Komatsu WA430-6 65001 & Up SEN00823-13 (Preview)
COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train
Power train system diagram
Drive shaft
Power train piping diagram
Torque converter
Transmission
Flow control valve
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Axle
Differential
Limited slip differential
Final drive
Steering system
Steering piping diagram
Steering column
Steering pump
Steering valve
Orbit-roll valve
Stop valve
Steering relief valve
Steering cylinder
Emergency steering motor
Emergency steering pump
Joystick steering lever linkage
Steering electric lever
Joystick EPC valve
Brake system
Brake piping diagram
Charge valve
Brake valve
Accumulator (for brake)
Brake
Parking brake control
Parking brake
Parking brake solenoid valve
Emergency parking brake release valve
Undercarriage and frame
Axle mount and center hinge pin
Tires
Hydraulic system, Part 1
Hydraulic piping diagram
Work equipment control lever linkage
Hydraulic tank
Power train pump
Work equipment pump
Work equipment control valve
CLSS
Each function and operation of each valve
Hydraulic system, Part 2
PPC valve
Stabilizer valve
Accumulator (for PPC circuit)
Accumulator (for ECSS)
Work equipment PPC cut-off solenoid valve
Work equipment
Work equipment linkage
Bucket
Bucket positioner and boom kick-out
Work equipment cylinder
Cab and its attachments
Cab
Air conditioner
Electrical system, Part 1
Machine monitor system
Machine monitor
Electrical system, Part 2
Electrical system (Transmission controller system)
Transmission controller
Electrical system (Work equipment controller system)
Work equipment controller
Electrical system, Part 3
Electric transmission control
Kickdown switch and hold switch
Multi-function knob
Joystick steering knob
KOMTRAX system
Engine starting circuit
Engine stopping circuit
Preheating circuit
Engine power mode selector circuit
Engine output derating function
Automatic warm-up function
Parking brake circuit
Sensor
20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis
30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Sketch of special tool
Testing exhaust gas color
Testing exhaust temperature
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Testing fuel pressure
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing leakage in fuel system
Handling reduced cylinder mode operation
Handling no-injection cranking operation
Handling controller voltage circuit
Check of muffler and muffler stack for looseness and damage
Check of muffler function
Check of installed condition of cylinder head and manifolds
Check of engine piping for damage and looseness
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Adjusting transmission speed sensor
Adjusting directional lever length
Adjusting gear shift lever length
Testing directional lever
Testing and adjusting power train oil pressure
Procedure for flushing torque converter and transmission hydraulic circuit
Method of moving machine when transmission valve is broken
Checking axle final drive for oil leakage
Checking drive shafts for looseness, play and damage
Testing and adjusting steering stop valve
Testing and adjusting steering wheel
Testing and adjusting steering oil pressure
Bleeding air from steering circuit
Testing and adjusting, Part 2
Testing hydraulic drive fan
Bleeding air from hydraulic drive fan circuit
Testing brake pedal
Testing and adjusting brake pedal linkage
Testing brake performance
Testing and adjusting accumulator charge pressure
Testing wheel brake oil pressure
Testing wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing residual pressure in brake accumulator circuit
Testing parking brake performance
Testing parking brake oil pressure
Testing wear of parking brake disc
Method of releasing parking brake manually
Testing and adjusting work equipment control lever
Testing and adjusting work equipment PPC oil pressure
Testing and adjusting work equipment oil pressure
Bleeding air from work equipment circuit
Releasing residual pressure in work equipment circuit
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator
Testing and adjusting bucket positioner
Testing and adjusting boom kickout
Checking proximity switch operation pilot lamp
Procedure for testing diodes
Preparation work for troubleshooting for electrical system
Starting KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Testing and adjusting, Part 3
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
Special functions of machine monitor (EMMS)
Pm-clinic inspection table
40 Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Testing before troubleshooting
Classification and procedures of troubleshooting
Information contained in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure code [1500L0] (TORQFLOW transmission: Double meshing)
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)
Failure code [2F00MA] (Parking brake: Malfunction)
Failure code [2G43ZG] (Accumulator: Low oil pressure)
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
Troubleshooting by failure code (Display of code), Part 2
Failure code [AA1ANX] (Air cleaner: Clogging)
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)
Failure code [AB00MA] (Alternator: Malfunction)
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)
Failure code [B@BAZK] (Engine oil: Low level)
Failure code [B@BCNS] (Coolant: Overheating)
Failure code [B@BCZK] (Coolant: Low level)
Failure code [B@BEBF] (Water in fuel error)
Failure code [B@C7NS] (Brake oil: Overheating)
Failure code [b@CENS] (Torque converter oil: Overheating)
Failure code [B@CENS] (Torque converter oil: Overheating)
Failure code [B@HANS] (Hydraulic oil: Overheating)
Failure code [CA111] (Abnormality in engine controller)
Failure code [CA115] (Engine Ne or Bkup speed sensor error)
Failure code [CA122] (Charge pressure sensor high error)
Failure code [CA123] (Charge pressure sensor low error)
Failure code [CA131] (Throttle sensor high error)
Failure code [CA132] (Throttle sensor low error)
Failure code [CA144] (Coolant sensor high error)
Failure code [CA145] (Coolant sensor low error)
Failure code [CA153] (Charge temperature sensor high error)
Failure code [CA154] (Charge temperature sensor low error)
Failure code [CA155] (Derating of speed by abnormally high charge temperature)
Failure code [CA187] (Sensor power supply 2 low error)
Failure code [CA221] (Atmospheric pressure sensor high error)
Failure code [CA222] (Atmospheric sensor low error)
Failure code [CA227] (Sensor power supply 2 high error)
Failure code [CA234] (Engine overspeed)
Failure code [CA238] (Ne speed sensor power supply error)
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA271] (IMV/PCV1 Short circuit)
Failure code [CA272] (IMV/PCV1 Disconnection)
Failure code [CA281] High pressure pump error
Failure code [CA322] (Injector #1 open/short error)
Failure code [CA323] (Injector #5 open/short error)
Failure code [CA324] (Injector #3 open/short error)
Failure code [CA325] (Injector #6 open/short error)
Failure code [CA331] (Injector #2 open/short error)
Failure code [CA332] (Injector #4 open/short error)
Failure code [CA342] (Calibration code inconsistency)
Failure code [CA351] (Injectors drive circuit error)
Failure code [CA352] (Sensor power supply 1 low error)
Failure code [CA386] (Sensor power supply 1 high error)
Failure code [CA428] (Abnormally high level in water sensor)
Failure code [CA429] (Abnormally low level in water sensor)
Failure code [CA431] (Idle validation switch error)
Failure code [CA432] (Idle validation action error)
Failure code [CA435] (Engine oil pressure switch error)
Failure code [CA441] (Battery voltage low error)
Failure code [CA442] (Battery voltage high error)
Failure code [CA449] Common rail pressure high error 2
Failure code [CA451] (Common rail pressure sensor high error)
Failure code [CA452] (Common rail pressure sensor low error)
Failure code [CA488] (Derating of torque by abnormally high charge temperature)
Failure code [CA553] (Common rail pressure high error 1)
Failure code [CA559] (Supply pump pressure very low error)
Failure code [CA689] (Engine Ne speed sensor error)
Failure code [CA731] (Engine Bkup speed sensor phase error)
Failure code [CA757] (All continuous data lost error)
Failure code [CA778] (Engine Bkup speed sensor error)
Failure code [CA1633] (KOMNET datalink timeout error)
Failure code [CA2185] (Throttle sensor power supply voltage high error)
Failure code [CA2186] (Throttle sensor power supply voltage low error)
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2249] (Supply pump pressure very low error 2)
Failure code [CA2265] (Abnormally high level in electric lift pump)
Failure code [CA2266] (Abnormally low level in electric lift pump)
Failure code [CA2311] (Abnormality in IMV solenoid)
Failure code [CA2555] (Intake heater relay disconnection error)
Failure code [CA2556] (Intake heater relay short circuit error)
Failure code [D150KA] (Emergency steering relay: Disconnection)
Failure code [D150KB] (Emergency steering relay: Short circuit)
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)
Failure code [D160KA] (Backup lamp relay: Disconnection)
Failure code [D160KB] (Backup lamp relay: Short circuit)
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)
Failure code [D192KA] (ECSS solenoid: Disconnection)
Failure code [D192KB] (ECSS solenoid: Short circuit)
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)
Failure code [D5ZHKA] (Terminal C signal: Disconnection)
Failure code [D5ZHKB] (Terminal C signal: Short circuit)
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)
Failure code [DAF5KP] (Machine monitor: Low output voltage)
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)
Troubleshooting by failure code (Display of code), Part 5
Failure code [DAQ0KK] (Transmission controller: Low source voltage)
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)
Failure code [DAQ1KA] (Terminal ACC input: Disconnection)
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)
Failure code [DAQRMA] (Transmission controller option setting: Disagreement of option selection)
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)
Failure code [DB90KK] Work equipment controller: Low source voltage (input)
Failure code [DB90KT] Work equipment controller: Abnormality in controller
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)
Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time
Failure code [DD16LD] ◇ switch (Panel switch 2): Switch is kept pressed for long time
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)
Troubleshooting by failure code (Display of code), Part 6
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
Failure code [DDK3KA] (Right FNR switch: Disconnection)
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)
Failure code [DDK6KA] (FNR lever switch: Disconnection)
Failure code [DDK6KB] (FNR lever switch: Short circuit)
Failure code [DDS5KA] (Steering pressure switch: Disconnected)
Failure code [DDS5KB] (Steering pressure switch: Short-circuit)
Failure code [DDS5L6] (Steering: Low oil pressure)
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)
Troubleshooting by failure code (Display of code), Part 7
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)
Troubleshooting by failure code (Display of code), Part 8
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)
Failure code [DV00KB] (Alarm buzzer: Short circuit)
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)
Troubleshooting by failure code (Display of code), Part 9
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
Troubleshooting by failure code (Display of code), Part 10
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)
Failure code [DY30ME] Emergency steering: Operating for more than 1 minute
Troubleshooting of electrical system (E-mode)
Installing positions of fuses
Information in troubleshooting table
E-1 Engine does not start
E-2 Wiper does not operate
E-3 Windshield washer does not operate
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
E-5 Working lamp does not light up or go off
E-6 Turn signal lamp and hazard lamp do not light up or go off
E-7 Brake lamp does not light or it keeps lighting up
E-8 Backup lamp does not light or it keeps lighting up
E-9 Backup buzzer does not sound or it keeps sounding
E-10 Horn does not sound or it keeps sounding
E-11 Alarm buzzer does not sound or it keeps sounding
E-12 Air conditioner does not operate or stop
E-13 The KOMTRAX system does not work properly
E-14 When kick-down switch is turned ON, kick-down operation does not start
E-15 When hold switch is pressed, holding operation does not start
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied
E-17 Transmission cut-off mode cannot be set or reset
E-18 Transmission cut-off set cannot be reset
E-19 FNR switch mode cannot be set or reset
E-20 Fan reverse function cannot be used or reset
E-21 Discharge from loader pump does not rise from minimum level
E-22 ECSS function cannot be used or reset
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate
E-25 Air cleaner clogging indicator lamp does not light up
E-26 Radiator coolant level caution lamp does not light up
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up
E-29 Steering oil pressure caution lamp does not light up
E-30 Abnormality in ■ switch (panel switch 1) input
E-31 Abnormality in ◇ switch (panel switch 2) input
E-32 Abnormality in < switch (panel switch 3) input
E-33 Abnormality in > switch (panel switch 4) input
E-34 Air conditioner does not operate
E-35 Air is not cooled
E-36 No air comes out or air flow is abnormal
E-37 Temperature cannot be controlled
E-38 Spurting out mode cannot be switched
E-39 Recirc/Fresh cannot be changed over
Troubleshooting of hydraulic and mechanical system (H-mode)
Method of using troubleshooting chart
Table of failure modes and causes
H-1 The machine does not start
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted
H-5 Shocks are large at the times of starting and shifting gear
H-6 Time lag is large at the times of starting and shifting gear
H-7 The torque converter oil temperature is high
H-8 Steering does not turn
H-9 Steering does not turn [Machine with joystick steering (if equipped)]
H-10 Steering response is low
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]
H-12 Steering is heavy
H-13 When machine turns, it shakes or makes large shocks
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]
H-15 The wheel brake does not work or does not work well
H-16 The wheel brake is not released or it drags
H-17 The parking brake does not work or does not work well
H-18 The parking brake is not released or it drags (including emergency release system)
H-19 Lift arm does not rise
H-20 Lift arm speed is low or rising force of lift arm is insufficient
H-21 When rising, the lift arm comes to move slowly at specific height
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)
H-23 Hydraulic drifts of the lift arm is large
H-24 The lift arm wobbles during operation
H-25 Bucket does not tilt back
H-26 Bucket speed is low or tilting back force is insufficient
H-27 The bucket comes to operate slowly in the midst of tilting-back
H-28 The bucket cylinder cannot hold down the bucket
H-29 Hydraulic drifts of the bucket is large
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)
H-31 Lift arm and bucket control levers do not move smoothly and are heavy
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls
H-33 Large shock is made when work equipment starts and stops
H-34 When work equipment circuit is relieved singly, other work equipment moves
H-35 ECSS does not operate, and pitching, bouncing occur
Troubleshooting of engine (S-mode)
Method of using troubleshooting charts
S-1 Engine does not start easily.
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (Incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Engine oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Coolant contains oil (blows back or reduces)
S-12 Oil pressure drops
S-13 Oil level rises (Water, fuel in oil)
S-14 Coolant temperature rises too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine hood and radiator guard assembly
Removal and installation of radiator assembly
Removal and installation of air aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of engine assembly
Removal and installation of front seal assembly
Removal and installation of rear oil seal assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of fuel tank assembly
Power train, Part 1
Removal and installation of torque converter and transmission assembly
Disassembly and assembly of torque converter assembly (Standard specification)
Disassembly and assembly of torque converter assembly (Lock-up specification)
Disassembly and assembly of transmission assembly
Disassembly and assembly of transmission clutch pack assembly
Disassembly and assembly of parking brake assembly
Power train, Part 2
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Disassembly and assembly of axle housing
Disassembly and assembly of differential assembly
Steering system
Removal and installation of steering demand valve assembly
Brake system
Removal and installation of parking brake disc and plate
Undercarriage and frame
Removal and installation of center hinge pin
Removal and installation of counterweight
Hydraulic system
Removal and installation of work equipment control valve assembly
Removal and installation of power train pump and work equipment pump assembly
Removal and installation of steering pump and cooling fan pump assembly
Removal and installation of hydraulic tank assembly
Work equipment
Removal and installation of work equipment assembly
Disassembly and assembly of hydraulic cylinder assembly
Cab and its attachments
Removal and installation of operator’s cab and floor frame assembly
Removal and installation of operator’s cab glass (stuck glass)
Disassembly and assembly of operator’s seat assembly (Standard specification)
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER)
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of KOMTRAX terminal assembly
90 Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Automatic greasing circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Work equipment controller system electrical circuit diagram
Connector list and sterogram
There are no reviews yet.