Pressure Low 926
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree 928
Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine: Overrun 931
Failure code [AA1ANX] Air Cleaner Clogging 932
Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine 934
Failure code [AB00MA] Alternator: Malfunction 936
Failure code [B@BAZG] Engine oil pressure: Low error 938
Failure code [B@BAZK] Eng Oil Level Low 939
Failure code [B@BCNS] Engine coolant temperature: Overheating 940
Failure code [B@BCZK] Engine coolant level low 942
Failure code [B@C7NS] Brake oil overheating 944
Failure code [b@CENS] Torque converter oil overheating 945
Failure code [B@CENS] Torque converter oil overheating 946
Failure code [B@GAZK] Low Battery Fluid Level 947
Failure code [B@HANS] Hyd Oil Overheat 949
Failure code [CA111] Abnormality in engine controller 950
Failure code [CA115] Engine Ne or Bkup speed sensor error 953
Failure code [CA122] Charge (boost) pressure sensor high error 954
Failure code [CA123] Charge (boost) pressure sensor low error 956
Failure code [CA131] Throttle sensor high error 958
Failure code [CA132] Throttle sensor low error 961
Failure code [CA135] Engine oil pressure sensor high error 964
Failure code [CA141] Engine oil pressure sensor low error 966
Failure code [CA144] Coolant temperature sensor high error 968
Failure code [CA145] Coolant temperature sensor low error 970
Failure code [CA153] Charge (boost) temperature sensor high error 972
Failure code [CA154] Charge (boost) temperature sensor low error 974
Failure code [CA187] Sensor power supply 2 low error 976
Failure code [CA212] Engine oil temperature sensor high error 978
Failure code [CA213] Engine oil temperature sensor low error 980
Failure code [CA221] Atmospheric pressure sensor high error 982
Failure code [CA222] Atmospheric pressure sensor low error 984
Failure code [CA227] Sensor power supply 2 high error 986
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3 989
Failure code [CA234] Engine overspeed 991
Failure code [CA238] Ne speed sensor power supply error 992
Failure code [CA263] Fuel temperature sensor high error 994
Failure code [CA265] Fuel temperature sensor low error 996
Failure code [CA271] PCV1 Short circuit 998
Failure code [CA272] PCV1 Disconnection 999
Failure code [CA273] PCV2 Short circuit1000
Failure code [CA274] PCV2 Disconnection1001
Failure code [CA322] Injector #1 open/short error1002
Failure code [CA323] Injector #5 open/short error1004
Failure code [CA324] Injector #3 open/short error1006
Failure code [CA325] Injector #6 open/short error1008
Failure code [CA331] Injector #2 open/short error1010
Failure code [CA332] Injector #4 open/short error1012
Failure code [CA342] Calibration code inconsistency1014
Failure code [CA351] Injectors drive circuit error1015
Failure code [CA352] Sensor power supply 1 low error1016
Failure code [CA386] Sensor power supply 1 high error1018
Failure code [CA431] Idle validation switch error1019
Failure code [CA432] Idle validation action error1022
Failure code [CA441] Battery voltage low error1025
Failure code [CA442] Battery voltage high error1026
Failure code [CA449] Common rail pressure high error 21027
Failure code [CA451] Common rail pressure sensor high error1028
Failure code [CA452] Common rail pressure sensor low error1030
Failure code [CA553] Common rail pressure high error 11032
Failure code [CA554] Common rail pressure sensor in range error1033
Failure code [CA559] Supply pump pressure very low error 11034
Failure code [CA689] Engine Ne speed sensor error1038
Failure code [CA731] Engine Bkup speed sensor phase error1040
Failure code [CA757] All continuous data lost error1041
Failure code [CA778] Engine Bkup speed sensor error1042
Failure code [CA1633] KOMNET datalink timeout error1044
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 41047
Failure code [CA2185] Throttle sensor supply voltage high error1050
Failure code [CA2186] Throttle sensor power supply low error1052
Failure code [CA2249] Supply pump pressure very low error 21054
Failure code [CA2555] Intake air heater relay open circuit error1056
Failure code [CA2556] Intake air heater relay short circuit error1058
Failure code [D191KA] AJSS neutral safety relay open circuit1060
Failure code [D191KB] AJSS neutral safety relay short circuit1062
Failure code [D192KA] ECSS solenoid: Disconnection1064
Failure code [D192KB] ECSS solenoid: Short circuit1065
Failure code [D192KY] ECSS solenoid: Short circuit with power supply line1066
Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection1067
Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit1068
Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply line1069
Failure code [D5ZHKA] Terminal C signal open circuit1070
Failure code [D5ZHKB] Terminal C signal short circuit1072
Failure code [D5ZHKZ] Terminal C signal open or short circuit1074
Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine1076
Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal1078
Failure code [DAF3KK] Machine monitor: Source voltage low (input)1080
Failure code [DAF5KP] Machine monitor: Output voltage low1082
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system)1084
Failure code [DAQ0KK] Transmission controller: Source voltage low1085
Failure code [DAQ0KT] Transmission controller: Defect in controller1088
Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)1089
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement1092
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system)1093
Failure code [DAQRMA] Transmission controller (Option setting): Malfunction1098
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 51101
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system)1104
Failure code [DB90KK] Work equipment controller: Source voltage low (input)1107
Failure code [DB90KT] Work equipment controller: Defect in controller1110
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input)1111
Failure code [DB95KX] Work equipment controller power supply output: Out of range1114
Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement1116
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system)1117
Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction1118
Failure code [DB9RMC] CAN communication with transmission controller: Malfunction1119
Failure code [DBB0KK] or change of VHMS_LED display from “n9” to “01” (VHMS controller: Source voltage low (input))1120
Failure code [DBB0KQ] or change of VHMS_LED display from “nF” to “11” (VHMS controller: Disagreement of model selection signals)1122
Failure code [DBB3KK] or change of VHMS_LED display from “n9” to “05” (VHMS controller battery power supply: Source voltage low (input))1124
Failure code [DBB5KP] or change of VHMS_LED display from “n9” to “04” (VHMS controller 5 V power supply output: Output voltage low)1126
Failure code [DBB6KP] or change of VHMS_LED display from “n9” to “02” (VHMS controller 24V power supply output: Output voltage low)1128
Failure code [DBB7KP] or change of VHMS_LED display from “n9” to “03” (VHMS controller 12V power supply output: Output voltage low)1130
Failure code [DBBQKR] or change of VHMS_LED display from “n8” to “02” (CAN communication of VHMS controller: Communication error (Abnormality in target component system))1132
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time1134
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time1136
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time1138
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time1140
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time1142
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time1144
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time1146
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time1148
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time1150
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 61153
Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time1156
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree1158
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit1160
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit1163
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree1166
Failure code [DDD1LD] Remote positioner bucket angle set switch: Switch is kept pressed for long time1170
Failure code [DDDBKA] Traction adjustment dial: Disconnection1174
Failure code [DDDBKB] Traction adjustment dial: Short circuit1176
Failure code [DDE5MA] Emergency steering drive switch: Malfunction1178
Failure code [DDK4KA] AJSS FNR switch: Disconnection1180
Failure code [DDK4KB] AJSS FNR switch: Short circuit1182
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree1184
Failure code [DDK6KA] FNR lever switch: Disconnection1187
Failure code [DDK6KB] FNR lever switch: Short circuit1190
Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection1192
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree1194
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time1196
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time1198
Failure code [DDY0LD] Load meter cancel switch: Switch is kept pressed for long time1200
Failure code [DF10KA] Transmission shift lever switch: Disconnection1202
Failure code [DF10KB] Transmission shift lever switch: Short circuit1206
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor: Out of input signal range1208
Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection1210
Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit1212
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 71215
Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range1218
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection1220
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range1222
Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection1224
Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit1225
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1226
Failure code [DGT4KA] (or VHMS_LED display: “n3” → “12”) Exhaust gas temperature sensor (F): Disconnection1228
Failure code [DGT4KB] (or VHMS_LED display: “n3” → “11”) Exhaust gas temperature sensor (F): Short circuit1231
Failure code [DGT5KA] (or VHMS_LED display: “n3” → “22”) Exhaust gas temperature sensor (R): Disconnection1234
Failure code [DGT5KB] (or VHMS_LED display: “n3” → “21”) Exhaust gas temperature sensor (R): Short circuit1237
Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection1240
Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit1242
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit1244
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with power supply line1246
Failure code [DHPCKX] Lift arm cylinder bottom pressure sensor: Out of input signal range1248
Failure code [DHPDKX] Lift arm cylinder head pressure sensor: Out of input signal range1251
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine1254
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input signal range1256
Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection1260
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit1262
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of input signal range1264
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of input signal range1266
Failure code [DK30KA] AJSS lever angle sensor: Disconnection1268
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line1270
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 81273
Failure code [DK59KA] Lift arm EPC lever potentiometer (Main): Disconnection1275
Failure code [DK59KY] Lift arm EPC lever potentiometer (Main): Short circuit with power supply line1278
Failure code [DK59L8] Lift arm EPC lever potentiometer (Main): Analog signals disagree1280
Failure code [DK5AKA] Lift arm EPC lever potentiometer (Sub): Disconnection1284
Failure code [DK5AKY] Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line1287
Failure code [DK5BKA] Bucket EPC lever potentiometer (Main): Disconnection1290
Failure code [DK5BKY] Bucket EPC lever potentiometer (Main): Short circuit with power supply line1293
Failure code [DK5BL8] Bucket EPC lever potentiometer (Main): Analog signals disagree1295
Failure code [DK5CKA] Bucket EPC lever potentiometer (Sub): Disconnection1299
Failure code [DK5CKY] Bucket EPC lever potentiometer (Sub): Short circuit with power supply line1302
Failure code [DK5DKA] 3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection1305
Failure code [DK5DKY] 3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line1308
Failure code [DK5DL8] 3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree1310
Failure code [DK5EKA] 3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection1313
Failure code [DK5EKY] 3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line1316
Failure code [DKA0KA] Lift arm angle sensor: Disconnection1318
Failure code [DKA0KX] Lift arm angle sensor: Out of input signal range1321
Failure code [DKA0KY] Lift arm angle sensor: Short circuit with power supply line1322
Failure code [DKA0L0] Lift arm angle sensor: Improper position1324
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 91327
Failure code [DKD0KA] Frame angle sensor: Disconnection1330
Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line1332
Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit1334
Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection1338
Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree1340
Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection1342
Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree1344
Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit1346
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range1348
Failure code [DUM1KB] Remote positioner raise indicator lamp: Short circuit1350
Failure code [DUM2KB] Remote positioner lower indicator lamp: Short circuit1352
Failure code [DV00KB] Alarm buzzer: Short circuit1354
Failure code [DW4PKA] Lift arm raise EPC solenoid: Disconnection1356
Failure code [DW4PKB] Lift arm raise EPC solenoid: Short circuit1358
Failure code [DW4PKY] Lift arm raise EPC solenoid: Short circuit with power supply line1359
Failure code [DW4QKA] Lift arm lower EPC solenoid: Disconnection1360
Failure code [DW4QKB] Lift arm lower EPC solenoid: Short circuit1361
Failure code [DW4QKY] Lift arm lower EPC solenoid: Short circuit with power supply line1362
Failure code [DW4RKA] Bucket tilt EPC solenoid: Disconnection1363
Failure code [DW4RKB] Bucket tilt EPC solenoid: Short circuit1364
Failure code [DW4RKY] Bucket tilt EPC solenoid: Short circuit with power supply line1365
Failure code [DW4SKA] Bucket dump EPC solenoid: Disconnection1366
Failure code [DW4SKB] Bucket dump EPC solenoid: Short circuit1367
Failure code [DW4SKY] Bucket dump EPC solenoid: Short circuit with power supply line1368
Failure code [DW7BKA] Fan reverse solenoid: Disconnection1370
Failure code [DW7BKB] Fan reverse solenoid: Short circuit1372
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line1374
Failure code [DW7DKA] Hydraulic drive fan neutral solenoid: Disconnection1375
Failure code [DW7DKB] Hydraulic drive fan neutral solenoid: Short circuit1376
Failure code [DW7DKY] Hydraulic drive fan neutral solenoid: Short circuit with power supply line1377
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 101379
Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection1382
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit1384
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line1386
Failure code [DWN6KA] Lift arm raise magnet detent solenoid: Disconnection1388
Failure code [DWN6KB] Lift arm raise magnet detent solenoid: Short circuit1390
Failure code [DWN6KY] Lift arm raise magnet detent solenoid: Short circuit with power supply line1392
Failure code [DWN7KA] Lift arm float magnet detent solenoid: Disconnection1394
Failure code [DWN7KB] Lift arm float magnet detent solenoid: Short circuit1396
Failure code [DWN7KY] Lift arm float magnet detent solenoid: Short circuit with power supply line1398
Failure code [DWN8KA] Bucket tilt magnet detent solenoid: Disconnection1400
Failure code [DWN8KB] Bucket tilt magnet detent solenoid: Short circuit1402
Failure code [DWN8KY] Bucket tilt magnet detent solenoid: Shorted with the power source1404
Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection1406
Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit1408
Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source line1410
Failure code [DX16KA] Fan pump EPC solenoid: Disconnection1412
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit1413
Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line1414
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection1415
Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit1416
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection1417
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit1418
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection1420
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit1422
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line1424
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection1426
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit1428
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line1430
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 111433
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection1436
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit1438
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line1440
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection1442
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit1444
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line1446
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection1448
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit1450
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line1452
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection1454
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit1456
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line1458
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection1460
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit1462
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line1464
Failure code [DXHJKA] 3-spool valve extract EPC solenoid: Disconnection1466
Failure code [DXHJKB] 3-spool valve extract EPC solenoid: Short circuit1468
Failure code [DXHJKY] 3-spool valve extract EPC solenoid: Short circuit with power supply line1469
Failure code [DXHKKA] 3-spool valve retract EPC solenoid: Disconnection1470
Failure code [DXHKKB] 3-spool valve retract EPC solenoid: Short circuit1472
Failure code [DXHKKY] 3-spool valve retract EPC solenoid: Short circuit with power supply line1473
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection1474
Failure code [DXHPKB] Modulation clutch solenoid: Short circuit1476
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line1478
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction1480
Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) Blow-by pressure: High error1482
Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust gas temperature (F): Abnormal heat1484
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F): Overheat1486
Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust gas temperature (R): abnormal heat1488
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat1490
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1493
Before carrying out troubleshooting of electrical system1496
Information in troubleshooting table1499
E-1 Engine does not start1500
E-2 Wiper does not operate1510
E-3 Windshield washer does not operate1518
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off1524
E-5 Working lamp does not light up or go off1538
E-6 Step lamp does not light up or go off1544
E-7 Turn signal lamp and hazard lamp do not light up or go off1546
E-8 Brake lamp does not light or it keeps lighting up1556
E-9 Backup lamp does not light or it keeps lighting up1558
E-10 Backup buzzer does not sound or it keeps sounding1562
E-11 Horn does not sound or it keeps sounding1566
E-12 Alarm buzzer does not sound or it keeps sounding1570
E-13 Air conditioner does not operate or stop1572
E-14 Electric priming pump does not operate or does not stop automatically1574
E-15 When starting switch is turned to ON position, machine monitor displays nothing1576
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)1581
METHOD OF USING TROUBLESHOOTING CHART1584
TABLE OF FAILURE MODES AND CAUSES1586
H-1 MACHINE DOES NOT START1590
H-2 TORQUE CONVERTER LOCKUP IS NOT SWITCHED (ENGINE STALLS)1592
H-3 TORQUE CONVERTER LOCKUP IS NOT TURNED ON1593
H-4 TRAVEL SPEED IS SLOW, THRUSTING FORCE IS WEAK, UPHILL TRAVELING POWER IS WEAK, AND GEAR IS NOT SHIFTED1594
H-5 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR1596
H-6 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR1598
H-7 TORQUE CONVERTER OIL TEMPERATURE IS HIGH1600
H-8 STEERING DOES NOT TURN [MACHINE WITH STEERING WHEEL] 1601
H-9 STEERING DOES NOT TURN [MACHINE WITH AJSS]1602
H-10 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH STEERING WHEEL]1603
H-11 TURNING, RESPONSE OF AJSS IS POOR [MACHINE WITH AJSS]1604
H-12 STEERING IS HEAVY [MACHINE WITH STEERING WHEEL]1605
H-13 WHEN MACHINE TURNS, IT SHAKES OR MAKES LARGE SHOCKS [MACHINE WITH STEERING WHEEL]1606
H-14 WHEN MACHINE TURNS, IT SHAKES OR MAKES LARGE SHOCKS [MACHINE WITH AJSS]1607
H-15 WHEEL BRAKE DOES NOT WORK OR DOES NOT WORK WELL1608
H-16 WHEEL BRAKE IS NOT RELEASED OR IT DRAGS1609
H-17 PARKING BRAKE DOES NOT WORK OR DOES NOT WORK WELL1610
H-18 PARKING BRAKE IS NOT RELEASED OR IT DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM) 1611
H-19 LIFT ARM DOES NOT RISE1612
H-20 LIFT ARM SPEED IS LOW OR RISING FORCE OF LIFT ARM IS INSUFFICIENT1613
H-21 WHEN RISING, LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT1614
H-22 LIFT ARM CYLINDER CANNOT HOLD DOWN BUCKET (BUCKET FLOATS)1614
H-23 HYDRAULIC DRIFTS OF LIFT ARM OCCUR OFTEN 1614
H-24 LIFT ARM WOBBLES DURING OPERATION1614
H-25 BUCKET DOES NOT TILT BACK1615
H-26 BUCKET SPEED IS LOW OR TILTING BACK FORCE IS INSUFFICIENT 1616
H-27 BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK1617
H-28 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET1617
H-29 HYDRAULIC DRIFTS OF BUCKET OCCUR OFTEN1617
H-30 BUCKET WOBBLES DURING TRAVEL WITH CARGO (WORK EQUIPMENT VALVE IS SET TO “HOLD”)1617
H-31 DURING OPERATION OF MACHINE, ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS1618
H-32 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS AND STOPS 1618
H-33 WHEN WORK EQUIPMENT CIRCUIT IS RELIEVED SINGLY, OTHER WORK EQUIPMENT MOVES1618
H-34 ECSS DOES NOT OPERATE, AND PITCHING BOUNCING OCCURS1619
H-35 FAN SPEED IS ABNORMAL (FAN SOUND AND VIBRATION ARE ABNORMALLY LARGE OR ENGINE OVERHEATS)1620
TROUBLESHOOTING OF ENGINE (S-MODE)1623
METHOD OF USING TROUBLESHOOTING CHART1625
S-1 ENGINE DOES NOT START EASILY1628
S-2 ENGINE DOES NOT START1629
S-3 ENGINE DOES NOT PICK UP SMOOTHLY1632
S-4 ENGINE STOPS DURING OPERATION1633
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING OCCURS)1634
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)1635
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)1636
S-8 OIL IS CONSUMED MUCH (OR EXHAUST GAS COLOR IS BLUE)1637
S-9 ENGINE OIL BECOMES CONTAMINATED QUICKLY1638
S-10 FUEL CONSUMPTION IS EXCESSIVE1639
S-11 COOLANT CONTAINS OIL (BLOWS BACK OR REDUCES)1640
S-12 OIL PRESSURE DROPS1641
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)1642
S-14 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1643
S-15 ABNORMAL NOISE IS MADE1644
S-16 VIBRATION IS EXCESSIVE1645
S-17 AIR CANNOT BE BLED FROM FUEL CIRCUIT1646
50 DISASSEMBLY AND ASSEMBLY1649
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY1649
HOW TO READ THIS MANUAL1650
COATING MATERIALS LIST1652
SPECIAL TOOL LIST1655
SKETCHES OF SPECIAL TOOLS1659
ENGINE AND COOLING SYSTEM, PART 1 1669
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1670
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 1673
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER1678
REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY 1679
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY1681
DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY 1683
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY1687
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY1689
REMOVAL AND INSTALLATION OF BULKHEAD ASSEMBLY1691
ENGINE AND COOLING SYSTEM, PART 21695
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY1696
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY1702
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY1717
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL1721
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL1724
POWER TRAIN, PART 11729
Removal and installation of parking brake assembly1730
Removal and installation of torque converter and transmission assembly1732
POWER TRAIN, PART 2 1739
Disassembly and assembly of torque converter assembly1740
Disassembly and assembly of transmission assembly1767
Disassembly and assembly of transfer assembly1794
Disassembly and assembly of parking brake assembly1810
POWER TRAIN, PART 3 1819
Removal and installation of front axle assembly1820
Removal and installation of rear axle assembly1822
Removal and installation of center support assembly1824
Disassembly and assembly of center support assembly1826
Disassembly and assembly of differential assembly1830
POWER TRAIN, PART 4 1845
REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY1846
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE CARRIER ASSEMBLY1848
REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE BRAKE ASSEMBLY 1849
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY1851
BRAKE SYSTEM 1855
Disassembly and assembly of brake assembly1856
Removal and installation of brake valve assembly1864
Disassembly and assembly of accumulator and charge valve assembly1865
Disassembly and assembly of slack adjustor assembly1868
UNDERCARRIAGE AND FRAME1871
REMOVAL AND INSTALLATION OF CENTER HINGE PIN1872
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY1879
HYDRAULIC SYSTEM1881
Removal and installation of hydraulic tank assembly1882
Removal and installation of hydraulic pump assembly1884
Removal and installation of control valve assembly1888
Disassembly and assembly of control valve assembly1890
Removal and installation of steering valve assembly1895
Removal and installation of ECSS accumulator assembly1896
Disassembly and assembly of hydraulic cylinder assembly1897
WORK EQUIPMENT 1903
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY1904
CAB AND ITS ATTACHMENTS 1911
Removal and installation of operator’s cab assembly1912
Removal and installation of operator’s cab glass (stuck glass)1916
Removal and installation of floor frame assembly1924
Removal and installation of AJSS lever switch assembly1927
ELECTRICAL SYSTEM1933
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY1934
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY1936
REMOVAL AND INSTALLATION OF LOADER CONTROLLER ASSEMBLY1936
REMOVAL AND INSTALLATION OF VHMS CONTROLLER ASSEMBLY1937
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY1938
REMOVAL AND INSTALLATION OF PRINTER ASSEMBLY1941
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY1942
90 DIAGRAMS AND DRAWINGS1947
Hydraulic diagrams and drawings1947
Power train hydraulic circuit diagram1948
Brake hydraulic circuit diagram1949
Work equipment hydraulic circuit diagram1951
Electrical diagrams and drawings1957
Air conditioner electrical circuit diagram1959
Electrical circuit diagram (1/10)1961
Electrical circuit diagram (2/10)1963
Electrical circuit diagram (3/10)1965
Electrical circuit diagram (4/10)1967
Electrical circuit diagram (5/10)1969
Electrical circuit diagram (6/10)1971
Electrical circuit diagram (7/10)1973
Electrical circuit diagram (8/10)1975
Electrical circuit diagram (9/10)1977
Electrical circuit diagram (10/10)1979
Electrical circuit diagram (1/10)1981
Electrical circuit diagram (2/10)1983
Electrical circuit diagram (3/10)1985
Electrical circuit diagram (4/10)1987
Electrical circuit diagram (5/10)1989
Electrical circuit diagram (6/10)1991
Electrical circuit diagram (7/10)1993
Electrical circuit diagram (8/10)1995
Electrical circuit diagram (9/10)1997
Electrical circuit diagram (10/10)1999
Connector arrangement diagram2001

S.M 29/12/24