Komatsu Wheel Dozers WD600, WD600H, WD900 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Dozer WD600-1, WD600-1H, WD600-3, WD600-6, WD900-3, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Dozer WD600-1, WD600-1H, WD600-3, WD600-6, WD900-3 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: 3,543 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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SEAW002500 - Wheel Dozer WD900-3 Field Assembly Instruction.pdf
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SEBM022904 - Wheel Dozer WD600-3 Shop Manual.pdf
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SEBMW01501 - Wheel Dozer WD600-1H (-50 degrees Specification) Shop Manual.pdf
SEN04979-06 - Wheel Dozer WD600-6 Shop Manual.pdf
TEN00169-02 - Wheel Dozer WD600-3 Operation & Maintenance Manual.pdf
TEN00322-00 - Wheel Dozer WD600-6 Operation & Maintenance Manual.pdf
TEN00461-03 - Wheel Dozer WD600-6 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER....1
00 Index and foreword....0
100 Index....3
Composition of shop manual....4
Table of contents....6
200 Foreword and general information....19
Safety notice....20
How to read the shop manual....25
Explanation of terms for maintenance standard....27
Handling of electric equipment and hydraulic component....29
Handling of connectors newly used for engines....38
How to read electric wire code....41
Precautions when carrying out operation....44
Method of disassembling and connecting push-pull type coupler....47
Standard tightening torque table....50
Conversion table....54
01 Specification....0
100 Specification and technical data....61
Specification dimension drawing....62
Specifications....63
Weight table....66
Table of fuel, coolant and lubricants....68
10 Structure, function and maintenance standard....0
100 Engine and cooling system....71
Engine mount and transmission mount....72
Damper....74
Cooling system....76
Cooling fan pump....80
Cooling fan motor....88
201 Power train, Part 1....95
Power train....96
Power train system diagram....97
Torque converter and transmission piping diagram....98
Torque converter....100
Modulation clutch....109
Torque converter regulator valve....110
Transmission....112
Transfer....132
Transmission control valve....134
ECMV....136
Main relief valve and torque converter relief valve....143
Lubrication relief valve....145
202 Power train, Part 2....147
Torque converter oil cooler....148
Torque converter oil filter....149
Drive shaft....151
Center support....154
Axle....156
Differential....160
Limited slip differential....169
Final drive....174
300 Steering system....179
Steering piping diagram....180
Steering column....182
Joystick steering lever linkage....183
Joystick EPC valve....184
Lock valve....185
Steering valve....186
Rotary valve....189
Steering control valve....192
Two-way restrictor valve....208
Stop valve....209
Steering pump....210
Steering cylinder....224
Emergency steering piping diagram....225
Diverter valve....226
Emergency steering pump....234
400 Brake system....237
Brake piping diagram....238
Brake....240
Brake valve....244
Accumulator charge valve....252
EPC relief valve....258
Accumulator (for brake)....260
Slack adjuster....262
Parking brake....266
Parking brake solenoid valve....268
Emergency parking brake release valve....270
Brake cooling pump....271
500 Undercarriage and frame....273
Axle mount....274
Center hinge pin....279
601 Hydraulic system, Part 1....283
Hydraulic piping diagram....284
Work equipment control lever linkage....286
Hydraulic tank....288
Work equipment pump....290
602 Hydraulic system, Part 2....311
Control valve....312
CLSS....326
Functions and operation by valve....330
Accumulator (for PPC circuit)....340
Triple pump....341
700 Work equipment....343
Work equipment linkage....344
Cutting edge and end bit....347
Work equipment lubrication....349
Hydraulic cylinder....352
800 Cab and its attachments....355
ROPS cab....356
Air conditioner....358
901 Electrical system, Part 1....363
Machine monitor system....364
Machine monitor....370
902 Electrical system, Part 2....419
Work equipment control system....420
Transmission controller system....446
903 Electrical system, Part 3....479
Electric transmission control....480
Engine starting/stopping circuit....482
Parking brake circuit....485
Sensor....489
VHMS controller related....509
Electric lever (Work equipment)....515
20 Standard value table....0
100 Standard service value table....519
Standard service value table for engine....520
Standard service value table for chassis....521
30 Testing and adjusting....0
101 Testing and adjusting, Part 1....531
Tools for testing, adjusting, and troubleshooting....533
Sketches of special tools....538
Measuring engine speed....539
Measuring exhaust gas color....541
Measuring exhaust temperature....542
Adjusting valve clearance....544
Testing compression pressures....546
Measuring blow-by pressure....549
Measuring engine oil pressure....550
Testing EGR valve and bypass valve drive oil pressure....551
Measuring intake air (boost) pressure....553
Handling fuel system equipment....554
Releasing residual pressure in fuel system....554
Testing fuel pressures....555
Testing return rate and leakage....556
Bleeding air from fuel circuit....559
Testing leakage in fuel system....561
Handling reduced cylinder mode operation....562
Handling no-injection cranking operation....562
Handling controller voltage circuit....563
Replacing and adjusting alternator and air conditioner compressor belt tension....564
Adjusting modulation clutch speed sensor and speed sensor....565
Measuring directional lever and gear shift lever (Steering wheel specification)....567
Testing and adjusting power train oil pressure....568
Flushing procedure for torque converter and transmission hydraulic circuit....582
Method of moving machine when transmission valve is broken....584
Moving method of machine disabled by short-to-power failure in work equipment potentiometer....586
Adjusting steering stop valve....588
102 Testing and adjusting, Part 2....591
Measuring operating effort of AJSS lever (AJSS specification)....593
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)....594
Testing and adjusting steering stopper bolt (AJSS specification)....596
Testing and adjusting steering wheel (Steering wheel specification)....598
Testing steering oil pressure....600
Bleeding air from steering cylinder circuit....604
Testing hydraulic drive fan....605
Bleeding air from hydraulic drive fan circuit....608
Measuring brake pedal....610
Measuring brake performance....611
Testing and adjusting accumulator charge pressure....612
Testing wheel brake oil pressure....614
Measuring wear of wheel brake disc....616
Bleeding air from wheel brake circuit....617
Releasing residual pressure in brake accumulator circuit....618
Testing parking brake performance....619
Measuring parking brake oil pressure....620
Testing wear of parking brake disc....623
Method of releasing parking brake manually....624
Measuring and adjusting work equipment control lever....625
Measuring work equipment oil pressure....626
Bleeding air from work equipment circuit....631
Moving machine for removing operator cab....632
Preparations for work on troubleshooting of electric system....634
Procedure for testing diodes....638
103 Testing and adjusting, Part 3....641
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller....642
Special functions of machine monitor (EMMS)....645
104 Testing and adjusting, Part 4....715
VHMS controller initial setting procedure....716
Precautions for replacing VHMS controller....738
Pm-clinic inspection table....744
40 Troubleshooting....0
100 Failure code table and fuse locations....747
Failure codes list....748
Fuse locations....760
200 General information on troubleshooting....763
Points to remember when troubleshooting....764
Sequence of events in troubleshooting....765
Testing before troubleshooting....766
Classification and procedures of troubleshooting....767
Information contained in troubleshooting table....768
Phenomena looking like troubles and troubleshooting Nos....770
Connection table for connector pin numbers....772
T- branch box and T- branch adapter table....808
301 Troubleshooting by failure code (Display of code), Part 1....813
Failure code [1500L0] (TORQFLOW transmission: Double meshing)....814
Failure code [15B0NX] (Transmission filter: Clogged)....816
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)....818
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)....820
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)....822
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)....824
Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON)....826
Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF)....828
Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON)....830
Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF)....832
Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON)....834
Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF)....836
Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON)....838
Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF)....840
Failure code [15W0NT] (Transmission modulation clutch: Overheating)....842
Failure code [2F00MA] (Parking brake: Malfunction)....843
Failure code [2G42ZG] (Front accumulator: Low oil pressure)....846
302 Troubleshooting by failure code (Display of code), Part 2....849
Failure code [2G43ZG] (Rear accumulator: Low oil pressure)....852
Failure code [A000N1] (or VHMS_LED display: ?n2? ? ?01?) (Engine: Overrun)....854
Failure code [AA1ANX] (Air cleaner: Clogging)....856
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)....858
Failure code [AB00MA] (Alternator: Malfunction)....860
Failure code [B@BAZG] (Engine oil pressure: Low error)....862
Failure code [B@BAZK] (Engine oil: Low level)....863
Failure code [B@BCNS] (Engine coolant temperature: Overheating)....864
Failure code [B@BCZK] (Coolant: Low level)....866
Failure code [B@C7NS] (Brake oil: Overheating)....868
Failure code [b@CENS] (Torque converter oil: Overheating)....870
Failure code [B@CENS] (Torque converter oil: Overheating)....872
Failure code [B@GAZK] (Battery electrolyte: Low level)....874
Failure code [B@HANS] (Hydraulic oil: Overheating)....876
Failure code [CA111] (Abnormality in engine controller)....878
Failure code [CA115] (Engine Ne or Bkup speed sensor error)....880
Failure code [CA122] (Charge (boost) pressure sensor high error)....882
Failure code [CA123] (Charge (boost) pressure sensor low error)....884
Failure code [CA131] (Throttle sensor high error)....886
Failure code [CA132] (Throttle sensor low error)....888
Failure code [CA135] (Engine oil pressure sensor high error)....890
Failure code [CA141] (Engine oil pressure sensor low error)....892
Failure code [CA144] (Coolant temperature sensor high error)....894
Failure code [CA145] (Coolant temperature sensor low error)....896
Failure code [CA153] (Charge (boost) temperature sensor high error)....898
Failure code [CA154] (Charge (boost) temperature sensor low error)....900
Failure code [CA187] (Sensor power supply 2 low error)....901
Failure code [CA212] (Engine oil temperature sensor high error)....902
Failure code [CA213] (Engine oil temperature sensor low error)....904
Failure code [CA221] (Atmospheric pressure sensor high error)....906
Failure code [CA222] (Atmospheric pressure sensor low error)....908
Failure code [CA227] (Sensor power supply 2 high error)....910
303 Troubleshooting by failure code (Display of code), Part 3....913
Failure code [CA234] (Engine overspeed)....915
Failure code [CA238] (Ne speed sensor power supply error)....916
Failure code [CA263] (Fuel temperature sensor high error)....918
Failure code [CA265] (Fuel temperature sensor low error)....920
Failure code [CA271] (PCV1 Short circuit)....922
Failure code [CA272] (PCV1 Disconnection)....924
Failure code [CA273] (PCV2 Short circuit)....926
Failure code [CA274] (PCV2 Disconnection)....928
Failure code [CA322] (Injector #1 open/short error)....930
Failure code [CA323] (Injector #5 open/short error)....932
Failure code [CA324] (Injector #3 open/short error)....934
Failure code [CA325] (Injector #6 open/short error)....936
Failure code [CA331] (Injector #2 open/short error)....938
Failure code [CA332] (Injector #4 open/short error)....940
Failure code [CA342] (Calibration code inconsistency)....942
Failure code [CA351] (Injectors drive circuit error)....944
Failure code [CA352] (Sensor power supply 1 low error)....946
Failure code [CA386] (Sensor power supply 1 high error)....948
Failure code [CA431] (Idle validation switch error)....950
Failure code [CA432] (Idle validation action error)....952
Failure code [CA441] (Battery voltage low error)....952
Failure code [CA442] (Battery voltage high error)....953
Failure code [CA449] Common rail pressure high error 2....953
Failure code [CA451] (Common rail pressure sensor high error)....954
Failure code [CA452] (Common rail pressure sensor low error)....956
Failure code [CA553] (Common rail pressure high error 1)....957
Failure code [CA554] (Common rail pressure sensor in range error)....958
Failure code [CA559] (Supply pump pressure very low error 1)....960
Failure code [CA689] (Engine Ne speed sensor error)....964
Failure code [CA731] (Engine Bkup speed sensor phase error)....966
Failure code [CA757] (All continuous data lost error)....967
Failure code [CA778] (Engine Bkup speed sensor error)....968
Failure code [CA1228] (EGR valve servo error 1)....970
Failure code [CA1625] (EGR valve servo error 2)....971
Failure code [CA1626] (Bypass valve solenoid current high error)....972
Failure code [CA1627] (Bypass valve solenoid current low error)....974
Failure code [CA1628] (Bypass valve servo error 1)....975
Failure code [CA1629] (Bypass valve servo error 2)....976
Failure code [CA1631] (Bypass valve lift sensor high error)....978
Failure code [CA1632] (Bypass valve lift sensor low error)....980
Failure code [CA1633] (KOMNET datalink timeout error)....981
304 Troubleshooting by failure code (Display of code), Part 4....983
Failure code [CA2185] (Throttle sensor supply voltage high error)....986
Failure code [CA2186] (Throttle sensor power supply low error)....988
Failure code [CA2249] (Supply pump pressure very low error 2)....989
Failure code [CA2271] (EGR valve lift sensor high error)....990
Failure code [CA2272] (EGR valve lift sensor low error)....992
Failure code [CA2351] (EGR valve solenoid operation short circuit)....994
Failure code [CA2352] (EGR valve solenoid operation disconnect)....996
Failure code [CA2555] (Intake heater relay disconnection error)....997
Failure code [CA2556] (Intake heater relay short circuit error)....998
Failure code [D191KA] (AJSS neutral safety relay: Disconnection)....1000
Failure code [D191KB] (AJSS neutral safety relay: Short circuit)....1002
Failure code [D198KA] (Transmission oil pressure bypass solenoid: Disconnection)....1004
Failure code [D198KB] (Transmission oil pressure bypass solenoid: Short circuit)....1005
Failure code [D198KY] (Transmission oil pressure bypass solenoid: Short circuit with power supply line)....1006
Failure code [D5ZHKA] (Terminal C signal: Disconnection)....1008
Failure code [D5ZHKB] (Terminal C signal: Short circuit)....1010
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)....1012
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)....1014
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)....1016
Failure code [DAF3KK] (Machine monitor: Low source voltage (input))....1018
Failure code [DAF5KP] (5V power source output voltage defective)....1020
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))....1022
Failure code [DAQ0KK] (Transmission controller: Low source voltage)....1024
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)....1026
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))....1028
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)....1030
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))....1032
Failure code [DAQRMA] (Transmission controller CAN communication: Malfunction)....1034
305 Troubleshooting by failure code (Display of code), Part 5....1037
Failure code [DB2RKR] CAN communication from engine controller: Defective communication (Abnormality in target component system)....1040
Failure code [DB90KK] Work equipment controller: Low source voltage (input)....1042
Failure code [DB90KT] (Work equipment controller: Abnormality in controller)....1044
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)....1046
Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range)....1048
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)....1050
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)....1052
Failure code [DB9RMA] (Work equipment controller CAN communication: Malfunction)....1054
Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation)....1056
Failure code [DBB0KK] (or VHMS_LED display: ?n9? ? ?01?) VHMS controller: Low source voltage (input)....1058
Failure code [DBB0KQ] (or VHMS_LED display: ?nF? ? ?11?) (VHMS controller: Disagreement of model selection signals)....1060
Failure code [DBB3KK] (or VHMS_LED display: ?n9? ? ?05?) VHMS controller battery power supply: Low source voltage (input)....1062
Failure code [DBB5KP] (or VHMS_LED display: ?n9? ? ?04?) (VHMS controller 5 V power supply output: Low output voltage)....1064
Failure code [DBB6KP] (or VHMS_LED display: ?n9? ? ?02?) (VHMS controller 24 V power supply output: Low output voltage)....1066
Failure code [DBB7KP] (or VHMS_LED display: ?n9? ? ?03?) (VHMS controller 12 V power supply output: Low output voltage)....1068
Failure code [DBBQKR] (or VHMS_LED display: ?n8? ? ?02?) VHMS controller CAN communication: Defective communication (Abnormality in target component system)....1070
Failure code [DD15LD] (? switch (Panel switch 1): Switch is kept pressed for long time)....1072
Failure code [DD16LD] (? switch (Panel switch 2): Switch is kept pressed for long time)....1074
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)....1076
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)....1078
306 Troubleshooting by failure code (Display of code), Part 6....1081
Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree....1084
Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)....1086
Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit)....1088
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)....1090
Failure code [DDD1LD] (Pitch operation switch: Switch is kept pressed for long time)....1094
Failure code [DDDBKA] (Traction adjustment dial: Disconnection)....1096
Failure code [DDDBKB] (Traction adjustment dial: Short circuit)....1098
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)....1100
Failure code [DDK4KA] (AJSS FNR switch: Disconnection)....1102
Failure code [DDK4KB] (AJSS FNR switch: Short circuit)....1104
Failure code [DDK5L4] (AJSS shift-up/down switch: ON/OFF signals disagree)....1106
Failure code [DDK6KA] (FNR lever switch: Disconnection)....1110
Failure code [DDK6KB] (FNR lever switch: Short circuit)....1112
Failure code [DDP5KA] (Lock detection pressure switch of steering lock lever: Disconnection)....1114
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)....1116
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)....1118
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)....1120
Failure code [DF10KA] (Transmission shift lever switch: Disconnection)....1122
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)....1124
Failure code [DGE5KX] (or VHMS_LED display: ?n4? ? ?01?) (Atmospheric temperature sensor: Out of input signal range)....1126
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)....1128
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)....1130
307 Troubleshooting by failure code (Display of code), Part 7....1133
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)....1136
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)....1138
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)....1140
Failure code [DGT1KA] (Torque converter oil temperature sensor: Disconnection)....1142
Failure code [DGT1KB] (Torque converter oil temperature sensor: Short circuit)....1143
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)....1144
Failure code [DGT4KA] (or VHMS_LED display: ?n3? ? ?12?) (Exhaust gas temperature sensor (F): Disconnection)....1146
Failure code [DGT4KB] (or VHMS_LED display: ?n3? ? ?11?) (Exhaust gas temperature sensor (F): Short circuit)....1148
Failure code [DGT5KA] (or VHMS_LED display: ?n3? ? ?22?) (Exhaust gas temperature sensor (R): Disconnection)....1150
Failure code [DGT5KB] (or VHMS_LED display: ?n3? ? ?21?) (Exhaust gas temperature sensor (R): Short circuit)....1152
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)....1154
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)....1156
Failure code [DHE5KB] (or VHMS_LED display: ?n3? ? ?32?) (Blow-by pressure sensor: Short circuit)....1158
Failure code [DHE5KY] (or VHMS_LED display: ?n3? ? ?31?) (Blow-by pressure sensor: Short circuit with power supply line)....1160
Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating state of engine)....1162
Failure code [DHT8KX] (or VHMS_LED display: ?n5? ? ?33?) (Steering oil pressure sensor: Out of input signal range)....1164
Failure code [DHTBKA] (Modulation clutch oil pressure sensor: Disconnection)....1166
Failure code [DHTBKB] (Modulation clutch oil pressure sensor: Short circuit)....1168
Failure code [DHU2KX] (or VHMS_LED display: ?n7? ? ?11?) (Front brake oil pressure sensor (F): Out of input signal range)....1170
Failure code [DHU3KX] (or VHMS_LED display: ?n7? ? ?12?) (Rear brake oil pressure sensor (R): Out of input signal range)....1172
Failure code [DK30KA] (AJSS lever angle sensor: Disconnection)....1174
Failure code [DK30KY] (AJSS lever angle sensor: Short circuit with power supply line)....1176
308 Troubleshooting by failure code (Display of code), Part 8....1179
Failure code [DK59KA] (Lift EPC lever potentiometer (Main): Disconnection)....1181
Failure code [DK59KY] (Lift EPC lever potentiometer (Main): Short circuit with power supply line)....1184
Failure code [DK59L8] (Lift EPC lever potentiometer (Main): Analog signals disagree)....1188
Failure code [DK5AKA] (Lift EPC lever potentiometer (Sub): Disconnection)....1191
Failure code [DK5AKY] (Lift EPC lever potentiometer (Sub): Short circuit with power supply line)....1194
Failure code [DK5BKA] (Tilt & pitch EPC lever potentiometer (Main): Disconnection)....1197
Failure code [DK5BKY] (Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply line)....1200
Failure code [DK5BL8] (Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree)....1202
Failure code [DK5CKA] (Tilt & pitch EPC lever potentiometer (Sub): Disconnection)....1205
Failure code [DK5CKY] (Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply line)....1208
Failure code [DKD0KA] (Frame angle sensor: Disconnection)....1210
Failure code [DKD0KY] (Frame angle sensor: Short circuit with power supply line)....1212
Failure code [DKD0KZ] (AJSS lever and frame angle sensor: Disconnection or short circuit)....1214
Failure code [DLFAKA] (Modulation clutch output shaft speed sensor: Disconnection)....1216
Failure code [DLFALC] (Modulation clutch output shaft speed sensor: Speed signals disagree)....1218
Failure code [DLT3KA] (Transmission output shaft speed sensor (2): Disconnection)....1220
Failure code [DLT3LC] (Transmission output shaft speed sensor (2): Speed signals disagree)....1222
Failure code [DLT4KB] (Transmission output shaft speed sensor (1): Short circuit)....1224
Failure code [DLT4KX] (Transmission output shaft speed sensor (1): Out of input signal range)....1226
Failure code [DV00KB] (Alarm buzzer: Short circuit)....1228
Failure code [DW4PKA] (Blade raise EPC solenoid: Disconnection)....1230
Failure code [DW4PKB] (Blade raise EPC solenoid: Short circuit)....1231
Failure code [DW4PKY] (Blade raise EPC solenoid: Short circuit with power supply line)....1232
Failure code [DW4QKA] (Blade lower EPC solenoid: Disconnection)....1234
Failure code [DW4QKB] (Blade lower EPC solenoid: Short circuit)....1235
Failure code [DW4QKY] (Blade lower EPC solenoid: Short circuit with power supply line)....1236
Failure code [DW4RKA] (Tilt & pitch EPC solenoid: Disconnection)....1238
Failure code [DW4RKB] (Tilt & pitch EPC solenoid: Short circuit)....1239
Failure code [DW4RKY] (Tilt & pitch EPC solenoid: Short circuit with power supply line)....1240
Failure code [DW4SKA] (Tilt & pitch EPC solenoid: Disconnection)....1242
Failure code [DW4SKB] (Tilt & pitch EPC solenoid: Short circuit)....1243
Failure code [DW4SKY] (Tilt & pitch EPC solenoid: Short circuit with power supply line)....1244
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)....1246
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)....1248
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)....1250
309 Troubleshooting by failure code (Display of code), Part 9....1253
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)....1256
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)....1258
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)....1260
Failure code [DWN7KA] (Blade float magnet detent solenoid: Disconnection)....1262
Failure code [DWN7KB] (Blade float magnet detent solenoid: Short circuit)....1264
Failure code [DWN7KY] (Blade float magnet detent solenoid: Short circuit with power supply line)....1266
Failure code [DWNFKA] (Modulation clutch cut-off release solenoid: Disconnection)....1268
Failure code [DWNFKB] (Modulation clutch cut-off release solenoid: Short circuit)....1270
Failure code [DWNFKY] (Modulation clutch cut-off release solenoid: Short circuit with power source line)....1272
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)....1274
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)....1275
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)....1276
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)....1277
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)....1278
Failure code [DXF0KA] (AJSS EPC solenoid: Disconnection)....1279
Failure code [DXF0KB] (AJSS EPC solenoid: Short circuit)....1280
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)....1281
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)....1282
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)....1284
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)....1286
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)....1288
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)....1290
310 Troubleshooting by failure code (Display of code), Part 10....1293
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)....1296
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)....1298
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)....1300
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)....1302
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)....1304
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)....1306
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....1308
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....1310
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)....1312
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....1314
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....1316
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)....1318
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)....1320
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)....1322
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)....1324
Failure code [DXHJKA] (RH pitch REAR EPC solenoid: Disconnection)....1326
Failure code [DXHJKB] (RH pitch REAR EPC solenoid: Short circuit)....1327
Failure code [DXHJKY] (RH pitch REAR EPC solenoid: Short circuit with power supply line)....1328
Failure code [DXHKKA] (RH pitch FORWARD EPC solenoid: Disconnection)....1329
Failure code [DXHKKB] (RH pitch FORWARD EPC solenoid: Short circuit)....1330
Failure code [DXHKKY] (RH pitch FORWARD EPC solenoid: Short circuit with power supply line)....1331
Failure code [DXHPKA] (Modulation clutch solenoid: Disconnection)....1332
Failure code [DXHPKB] (Modulation clutch solenoid: Short circuit)....1334
Failure code [DXHPKY] (Modulation clutch solenoid: Short circuit with power source line)....1336
Failure code [DXHPMA] (Modulation clutch solenoid: Malfunction)....1338
Failure code [F@BBZL] (or VHMS_LED display: ?n3? ? ?38?) (Blow-by pressure: High error)....1340
Failure code [F@BYNR] (or VHMS_LED display: ?n3? ? ?62?) (Exhaust gas temperature (F): Abnormal heat)....1342
Failure code [F@BYNS] (or VHMS_LED display: ?n3? ? ?61?) (Exhaust gas temperature (F): Overheat)....1344
Failure code [F@BZNR] (or VHMS_LED display: ?n3? ? ?72?) (Exhaust gas temperature (R): abnormal heat)....1346
Failure code [F@BZNS] (or VHMS_LED display ?n3? ? ?71?) (Exhaust gas temperature (R): Overheat)....1348
400 Troubleshooting of electrical system (E-mode)....1351
Before carrying out troubleshooting of electrical system....1352
Information in troubleshooting table....1355
E-1 Engine does not start....1356
E-2 Wiper does not operate....1366
E-3 Windshield washer does not operate....1374
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off....1380
E-5 Working lamp does not light up or go off....1396
E-6 Step lamp does not light up or go off....1404
E-7 Turn signal lamp and hazard lamp do not light up or go off....1406
E-8 Brake lamp does not light or it keeps lighting up....1416
E-9 Backup lamp does not light or it keeps lighting up....1420
E-10 Backup buzzer does not sound or it keeps sounding....1424
E-11 Horn does not sound or it keeps sounding....1428
E-12 Alarm buzzer does not sound or it keeps sounding....1432
E-13 Air conditioner does not operate or stop....1434
E-14 Electric priming pump does not operate or does not stop automatically....1436
500 Troubleshooting of hydraulic and mechanical system (H-mode)....1439
Method of using troubleshooting chart....1442
Table of failure modes and causes....1444
H-1 Machine does not start....1448
H-2 Torque converter lockup is not switched (engine stalls)....1450
H-3 Torque converter lockup is not turned on....1451
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted....1452
H-5 Shocks are large at the times of starting and shifting gear....1454
H-6 Time lag is large at the times of starting and shifting gear....1456
H-7 Torque converter oil temperature is high....1458
H-8 Steering does not turn [machine with steering wheel]....1459
H-9 Steering does not turn [machine with AJSS]....1460
H-10 Turning, response of steering is poor [machine with steering wheel]....1461
H-11 Turning, response of AJSS is poor [machine with AJSS]....1462
H-12 Steering is heavy [machine with steering wheel]....1463
H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel]....1464
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]....1465
H-15 Wheel brake does not work or does not work well....1466
H-16 Wheel brake is not released or it drags....1467
H-17 Parking brake does not work or does not work well....1468
H-18 Parking brake is not released or it drags (including emergency release system)....1469
H-19 Blade does not rise....1470
H-20 Blade speed is low or rising force of lift is insufficient....1471
H-21 When rising, blade comes to move slowly at specific height....1472
H-22 Lift cylinder cannot hold down blade (Blade floats)....1472
H-23 Hydraulic drifts of blade occur often....1472
H-24 Blade wobbles during operation....1472
H-25 Blade does not tilt and pitch....1473
H-26 Blade speed is low or tilt and pitch force is insufficient....1474
H-27 Bucket comes to operate slowly in the midst of tilt and pitch....1475
H-28 Tilt & pitch cylinder cannot hold down blade....1475
H-29 Hydraulic drifts of blade occur often....1475
H-30 Blade wobbles during travel when loaded (Work equipment valve is set to ?HOLD?)....1475
H-31 During operation of machine, engine speed lowers remarkably or engine stalls....1476
H-32 Large shocks are made when work equipment starts and stops....1476
H-33 When work equipment circuit is relieved singly, other work equipment moves....1476
H-34 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats)....1477
600 Troubleshooting of engine (S-mode)....1479
Method of using troubleshooting chart....1480
S-1 Engine does not start easily....1484
S-2 Engine does not start....1486
S-3 Engine does not pick up smoothly....1490
S-4 Engine stops during operation....1491
S-5 Engine does not rotate smoothly (Hunting occurs)....1492
S-6 Engine lacks output (or lacks power)....1493
S-7 Exhaust smoke is black (Incomplete combustion)....1494
S-8 Oil is consumed much (or exhaust gas color is blue)....1496
S-9 Engine oil becomes contaminated quickly....1497
S-10 Fuel consumption is excessive....1498
S-11 Coolant contains oil (blows back or reduces)....1499
S-12 Oil pressure drops....1500
S-13 Oil level rises (Water, fuel in oil)....1502
S-14 Coolant temperature rises too high (Overheating)....1504
S-15 Abnormal noise is made....1505
S-16 Vibration is excessive....1506
S-17 Air cannot be bled from fuel circuit....1508
50 Disassembly and assembly....0
100 General information on disassembly and assembly....1511
How to read this manual....1512
Coating materials list....1514
Special tools list....1517
Sketches of special tools....1521
201 Engine and cooling system, Part 1....1531
Removal and installation of engine assembly....1532
Removal and installation of radiator assembly....1536
Removal and installation of air aftercooler....1541
Removal and installation of cooling fan and fan motor assembly....1542
Removal and installation of damper assembly....1544
Disassembly and assembly of damper assembly....1546
Removal and installation of fuel tank assembly....1550
Removal and installation of engine hood assembly....1552
Removal and installation of bulkhead assembly....1554
202 Engine and cooling system, Part 2....1559
Removal and installation of fuel supply pump assembly....1560
Removal and installation of cylinder head assembly....1566
Removal and installation of fuel injector assembly....1582
Removal and installation of engine front seal....1586
Removal and installation of engine rear seal....1589
301 Power train, Part 1....1595
Removal and installation of parking brake assembly....1596
Removal and installation of torque converter and transmission assembly....1598
302 Power train, Part 2....1605
Disassembly and assembly of torque converter assembly....1606
Disassembly and assembly of transmission assembly....1633
Disassembly and assembly of transfer assembly....1660
Disassembly and assembly of parking brake assembly....1675
303 Power train, Part 3....1683
Removal and installation of front axle assembly....1684
Removal and installation of rear axle assembly....1686
Removal and installation of center support assembly....1688
Disassembly and assembly of center support assembly....1690
Disassembly and assembly of differential assembly....1694
304 Power train, Part 4....1709
Removal and installation of final drive carrier assembly....1710
Disassembly and assembly of final drive carrier assembly....1712
Removal and installation of front final drive brake assembly....1713
Disassembly and assembly of final drive assembly....1715
400 Brake system....1719
Disassembly and assembly of brake assembly....1720
Removal and installation of brake valve assembly....1728
Disassembly and assembly of accumulator and charge valve assembly....1729
Disassembly and assembly of slack adjustor assembly....1732
500 Undercarriage and frame....1735
Removal and installation of center hinge pin....1736
Removal and installation of counterweight assembly....1743
600 Hydraulic system....1745
Removal and installation of hydraulic tank assembly....1746
Removal and installation of hydraulic pump assembly....1748
Removal and installation of control valve assembly....1752
Disassembly and assembly of control valve assembly....1754
Removal and installation of steering valve assembly....1759
Disassembly and assembly of hydraulic cylinder assembly....1760
700 Work equipment....1767
Removal and installation of work equipment assembly....1769
800 Cab and its attachments....1774
Removal and installation of operator's cab assembly....1775
Removal and installation of operator's cab glass (stuck glass)....1779
Removal and installation of floor frame assembly....1787
Disassembly and assembly of operator?s seat assembly....1790
Removal and installation of air conditioner unit assembly....1823
900 Electrical system....1828
Removal and installation of engine controller assembly....1829
Removal and installation of transmission controller assembly....1831
Removal and installation of loader controller assembly....1831
Removal and installation of VHMS controller assembly....1832
Removal and installation of machine monitor assembly....1833
90 Diagrams and drawings....0
100 Hydraulic diagrams and drawings....1838
Power train hydraulic circuit diagram....1839
Brake hydraulic circuit diagram....1840
Work equipment hydraulic circuit diagram....1842
200 Electrical diagrams and drawings....1845
Air conditioner electrical circuit diagram....1847
Electrical circuit diagram (1/10)....1848
Electrical circuit diagram (2/10)....1849
Electrical circuit diagram (3/10)....1850
Electrical circuit diagram (4/10)....1851
Electrical circuit diagram (5/10)....1852
Electrical circuit diagram (6/10)....1853
Electrical circuit diagram (7/10)....1854
Electrical circuit diagram (8/10)....1855
Electrical circuit diagram (9/10)....1856
Electrical circuit diagram (10/10)....1857
Connector list and stereogram....1858
