Service manual Komatsu WA500-6 55001 & Up | SEN00236-23

Komatsu WA500-6 55001 & Up SEN00236-23 (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 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 and cooling system
— Cooling system
— Engine mount and transmission mount
— Joint
— Cooling fan pump
— Cooling fan motor
– Power train, Part 1
— Power train, Part 1
— Power train
— Power train system diagram
— Drive shaft
— Power train piping diagram
— Torque converter
— Torque converter regulator valve
— Transmission
— Transfer
— Transmission control valve
— ECMV
— Main relief valve and torque converter relief valve
— Lubrication relief valve
– Power train, Part 2
— Power train, Part 2
— Torque converter oil cooler
— Torque converter oil filter
— Center support
— Axle
— Differential
— Limited slip differential
— Final drive
– Steering system
— Steering system
— Steering piping diagram
— Steering column
— Steering control valve
— Steering valve
— Stop valve
— Joystick steering lever linkage (if equipped)
— Steering cylinder
— Emergency steering piping diagram (if equipped)
— Diverter valve
– Brake system
— Brake piping diagram
— Brake valve
— Slack adjuster
— Accumulator charge valve
— PPC relief valve
— Accumulator (for brake)
— Brake
— Parking brake control
— Parking brake
— Parking brake solenoid valve
— Emergency parking brake release valve
– Undercarriage and frame
— Undercarriage and frame
— Axle mount
— Center hinge pin
– Hydraulic system, Part 1
— Hydraulic system, Part 1
— Hydraulic piping diagram
— Work equipment control lever linkage
— Hydraulic tank
— Steering pump
— Work equipment hydraulic pump
– Hydraulic system, Part 2
— Hydraulic system, Part 2
— Control valve
— CLSS
— Each function and operation of each valve
— Accumulator (for PPC circuit)
— Work equipment electric lever
– Work equipment
— Work equipment
— Work equipment linkage
— Bucket
— Bucket positioner and boom kick-out
— Work equipment lubrication
— Work equipment cylinder
– Cab and its attachments
— Cab and its attachments
— ROPS cab
— Air conditioner
– Electrical system, Part 1
— Electrical system, Part 1
— Machine monitor system
— Machine monitor
– Electrical system, Part 2
— Electrical system, Part 2
— Work equipment control system
— Transmission controller system
– Electrical system, Part 3
— Electrical system, Part 3
— Electric transmission control
— Engine starting circuit
— Engine stopping circuit
— Preheating circuit
— Parking brake circuit
— Backup and stop lamp circuits
— Small lamp and head lamp circuits
— Working lamp circuit
— Horn circuit
— Wiper and window washer circuits
— Sensor
— KOMTRAX system
20 Standard value table
– Standard service value table
— Standard service value table
— Standard service value table for engine
— Standard service value table for chassis
30 Testing and adjusting
– Testing and adjusting, Part 1
— Tools for testing, adjusting, and troubleshooting
— Measuring engine speed
— Measuring exhaust gas color
— Measuring exhaust temperature
— Adjusting valve clearance
— Testing compression pressure
— Measuring blow-by pressure
— Measuring engine oil pressure
— Measuring intake air (boost) pressure
— Handling fuel system equipment
— Releasing residual pressure in fuel system
— Testing fuel pressure
— Testing return rate and leakage
— Bleeding air from fuel circuit
— Testing leakage in fuel system
— Handling reduced cylinder mode operation
— Handling no injection cranking operation
— Handling controller voltage circuit
— Testing and adjusting alternator belt tension
— Testing and adjusting air conditioner compressor belt tension
— Adjusting transmission speed sensor
— Measuring directional lever (Steering wheel specification)
— Testing and adjusting power train oil pressure
— Flushing procedure for torque converter and transmission hydraulic circuit
— Method of moving machine when transmission valve is broken
– Testing and adjusting, Part 2
— Testing and adjusting steering stop valve
— Testing and adjusting steering wheel
— Testing steering oil pressure
— Bleeding air from steering cylinder circuit
— Testing hydraulic drive fan
— Bleeding air from hydraulic drive fan circuit
— Measuring brake pedal
— Measuring brake performance
— Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
— Testing and adjusting accumulator charge pressure
— Testing wheel brake oil pressure
— Measuring wear of wheel brake disc
— Bleeding air from brake circuit
— Releasing residual pressure in brake accumulator circuit
— Testing parking brake performance
— Measuring parking brake oil pressure
— Testing wear of parking brake disc
— Method of releasing parking brake manually
— Measuring and adjusting work equipment control lever
— Testing and adjusting work equipment PPC oil pressure
— Measuring work equipment oil pressure
— Bleeding air from work equipment circuit
— Releasing residual pressure in work equipment circuit
— Method of moving machine when removing operator cab (when separate cab and floor specification)
— Testing and adjusting bucket positioner
— Testing and adjusting lift arm position detecting lever
— Checking proximity switch operation indication lamp
— Procedure for testing diodes
— Preparations for work on troubleshooting of electrical system
– Testing and adjusting, Part 3
— Testing and adjusting, Part 3
— How to start KOMTRAX terminal operations (if equipped)
— Indicator lamps of KOMTRAX terminal (if equipped)
— Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller
— Special functions of machine monitor (EMMS)
– Testing and adjusting, Part 4
— Testing and adjusting, Part 4
— Special functions of machine monitor (EMMS)
— Pm clinic inspection table
40 Troubleshooting
– General information on troubleshooting
— Points to remember when performing troubleshooting
— How to proceed in troubleshooting
— Testing before troubleshooting
— Classification and procedures of troubleshooting
— Information in troubleshooting table
— Troubleshooting method for disconnecting wiring harness of pressure sensor system
— Connection table for connector pin numbers
— T- branch box and T- branch adapter table
– Troubleshooting by failure code (Display of code), Part 1
— Troubleshooting by failure code (Display of code), Part 1
— Failure codes list
— Before carrying out troubleshooting for electrical system
— Information contained in troubleshooting table
— Failure code [1500L0] (TORQFLOW transmission : Double meshing)
— Failure code [15B0NX] (Transmission filter: Clogged)
— 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 [2G42ZG] (Front accumulator: Low oil pressure)
– Troubleshooting by failure code (Display of code), Part 2
— Failure code [2G43ZG] Rear accumulator: Low oil pressure
— Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree
— 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] 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@CENS] Torque converter oil: Overheating
— Failure code [B@CENS] Torque converter oil: Overheating
— Failure code [B@GAZK] Battery electrolyte: Low level
— 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 (boost) pressure sensor high error
— Failure code [CA123] Charge (boost) pressure sensor low error
— Failure code [CA131] Throttle sensor high error
— Failure code [CA132] Throttle sensor low error
— Failure code [CA135] Engine oil pressure sensor high error
— Failure code [CA141] Engine oil pressure sensor low error
— Failure code [CA144] Coolant temperature sensor high error
— Failure code [CA145] Coolant temperature sensor low error
— Failure code [CA153] Charge (boost) temperature sensor high error
— Failure code [CA154] Charge (boost) temperature sensor low error
— Failure code [CA187] Sensor power supply 2 low error
— Failure code [CA221] Atmospheric pressure sensor high error
— Failure code [CA222] Atmospheric pressure sensor low error
— Failure code [CA227] Sensor power supply 2 high error
– Troubleshooting by failure code (Display of code), Part 3
— Failure code [CA234] Engine overspeed
— Failure code [CA238] Ne speed sensor power supply error
— Failure code [CA263] Fuel Temp Sensor High Error
— Failure code [CA265] Fuel Temp Sensor Low Error
— Failure code [CA271] PCV1 Short circuit
— Failure code [CA272] PCV1 Disconnection
— Failure code [CA273] PCV2 Short circuit
— Failure code [CA274] PCV2 Disconnection
— 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] Sens Supply 1 Volt Low Error
— Failure code [CA386] Sensor power supply 1 high error
— Failure code [CA431] Idle validation switch error
— Failure code [CA432] Idle validation action 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] Rail Press Sensor High Error
— Failure code [CA452] Rail Press Sensor Low Error
— Failure code [CA553] Common rail pressure high error 1
— Failure code [CA554] Common rail pressure sensor in range error
— Failure code [CA559] Supply pump pressure very low error 1
— 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 [CA1228] EGR valve servo error 1
— Failure code [CA1625] EGR valve servo error 2
— Failure code [CA1626] Bypass valve solenoid current high error
— Failure code [CA1627] Bypass valve solenoid current low error
— Failure code [CA1628] Bypass Valve Servo Error 1
— Failure code [CA1629] Bypass Valve Servo Error 2
— Failure code [CA1631] Bypass valve lift sensor high error
— Failure code [CA1632] Bypass valve lift sensor low error
— Failure code [CA1633] KOMNET datalink timeout error
— Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor
— Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor
– Troubleshooting by failure code (Display of code), Part 4
— Failure code [CA2185] Throttle sensor supply voltage high error
— Failure code [CA2186] Throttle sensor power supply low error
— Failure code [CA2249] Supply pump pressure very low error 2
— Failure code [CA2271] EGR valve lift sensor high error
— Failure code [CA2272] EGR valve lift sensor low error
— Failure code [CA2351] EGR valve solenoid operation short circuit
— Failure code [CA2352] EGR valve solenoid operation disconnect
— Failure code [CA2555] Intake air heater relay open circuit error
— Failure code [CA2556] Intake air heater relay short circuit error
— 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 [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: Communication error (Abnormality in target component system)
— Failure code [DAQ0KK] Transmission controller: Low source voltage
— Failure code [DAQ0KT] Transmission controller: Abnormality in controller
— 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
– Troubleshooting by failure code (Display of code), Part 5
— Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system)
— Failure code [DAQRMA] Transmission controller option setting: Malfunction
— Failure code [DB2RKR] CAN communication from engine controller: Communication error (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 of model selection signals
— Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system)
— Failure code [DB9RMA] Work equipment controller option setting: Malfunction
— Failure code [DB9RMC] CAN communication with work equipment controller: Defective operation
— Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time
— Failure code [DD16LD] U 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 [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree
— Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit
— Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit
— Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree
– Troubleshooting by failure code (Display of code), Part 6
— Troubleshooting by failure code (Display of code), Part 6
— Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)
— Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
— Failure code [DDK3KA] (Right FNR switch: Disconnection)
— Failure code [DDK3KB] (Right FNR switch: Short circuit)
— Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)
— Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)
— 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 [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: Disconnection)
— Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
— Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)
— 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: Disconnection)
— 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)
— Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)
– Troubleshooting by failure code (Display of code), Part 7
— Troubleshooting by failure code (Display of code), Part 7
— Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)
— 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] (Left brake pressure sensor: Out of input signal range)
— Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine)
— 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)
— Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)
— Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)
— Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)
— Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)
– Troubleshooting by failure code (Display of code), Part 8
— Troubleshooting by failure code (Display of code), Part 8
— Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)
— 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 [DKA0KX] (Lift arm angle sensor: Out of input signal range)
— Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
— Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)
— Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)
— Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)
— Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)
— Failure code [DLT4KX] (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
— 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 [DXA1KA] (Pump PC-EPC solenoid: Disconnection)
— Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)
— 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)
– Troubleshooting by failure code (Display of code), Part 10
— Troubleshooting by failure code (Display of code), Part 10
— Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
— 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 [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)
— Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)
— Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)
— Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)
— Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)
— Failure code [DXHKKY] (3-spool valve retract EPC 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)
– Troubleshooting of electrical system (E-mode)
— Before carrying out troubleshooting of electrical system
— 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 KOMTRAX system does not work properly
– Troubleshooting of hydraulic and mechanical system (H-mode)
— Troubleshooting of hydraulic and mechanical system (H-mode)
— Method of using troubleshooting chart
— Table of failure modes and causes
— H-1 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 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and 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 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 Wheel brake does not work or does not work well
— H-16 Wheel brake is not released or it drags
— H-17 Parking brake does not work or does not work well
— H-18 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, lift arm comes to move slowly at specific height
— H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)
— H-23 Hydraulic drifts of lift arm occur often
— H-24 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 Bucket comes to operate slowly in the midst of tilting-back
— H-28 Bucket cylinder cannot hold down the bucket
— H-29 Hydraulic drifts of bucket occur often
— H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)
— H-31 During operation of machine, engine speed lowers remarkably or engine stalls
— H-32 Large shocks are made when work equipment starts and stops
— H-33 When work equipment circuit is relieved singly, other work equipment moves
— H-34 ECSS does not operate, and pitching and bouncing occur
– Troubleshooting of engine (S-mode)
— Troubleshooting of engine (S-mode)
— Method of using troubleshooting chart
— 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 operation
— S-5 Engine does not rotate smoothly (Engine hunts.)
— S-6 Engine lacks output (or lacks power)
— S-7 Exhaust smoke is black (Incomplete combustion)
— S-8 Oil is consumed much (or exhaust gas color 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 tool list
— Sketches of special tools
– Engine and cooling system, Part 1
— Removal and installation of engine assembly
— Removal and installation of radiator assembly
— Removal and installation of air aftercooler
— Removal and installation of cooling fan and fan motor assembly
— Removal and installation of radiator guard and cooling fan motor assembly
— Removal and installation of fuel tank assembly
— Removal and installation of hood
– Engine and cooling system, Part 2
— Removal and installation of fuel supply pump assembly
— Removal and installation of cylinder head assembly
— Removal and installation of fuel injector assembly
— Removal and installation of engine front seal
— Removal and installation of engine rear seal
– Power train, Part 1
— Removal and installation of torque converter and transmission assembly
— Disconnection and connection of power train unit
— Disassembly and assembly of input transfer assembly
— Disassembly and assembly of torque converter assembly (lockup specification)
— Disassembly and assembly of torque converter assembly (lockup-less specification)
– Power train, Part 2
— Disassembly and assembly of transmission assembly
— Disassembly and assembly of transfer and parking brake assembly
— Removal and installation of front axle assembly
— Removal and installation of rear axle assembly
– Power train, Part 3
— Removal and installation of front differential assembly
— Disassembly and assembly of differential assembly (LSD specification)
— Disassembly and assembly of differential assembly (LSD-less specification)
— Disassembly and assembly of final drive assembly (front and rear)
– Brake system
— Removal and installation of brake assembly (front and rear)
— Disassembly and assembly of brake assembly (front and rear)
— Disassembly and assembly of slack adjuster assembly
— Disassembly and assembly of brake accumulator charge valve assembly
– Undercarriage and frame
— Removal and installation of center hinge pin
– Hydraulic system
— Removal and installation of hydraulic tank assembly
— Removal and installation of hydraulic cooling pump assembly
— Removal and installation of cooling fan pump assembly
— Removal and installation of work equipment pump assembly
— Removal and installation of steering, torque converter charge and EPC pump assembly
— Removal and installation of work equipment valve assembly
— Disassembly and assembly of work equipment control valve assembly
— Disassembly and assembly of steering cylinder assembly
— Disassembly and assembly of lift arm and bucket cylinder assembly
— Removal and installation of steering control valve assembly
– Work equipment
— Removal and installation of work equipment assembly
— Removal and installation of large counterweight assembly
— Removal and installation of small counterweight assembly
– Cab and its attachments
— Removal and installation of operator’s cab assembly (separate cab and floor specification)
— Removal and installation of operator’s cab and floor frame assembly (cab-floor unit specification)
— Removal and installation of operator’s cab glass (stuck glass)
— Disassembly and assembly of operator’s seat assembly
– Electrical system
— Removal and installation of engine controller assembly
— Removal and installation of transmission controller assembly
— Removal and installation of work equipment controller assembly
— Removal and installation of KOMTRAX terminal assembly
— Removal and installation of air conditioner unit assembly
80 Appendix
– Air conditioner
— Precautions for refrigerant
— Troubleshooting procedure
— Circuit diagram and arrangement of connector pins
— System diagram
— Detail of air conditioner unit
— Parts and connectors layout
— Testing with self-diagnosis function (indication on control panel)
— Testing temperature control
— Testing vent (mode) changeover
— Testing Fresh/Recirc changeover
— Testing inside air temp. sensor and outside air temp. sensor
— Testing evaporator temperature sensor
— Testing sunlight sensor
— Testing relays
— Troubleshooting chart 1
— Troubleshooting chart 2
— Information in troubleshooting table
— Troubleshooting for power supply system (Air conditioner does not operate)
— Troubleshooting for compressor and refrigerant system (Air is not cooled)
— Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
— Troubleshooting for temperature control
— Troubleshooting for vent (mode) changeover
— Troubleshooting for Fresh/Recirc air changeover
— Troubleshooting with gauge pressure
— Connection of service tool
— Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
— Handling of compressor oil
90 Diagrams and drawings
– Hydraulic diagrams and drawings
— Automatic greasing circuit diagram
— Power train hydraulic circuit diagram
— Brake hydraulic circuit diagram
— Work equipment hydraulic circuit diagram
– Electrical diagrams and drawings
— Engine electrical circuit diagram
— Air conditioner electrical circuit diagram
— Electrical circuit diagram
— Connector arrangement diagram