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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SEAMW01900 - Wheel Dozer WD600-1H Operation & Maintenance Manual.pdf
SEAW002500 - Wheel Dozer WD900-3 Field Assembly Instruction.pdf
SEBM041E0104 - Wheel Dozer WD600-1 Shop Manual.pdf
SEBM022904 - Wheel Dozer WD600-3 Shop Manual.pdf
SEBM036903 - Wheel Dozer WD900-3 Shop Manual.pdf
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