Komatsu Wheel Loaders WA800-E0, WA900-E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA800-E0, WA900-E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loaders WA800-E0, WA900-E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,140 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
Cover...1
00 Index and foreword...0
Index...3
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...0
Specification and technical data...63
General assembly drawing...64
Specifications...66
Weight table...69
Table of fuel, coolant and lubricants...72
10 Structure, function and maintenance standard...0
Engine and cooling system...75
Engine mount...76
Transmission mount...77
Damper...78
Radiator, oil cooler, aftercooler...80
Fuel system...83
Power train, Part 1...85
Power train...86
Power train system...88
Torque converter...90
Torque converter regulator valve...98
Transmission...100
Transfer...112
Transmission control valve...115
Power train, Part 2...133
Torque converter oil cooler...134
Drive shaft...136
Center support...138
Axle...140
Differential...142
Final drive...148
Steering system...153
Steering piping...154
AJSS lever linkage...156
EPC valve...157
Steering column...158
Rotary valve...159
Steering control valve...162
Steering unit (orbit-roll valve)...174
Steering pump...177
Steering cylinder...179
Slow return valve...181
Emergency steering piping...182
Diverter valve...183
Emergency steering pump...189
Brake system...191
Brake piping...192
Brake...193
Brake valve...196
Accumulator charge valve...204
PPC relief valve...208
Accumulator (for brake)...210
Slack adjuster...211
Parking brake...213
Parking brake caliper...215
Spring cylinder...216
Parking brake solenoid...217
Brake cooling system (if equipped)...218
Brake cooling system (55?C specification) (If equipped)...228
Undercarriage and frame...237
Axle mount...238
Center hinge pin...241
Tire and wheel...243
Jack up point...244
Hydraulic system, Part 1...247
Hydraulic piping...248
Work equipment lever linkage...249
Hydraulic tank...250
Torque conbverter charging, PPC and brake pump...254
Hydraulic system, Part 2...257
Main control valve...258
Accumulator (For PPC valve)...273
Main piston pump...274
Main piston pump cut-off solenoid valve...285
PPC valve...286
PPC relief valve...291
Switch pump...292
Control pump...301
Work equipment...305
Work equipment linkage...306
Bucket positioner and lift arm kick-out...310
Remote lift arm positioner...312
Auto greasing system...313
Hydraulic cylinder...314
Cab and its attachments...317
ROPS cab...318
Air conditioner...319
Electrical system, Part 1...323
Machine monitor system...324
Main monitor...326
Maintenance monitor...330
Electrical system, Part 2...371
Work equipment control system...372
Remote position, joystick steering controller...375
Active power maximizing electrical circuit...376
Automatic transmission system (ATM)...383
Electrical system, Part 3...405
Engine starting/stopping circuit...406
Parking brake circuit...408
Preheating circuit...414
Emergency engine stop...416
Hydraulic oil level sensor...418
Battery and starting motor disconnector switch and starting aid connector...420
Sensor...422
20 Standard value table...0
Standard service value table...447
Standard value table for engine...448
Standard value table for chassis...449
Standard value table for electrical system...454
30 Testing and adjusting...0
Testing and adjusting, Part 1...471
Tools for testing, adjusting, and troubleshooting...473
Measuring engine speed...478
Measuring intake air (boost) pressure...480
Measuring exhaust gas color...481
Measuring exhaust temperature...482
Adjusting valve clearance...484
Measuring compression pressure...485
Measuring blow-by pressure...487
Measuring engine oil pressure...489
Handling fuel system equipment...490
Releasing residual pressure in fuel system...490
Testing fuel pressure...491
Measuring fuel return rate and leakage...492
Bleeding air from fuel circuit...495
Testing leakage in fuel system...497
Handling reduced cylinder mode operation...498
Handling no-injection cranking operation...498
Handling controller voltage circuit...499
Adjusting speed sensor...499
Testing and adjusting alternator belt tension...500
Testing and adjusting belt tension for air conditioner compressor...501
Testing and adjusting power train oil pressure...502
Procedure for operating emergency steering spool when transmission valve fails...507
Testing and adjusting, Part 2...511
Measuring operating effort of AJSS lever (AJSS specification)...513
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)...514
Testing and adjusting steering stopper bolt (AJSS specification)...516
Testing and adjusting steering stop valve...518
Measuring steering oil pressure...519
Testing and adjusting emergency steering oil pressure...520
Bleeding air from steering circuit...522
Measuring brake pedal...523
Measuring brake performance...524
Testing and adjusting accumulator charge pressure...525
Measuring wheel brake oil pressure reduction...527
Measuring wear of wheel brake disc...529
Bleeding air from wheel brake circuit...530
Releasing residual pressure in brake accumulator circuit...531
Testing parking brake performance...532
Measuring parking brake solenoid oil pressure...533
Testing and adjusting wear of parking brake pad...534
Testing and adjusting PPC oil pressure...535
Adjusting PPC valve linkage...537
Testing and adjusting work equipment oil pressure...538
Bleeding air from piston pump...540
Bleeding air from work equipment circuit...541
Adjusting work equipment lever linkage...542
Releasing remaining pressure in hydraulic circuit...544
Testing and adjusting bucket proximity switch...545
Testing and adjusting bucket positioner and tilt limiter...546
Testing and adjusting lift arm proximity switch...548
Testing and adjusting active working proximity switch...549
Checking proximity switch operation pilot lamp...550
Testing and adjusting lift arm position detection lever...551
Adjusting speedometer module of main monitor...552
Testing and adjusting, Part 3...555
Special function of engine service monitor...556
VHMS controller initial setting procedure...580
Precautions for replacing VHMS controller...602
Pm-clinic inspection table...608
40 Troubleshooting...0
Failure code table and fuse locations...613
Failure code table...614
Method of displaying action code and failure code on machine monitor...621
Transmission & AJSS controller LED display...623
Transmission control system...624
AJSS (Advanced Joystick Steering System) control system...625
Location of fuse...626
Location of relay...630
General information on troubleshooting...635
Points to remember when troubleshooting...636
Sequence of events in troubleshooting...637
Testing before troubleshooting...638
Classification and procedures of troubleshooting...639
Contents of troubleshooting table...640
Connection table for connector pin numbers...642
T- branch box and T- branch adapter table...678
Troubleshooting by failure code (Display of code), Part 1...683
Failure code [15B0NX] (Transmission oil filter: Clogging)...686
Failure code [AA1ANX] (Air cleaner L.H: Clogged)...688
Failure code [AA1BNX] (Air cleaner R.H: Clogged)...691
Failure code [AB00L4] (Alternator: Failure on battery charge circuit (Rterminal signal is present and engine is stopped)...694
Failure code [AB00L6] (Alternator: Failure on battery charge circuit (Rterminal signal is present and engine is stopped)...696
Failure code [AB00MA] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)...698
Failure code [AB00MB] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)...700
Failure code [AB00MC] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)...702
Failure code [B@BAZK] (Engine oil: Oil level low)...704
Failure code [B@BAZG] (Engine oil: Low oil pressure)...706
Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level)...710
Failure code [B@BDNS] (Engine: Overheating)...712
Failure code [B@C6NS] (Front brake oil temperature: Overheating)...714
Failure code [B@CENS] (Torque converter oil temperature overheating)...716
Failure code [B@JFZG] (Brake oil: Low oil pressure)...718
Troubleshooting by failure code (Display of code), Part 2...723
Failure code [CA111] Engine controller (Left bank): Internal abnormality...726
Failure code [CB111] Engine controller (Right bank): Internal abnormality...728
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal...730
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal...731
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected...732
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected...734
Failure code [CA131] Throttle sensor abnormally high level (Only left bank): High voltage detection...735
Failure code [CA132] Throttle sensor too low (At left bank only): Excessively low voltage detected...737
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected...738
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected...740
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected...742
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected...744
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected...746
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected...748
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection...750
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection...751
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection...752
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection...754
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected...755
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected...757
Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected...758
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection...760
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed...762
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected...764
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected...766
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected...768
Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected...770
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection...771
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection...771
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit...772
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit...773
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection...774
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection...775
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit...776
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit...777
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection...778
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection...779
Troubleshooting by failure code (Display of code), Part 3...781
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank): Disconnection, short circuit...784
Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (At left bank): Disconnection, short circuit...786
Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (At left bank): Disconnection, short circuit...788
Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (At left bank): Disconnection, short circuit ...790
Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (At left bank): Disconnection, short circuit...792
Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (At left bank): Disconnection, short circuit...794
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch...796
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch...797
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit...798
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality...800
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection...802
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection...803
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection...804
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection...806
Failure code [CA431] Trouble in idle validation switch...808
Failure code [CA432] Idle validation action error...810
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection...811
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection...811
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection...812
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection...812
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence...813
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence...813
Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected...814
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection...816
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection...818
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection...818
Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected...819
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected...820
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error...821
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error...821
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected...822
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected...828
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal...830
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal...832
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection...834
Failure code [CA692] Intake air temperature sensor abnormally low level Failure code [CA692] Intake air temperature sensor abnormally low level...836
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase...837
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase...837
Troubleshooting by failure code (Display of code), Part 4...839
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data...841
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data...841
Failure code [CA778] Engine Bkup speed sensor abnormality (At left bank): Bkup signal error...842
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error...844
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error...846
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error...848
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error...849
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error...850
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit...852
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit...854
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit...856
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit...858
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit...860
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit...862
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error...864
Failure code [CA2185] Throttle sensor power supply abnormally high level (Only left bank): High voltage detection...866
Failure code [CA2186] Throttle sensor power source too low (At left bank only): Excessively low voltage detected...868
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected...869
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected...869
Failure code [CA2555] Intake heater relay voltage low error (Left bank only)...870
Failure code [CA2556] Intake heater relay voltage high error (Left bank only)...872
Failure code [D160KZ] (or TM & AJSS controller LED display [10], abnormality in backup lamp relay system: Disconnection, short circuit or hot short circuit...874
Failure code [D180KA] (Preheating relay output system: Disconnection)...876
Failure code [D180KB] (Preheating relay output system: Grounding fault)...877
Failure code [D180KY] (Preheating relay output system: Hot short circuit)...878
Failure code [D19AKB] (or TM & AJSS controller LED display [56], abnormality in joystick caution relay output system: Disconnection or short circuit)...880
Failure code [D19BKZ] (or TM & AJSS controller LED display [62], abnormality in joystick neutral interlock relay output system: Disconnection or short circuit)...882
Failure code [D1EFKA] (Pre-lubrication start relay output system: Disconnection)...884
Failure code [D1EFKB] (Pre-lubrication start relay output system: Grounding fault)...886
Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot short circuit)...888
Failure code [D1EHKA] (Engine start relay output system: Disconnection)...890
Failure code [D1EHKB] (Engine start relay output system: Grounding fault)...892
Failure code [D1EHKY] (Engine start relay output system: Hot short circuit)...894
Failure code [D5ZHL6] (Starting switch terminal C signal: Error)...896
Failure code [D5ZSKA] (Machine monitor communication output: Disconnection)...898
Failure code [D5ZSKB] (Machine monitor communication output: Grounding fault)...899
Failure code [D5ZSKY] (Machine monitor communication output: Hot short circuit)...900
Troubleshooting by failure code (Display of code), Part 5...903
Failure code [DB2RKR] (Engine controller CAN-NET communication: Disconnection and grounding fault)...905
Failure code [DBB0KK] (or VHMS LED display: "n9" ? "01", VHMS controller: Low supply voltage)...908
Failure code [DBB0KQ] (or VHMS LED display: "nF" ? "11", VHMS controller model selection: Disagreement of model selection signals)...910
Failure code [DBB3KK] (or VHMS LED display: "n9" ? "05", VHMS controller: Low direct supply voltage)...912
Failure code [DBB5KP] (or VHMS LED display: "n9" ? "04", VHMS controller sensor power supply (5 V): Low output voltage)...914
Failure code [DBB6KP] (or VHMS LED display: "n9" ? "02", VHMS controller sensor power supply (24 V): Low output voltage)...916
Failure code [DBBQKR] (or VHMS LED display: "n8" ? "02", VHMS controller CAN communication abnormality)...918
Failure code [DBG2KK] (Solenoid power supply: Low voltage)...920
Failure code [DBG3KK] (Battery direct power supply: Low voltage)...922
Failure code [DBG9KQ] (Model selection signal: Abnormal)...924
Failure code [DBGRKR] (Pre-lubrication controller CAN-NET communication: Disconnection or grounding fault)...925
Failure code [DBL0KR] (Power ladder controller CAN-NET communication: Disconnection or grounding fault)...928
Failure code [DDE2KB] (Engine oil pressure switch error: Grounding fault)...930
Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection or hot short circuit)...932
Failure code [DDK3KZ] (or TM & AJSS controller LED display [20], abnormality in joystick forward-reverse switch system: Disconnection or hot short circuit)...934
Failure code [DDK5KZ] (or TM & AJSS controller LED display: ?21?, Abnormality in shifting up/down switch system: Disconnection, short circuit or hot short circuit)...937
Failure code [DDP5KZ] (Abnormality in steering lock switch system: Disconnection or short circuit)...940
Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input signal range (short))...942
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range (short))...944
Failure code [DGR4KX] (Front brake oil temperature sensor: Out of input signal range (short))...946
Troubleshooting by failure code (Display of code), Part 6...949
Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit)...951
Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank exhaust gas temperature sensor system (Rear): Disconnection or short circuit)...954
Failure code [DGT5KB] (or VHMS LED display: "n3" o "11", L.H. bank exhaust gas temperature sensor system (Front): Hot short circuit)...958
Failure code [dGT5KB] (or VHMS LED display: "n3" o "21", L.H. bank exhaust gas temperature sensor system (Rear): Hot short circuit)...960
Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit)...962
Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H. exhaust gas temperature sensor system (Rear): Disconnection or short circuit)...965
Failure code [DGT6KB] (or VHMS LED display "n3" o "23", R.H. bank exhaust gas temperature sensor system (front): Hot short circuit)...968
Failure code [dGT6KB] (or VHMS LED display "n3" o "25", R.H. bank exhaust gas temperature sensor system (rear): Hot short circuit)...970
Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32", Blow-by pressure sensor system: Short circuit)...972
Failure code [DHE5KY] (or VHMS LED display: "n3" o "31", Blow-by pressure sensor system: Hot short circuit)...974
Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection or short circuit)...976
Failure code [DHT3KX] (or VHMS LED display: "n6" o "14", Transmission oil pressure sensor system: Out of input signal range)...978
Failure code [DHT8KX] (Steering pump oil pressure sensor error): Disconnection or short circuit)...980
Failure code [DHU2KX] (Front brake oil pressure sensor error: Disconnection or short circuit)...982
Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection or short circuit)...984
Failure code [DK00L8] (or TM & AJSS controller LED display [58], steering and frame angle displacement)...986
Failure code [DK30KX] (or TM & AJSS controller LED display [57], abnormality in steering angle potentiometer system): Disconnection or short circuit)...988
Failure code [DKD0KX] (or TM & AJSS controller LED display [59], abnormality in frame angle potentiometer system: Disconnection or short circuit)...990
Failure code [DLE4KA] (or TM & AJSS controller LED display [23], abnormality in engine speed sensor system: Disconnection, short circuit or hot short circuit)...992
Failure code [DLT4KA] (or TM & AJSS controller LED display [22], abnormality in speed sensor system: Disconnection, short circuit or hot short circuit)...994
Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality: Hot short circuit)...996
Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault)...997
Failure code [DXF0KZ] (or TM & AJSS controller LED display [63], abnormality in joystick EPC solenoid system: Disconnection, short circuit or hot short circuit)...999
Failure code [DXH4KZ] (or TM & AJSS controller LED display [14], abnormality in 1st solenoid system: Disconnection, short circuit or hot short circuit)...1000
Failure code [DXH5KZ] (or TM & AJSS controller LED display [15], abnormality in 2nd solenoid system: Disconnection, short circuit or hot short circuit)...1002
Failure code [DXH6KZ] (or TM & AJSS controller LED display [16], abnormality in 3rd solenoid system: Disconnection, short circuit or hot short circuit)...1004
Failure code [DXH7KZ] (or TM & AJSS controller LED display [13], abnormality in R solenoid system: Disconnection, short circuit or hot short circuit)...1006
Failure code [DXH8KZ] (or TM & AJSS controller LED display [12], abnormality in F solenoid system: Disconnection, short circuit or hot short circuit)...1008
Failure code [F@BBZL] (or VHMS LED display: "n3" o "38", Blow-by pressure sensor system: High pressure error)...1010
Failure code [F@BYNR] (or VHMS LED display: "n3" o "62", L.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)...1011
Failure code [f@BYNR] (or VHMS LED display: "n3" o "72", L.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)...1011
Failure code [F@BYNS] (or VHMS LED display: "n3" o "61", L.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)...1012
Failure code [f@BYNS] (or VHMS LED display: "n3" o "71", L.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)...1012
Failure code [F@BZNR] (or VHMS LED display: "n3" o "82", R.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)...1013
Failure code [f@BZNR] (or VHMS LED display: "n3" o "92", R.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)...1013
Failure code [F@BZNS] (or VHMS LED display: "n3" o "38", R.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)...1014
Failure code [f@BZNS] (or VHMS LED display: "n3" o "39", R.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)...1014
Troubleshooting of electrical system (E-mode)...1017
E-1 Engine does not start...1020
E-2 Abnormality in preheating system...1026
E-3 Transmission and AJSS controller does not work...1032
E-4 Transmission and AJSS controller model selection error...1034
E-5 Parking brake does not work (as the emergency brake)...1036
E-6 Parking brake is applied while machine is traveling...1040
E-7 Parking brake is released as starting switch is turned ON...1042
E-8 Setting to the neutral position becomes unavailable while the parking brake is in operation (parking brake operates normally)...1044
E-9 Parking brake remains in the neutral and not removable to other position (when parking brake is not applied)...1046
E-10 Defective kick-down switch...1048
E-11 Defective hold switch...1052
E-12 Lift arm (boom) kick-out is unavailable...1056
E-13 Bucket positioner functional error...1058
E-14 Active working functional error...1060
E-15 Turn signal or hazard display do not flash...1066
E-16 Small lamp does not light up...1072
E-17 Head lamp does not light up...1075
E-18 Abnormality in lighting up of front working lamp...1078
E-19 Abnormality in lighting up of rear working lamp...1078
E-20 Abnormality in transmission cut-off...1078
E-21 Abnormality in low idle selection...1078
E-22 Abnormality in parking brake dragging warning...1078
E-23 Abnormality in buzzer...1078
Troubleshooting of hydraulic and mechanical system (H-mode)...1081
Method of using troubleshooting chart...1083
H-1 Machine does not move...1085
H-2 Machine lacks power or speed (every speed range)...1086
H-3 Excessive time lag when starting machine or shifting gear...1087
H-4 Torque converter oil temperature is high...1088
H-5 Steering does not turn...1089
H-6 Turning, response of steering is poor...1090
H-7 Joystick lever is heavy...1091
H-8 Steering wheel shakes or jerks...1092
H-9 Minimum turning radii to right and left are different...1093
H-10 Wheel brakes do not work or braking effect is poor...1094
H-11 Wheel brakes are not released or brakes drag...1095
H-12 Lift arm does not rise...1096
H-13 Lift arm moves slowly or does not have sufficient lifting power...1097
H-14 When raising lift arm, becomes slow at certain height...1098
H-15 Lift arm cylinder cannot hold down bucket...1098
H-16 Lift arm has large amount of hydraulic drift...1098
H-17 Lift arm fluctuates while working...1099
H-18 Lift arm drops momentarily when lever is operated from HOLD to RAISE...1099
H-19 Bucket does not tilt back...1100
H-20 Bucket moves slowly or has insufficient tilt back power...1101
H-21 Bucket movement becomes slow during tilt back...1102
H-22 Bucket cylinder cannot hold down bucket...1102
H-23 Bucket has large amount of hydraulic drift...1102
H-24 Bucket fluctuates while traveling under load (work equipment valve "HOLD")...1103
H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT...1103
H-26 Lift arm and bucket levers do not move smoothly...1104
Troubleshooting of engine (S-mode)...1107
Method of using troubleshooting chart...1109
S-1 Starting performance is poor...1112
S-2 Engine does not start...1113
S-3 Engine does not pick up smoothly...1116
S-4 Engine stops during operations...1117
S-5 Engine does not rotate smoothly...1118
S-6 Engine lacks output (or lacks power)...1119
S-7 Exhaust smoke is black (incomplete combustion)...1121
S-8 Oil consumption is excessive (or exhaust smoke is blue)...1122
S-9 Oil becomes contaminated quickly...1123
S-10 Fuel consumption is excessive...1124
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...1125
S-12 Oil pressure drops...1126
S-13 Oil level rises (Entry of coolant or fuel)...1127
S-14 Coolant temperature becomes too high (overheating)...1128
S-15 Abnormal noise is made...1129
S-16 Vibration is excessive...1130
Troubleshooting of machine monitor system (M-mode)...1133
Machine monitor system...1135
M-1 Machine monitor does not work...1136
M-2 Engine starts immediately after (within 3 sec of) turning starting switch ON, but all the machine monitors remain lit...1138
M-3 Speedometer display does not work...1139
M-4 Shift indicator error...1141
M-5 Monitor turn signal (hazard) indicator does not light up...1151
M-6 Parking indication error...1153
M-7 Abnormality in preheating system...1154
M-8 Night lamp does not light up...1158
M-9 Front work lamp error...1160
M-10 Rear work lamp error...1164
M-11 Abnormality in transmission cut-off switch...1168
M-12 Abnormality in low idle selection...1172
M-13 Emergency steering indication error...1174
M-14 Parking brake dragging warning error...1176
M-15 Buzzer and caution lamp error upon parking brake dragging warning outputting...1177
M-16 Buzzer error...1179
M-17 Switching state of machine monitor is not stored...1185
M-18 Failure indication mode error...1186
M-19 Machine monitor does not indicate failure code...1188
M-20 Abnormality in auto grease system...1190
Troubleshooting of maintenance monitor system (K-mode)...1195
Maintenance monitor system...1197
K-1 Maintenance monitor does not work...1198
K-2 Immediately after turning starting switch ON (within 3 sec.), engine starts but the maintenance monitor remains fully lit up...1200
K-3 Work check item flashes upon turning starting switch ON (engine not running)...1202
K-4 Caution item flashes upon turning starting switch ON (engine running)...1206
K-5 The warning buzzer does not sound while caution item indicator flashes...1222
K-6 The warning buzzer sounds while monitor indicates no error...1224
K-7 The warning lamps (check lamp and caution lamp) do not flash while caution item indicator flashes...1225
K-8 Warning lamps (check and caution lamps) lights up while the maintenance monitor indicates no error...1227
K-9 Night lamp does not light up...1230
K-10 Night lamp remains lit up...1232
K-11 Service meter does not work...1234
K-12 Service meter keeps on working (when engine stops)...1236
K-13 Gauge items (fuel, engine coolant temperature and torque converter oil temperature) error...1238
Troubleshooting of remote boom positioner controller system (if equipped) (W-mode)...1247
W-1 Short circuit, disconnection in dumping solenoid system...1250
W-2 Short circuit in power source at hot end of dumping solenoid...1251
W-3 Short circuit in power source at return end of dumping solenoid...1252
W-4 Boom kick-out function trouble...1254
W-5 Disconnection in boom RAISE, LOWER detection pressure switch...1256
W-6 Short circuit, disconnection in boom angle potentiometer system...1258
W-7 Sensor cannot be adjusted...1260
W-8 Abnormality in engine speed signal system...1261
W-9 Remote positioner RAISE, LOWER LEDs do not light up...1262
W-10 Remote positioner RAISE set LED does not flash...1264
W-11 Remote positioner LOWER set LED does not flash...1266
W-12 Buzzer for switch operation does not sound...1268
W-13 Shock when stopping boom...1269
W-14 Short circuit in boom RAISE, LOWER pressure detection switch...1270
50 Disassembly and assembly...0
General information on disassembly and assembly...1273
How to read this manual...1274
Coating materials list...1276
Special tools list...1279
Sketches of special tools...1285
Engine and cooling system, Part 1...1295
Removal and installation of engine assembly...1296
Removal and installation of radiator assembly...1301
Removal and installation of damper assembly...1304
Disassembly and assembly of damper assembly...1305
Removal and installation of fuel tank assembly...1309
Engine and cooling system, Part 2...1313
Removal and installation of right bank fuel supply pump assembly...1314
Removal and installation of left bank fuel supply pump assembly...1318
Removal and installation of cylinder head assembly...1322
Removal and installation of fuel injector assembly...1332
Removal and installation of engine front oil seal...1337
Removal and installation of engine rear oil seal...1340
Power train, Part 1...1345
Disassembly and assembly of transfer assembly...1346
Disassembly and assembly of PTO assembly...1360
Removal and installation of parking brake calipers assembly...1364
Disassembly and assembly of parking brake calipers assembly...1365
Removal and installation of parking brake pad...1367
Removal and installation of parking brake spring cylinder...1368
Removal and installation of torque converter and transmission assembly...1369
Power train, Part 2...1377
Disassembly and assembly of torque converter assembly...1378
Disassembly and assembly of transmission assembly...1386
Power train, Part 3...1411
Removal and installation of front axle assembly...1412
Removal and installation of rear axle assembly...1414
Removal and installation of center support assembly...1420
Disassembly and assembly of center support assembly...1422
Removal and installation of differential assembly...1426
Disassembly and assembly of differential assembly...1428
Disassembly and assembly of final drive assembly...1437
Brake system...1445
Removal and installation of brake assembly...1446
Disassembly and assembly of brake assembly...1447
Removal and installation of left brake valve assembly...1452
Removal and installation of right brake valve assembly...1453
Disassembly and assembly of accumulator charge valve...1454
Disassembly and assembly of slack adjuster...1456
Undercarriage and frame...1459
Removal and installation of center hinge pin...1460
Removal and installation of counterweight assembly...1472
Hydraulic system...1475
Removal and installation of hydraulic tank and filter case assembly...1476
Removal and installation of hydraulic pump assembly...1478
Removal and installation of work equipment control valve assembly...1481
Disassembly and assembly of work equipment control valve assembly...1483
Disassembly and assembly of PPC valve assembly...1486
Removal and installation of steering valve assembly...1487
Removal and installation of diverter valve assembly...1489
Disassembly and assembly of diverter valve assembly...1490
Removal and installation of Orbit- roll assembly...1492
Removal of steering stop valve...1494
Installtion of steering stop valve...1494
Disassembly and assembly of hydraulic cylinder assembly...1495
Work equipment...1501
Removal and installation of work equipment assembly...1502
Replacement of boom front bushing...1507
Cab and its attachments...1509
Removal and installation of operator cab assembly...1510
Removal and installation of floor frame assembly...1512
Disassembly and assembly of operator?s seat assembly...1515
Removal and installation of AJSS lever switch assembly...1548
Electrical system...1555
Removal and installation of engine controller assembly...1556
Removal and installation of transmission and steering controller assembly...1557
Removal and installation of main monitor assembly...1558
Removal and installation of air conditioner unit assembly...1560
90 Diagrams and drawings...0
Hydraulic diagrams and drawings...1563
Power train hydraulic circuit diagram...1564
Brake hydraulic circuit diagram...1565
Work equipment hydraulic circuit diagram...1567
Electrical diagrams and drawings...1570
Electrical circuit diagram (1/8)...1572
Electrical circuit diagram (2/8)...1573
Electrical circuit diagram (3/8)...1574
Electrical circuit diagram (4/8)...1575
Electrical circuit diagram (5/8)...1576
Electrical circuit diagram (5/8)...1577
Electrical circuit diagram (6/8)...1578
Electrical circuit diagram (7/8)...1579
Electrical circuit diagram (8/8)...1580
Electrical circuit diagram of emergency engine stop...1581
Electrical circuit diagram of hydraulic oil level sensor...1582
Electrical circuit diagram for KAL (1/2)...1583
Electrical circuit diagram for KAL (2/2)...1584
Electrical circuit diagram of battery and starting motor disconnector switch and starting aid connector...1585
Electrical circuit diagram for bucket tilt limitter (If equipped)...1586
Connector arrangement diagram...1587
