Komatsu Wheel Loader WA450, WA480 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA450, WA480, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheeled Loader WA450, WA480 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: 4,361 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM018601 - Wheel Loader WA450-6, WA480-6 Shop Manual.pdf
SEN00809-04 - Wheel Loader GALEO WA450-6, WA480-6 (KA Spec.) Shop Manual.pdf
CEAM018403 - Wheel Loader WA480-6 Operation & Maintenance Manual.pdf
TEN00124-05 - Wheel Loader WA480-6 Operation & Maintenance Manual.pdf
TEN00340-03 - Wheel Loader WA480-6 Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM018403 - Wheel Loader WA480-6 Operation & Maintenance Manual....2
CEAM018403....2
INTRODUCTION....5
FOREWORD....6
SAFETY INFORMATION....7
APPROVED AND NON-APPROVED USES....8
Approved Functions....8
Non-Approved Functions....8
VISIBILITY STANDARD....9
Visibility in Immediate Area....9
12-M Radius Visibility....9
PRODUCT IDENTIFICATION....10
Machine....10
Service Meter Location....11
Directions of Machine....11
Machine Serial Number/Product Identification Number (PIN)....12
Engine Serial Number, EPA Regulations....12
SERIAL NUMBERS AND DEALER INFORMATION....13
Model: WA480-6....13
TABLE OF CONTENTS....15
SAFETY....27
SAFETY AND WARNING DECALS....28
Location of the Safety Labels....28
Safety Labels....29
GENERAL SAFETY RULES AND PRECAUTIONS....36
General Safety Rules....36
Safety at Job Site....37
Safety Features....37
Clothing and Protective Equipment....37
Keep Machine Clean....38
Fire and Explosion Prevention....38
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid....38
Fire Caused by Accumulation of Flammable Material....39
Fire Caused by Electrical Wiring....39
Fire Caused by Piping....39
Explosion Caused by Lighting Equipment....39
Action if Fire Occurs....40
Fire Extinguisher and First Aid Kit....40
Mounting and Dismounting....41
Inside Operators Compartment....42
Emergency Escape from Operators Cab....42
Precautions When Standing Up from Operators Seat....43
Leaving Operators Compartment....44
Parking the Machine....45
Transporting the Machine....46
Precautions When Using ROPS....48
Unauthorized Modification....48
Precautions for Attachments and Options....48
Precautions When Cleaning Cab Glass....49
Asbestos Hazard Alert....49
Crush or Pinch-Point Dangers....50
Precautions for Ventilation Exhaust Gas....50
PRECAUTIONS BEFORE STARTING OPERATIONS....51
Pre-Operational Checks....51
Ensure Good Visibility....51
Signs and Signals....51
Precaution for Warning Tag....52
Checks Before Starting Engine, Adjustments....52
Precautions When Starting....53
Precautions in Cold Areas....53
Precautions for Job Site....54
Work Site Hazards....54
Working on Loose or Unstable Ground....54
Prohibited Operations....55
Avoiding Dangerous Situations....55
Working Near High Voltage Cables....57
RULES FOR ROAD TRAVEL....58
Travel Precautions....58
Traveling on Slopes....59
Using the Brakes....60
Traveling in Reverse....60
Operating on Snow or Frozen Surfaces....61
PRECAUTIONS DURING INSPECTION AND MAINTENANCE....62
Warning Tags....62
Workplace Environment....62
Systems Equipped with ECSS....62
Equipment Storage....63
Working Under the Machine....63
Using Drop Lamps....64
Using Proper Tools....64
Keeping the Machine Clean....64
Precautions When Welding....64
Precautions When Using Hammer....65
Noise....65
Stopping Engine During Inspection and Maintenance....66
Running the Machine During Maintenance....68
Rules for Refueling the Machine....69
Cooling System Precautions....69
Window Washer Fluid....69
Battery Information....69
Precautions....69
Hazards....70
Using Booster Cables....71
Starting the Machine with Booster Cables....71
High-Pressure Precautions....72
Precautions for High-Pressure Oil....72
Safe Handling of High-Pressure Hoses....72
Precautions for High-Pressure Fuel....72
High-Temperature Precautions....73
High-Temperature Areas....73
High-Temperature Coolant....73
High-Temperature Oil....73
High Voltage....73
Accumulator and Gas Spring....74
Using Compressed Air....74
Disposal of Waste Materials....74
Inflating Tires....75
Storing Tires....75
Maintenance of Air Conditioner....76
Critical Parts....76
OPERATION....77
GENERAL VIEW....78
General View of Machine....78
General View of Controls and Gauges....79
Machine Monitor....80
Switch Panel....82
EXPLANATION OF COMPONENTS....83
Machine Monitor....83
Types of Warnings....84
Emergency Stop....84
Mistaken Operation....84
Inspection and Maintenance....84
Central Warning Lamp....84
Character Display Portion....85
Service Meter....86
Action Code Display....86
Failure Code Display....87
Filter, Oil Replacement Time Display....88
Emergency Stop Items....91
Brake Oil Pressure Caution Lamp....92
Engine Oil Pressure Caution Lamp....92
Battery Charge Circuit Caution Lamp....93
Steering Oil Pressure Caution Lamp (if equipped)....93
Caution Items....94
Brake Oil Temperature Caution Lamp....95
Torque Converter Oil Temperature Caution Lamp....95
Engine Coolant Temperature Caution Lamp....96
Hydraulic Oil Temperature Caution Lamp....96
Fuel Level Caution Lamp....96
Inspection and Maintenance Items....97
Radiator Coolant Level Caution Lamp....97
Engine Oil Level Caution Lamp....98
Battery Electrolyte Level Caution Lamp (if equipped)....98
Maintenance Caution Lamp....98
Air Cleaner Clogging Caution Lamp....99
Water Separator Caution Lamp....99
Transmission Oil Filter Clogging Caution Lamp....99
Pilot Display Portion....100
Parking Brake Pilot Lamp....101
Cooling Fan Reverse Rotation Pilot Lamp....101
Emergency Steering Pilot Lamp (if equipped)....101
Power Mode Pilot Lamp (P Mode)....102
Preheating Pilot Lamp....102
Semi-Auto Digging Pilot Lamp....102
Auto-Greasing Pilot Lamp....102
Joystick Pilot Lamp (if equipped)....102
Directional Selector Pilot Lamp....102
Economy Operation Display Lamp....103
Shift Indicator....103
Auto-Shift Pilot Lamp....103
Torque Converter Lockup Pilot Light (if equipped)....103
Shift Hold Pilot Lamp....104
Shift Lever Position Pilot Lamp....104
Turn Signal Pilot Lamp....104
Head Lamp High-Beam Pilot Lamp....104
Meter Display Portion....105
Torque Converter Oil Temperature Gauge....105
Engine Coolant Temperature Gauge....106
Hydraulic Oil Temperature Gauge....106
Fuel Gauge....106
Speedometer....107
Meter Display Pilot Lamp....107
OTHER FUNCTIONS OF MACHINE MONITOR....108
Overall Menu....108
Displaying Odometer....110
Resetting Filter, Oil Replacement Time....110
Entering Telephone Number....111
Selecting Language....112
Adjusting Monitor Brightness....114
Switching Travel Speed/Engine Speed Display....116
Switching Travel Speed/Engine Speed Display/Non-Display....117
SWITCHES AND CONTROLS....118
General View....118
Starting Switch....120
Power Mode Selector Switch....120
Transmission Shift Mode Selector Switch....121
Transmission Cutoff Switch....121
Transmission Cutoff Set Switch....122
Lamp Switch....122
Turn Signal Lever....122
Dimmer Switch....123
Horn Button....123
Hazard Lamp Switch....123
Parking Brake Switch....124
Front Working Lamp Switch....124
Rear Working Lamp Switch....125
Machine Monitor Mode Selector Switch 1....125
Machine Monitor Mode Selector Switch 2....125
Kickdown Switch....126
Hold Switch....127
Front Wiper Switch....127
Rear Wiper Switch....128
Cigarette Lighter....128
Room Lamp Switch....128
Rear Heated Wire Glass Switch....128
ECSS Switch....129
Emergency Steering Switch (if equipped)....129
Cooling Fan Auto-Reverse Rotation Switch....130
Torque Converter Lockup Switch (if equipped)....133
CONTROL LEVERS, PEDALS....134
General View....134
Gearshift Lever....135
Directional Lever....136
Gearshift Lever Stopper....137
Work Equipment Lock Lever....137
Bucket Control Lever....138
Lift Arm Control Lever....138
Brake Pedals....139
Accelerator Pedal....139
SECURITY LOCKS AND SAFETY FEATURES....140
Steering Tilt Lock Lever....140
Frame Lock Bar....140
Cap with Lock....141
Fuel Tank Filler Port Cap....141
Hydraulic Tank Filler Port Cap....141
Backup Alarm....142
MACHINE FEATURES....143
Towing Pin....143
Grease Pump....143
Cab Door....144
Emergency Escape Right Door....144
Left Cab Door, Door Open Lock....146
Left Cab Door, Knob....147
Left Cab Door, Handle....147
Left Cab Sliding Window (Lock Release Knob)....147
Cab Wiper....148
Dust Indicator....148
Fire Extinguisher (if equipped)....148
ELECTRICAL....149
Power Outlet....149
Fuses....149
Fuse Capacity and Name of Circuit....150
Slow-Blow Fuse....151
WORK OPERATIONS....152
Walk-Around Check....152
Precautions Before Starting Work Operations....152
Check Before Starting Engine....156
Check Machine Monitor....156
Check Coolant Level, Add Coolant....157
Check Oil Level in Engine Oil Pan, Add Oil....158
Check Water Separator, Drain Water....159
Check Air Cleaner....160
Check Fuel Level, Add Fuel....161
Check Electric Wiring....162
Adjustments....164
Adjusting Seat....164
Removing or Installing Headrest....166
Adjusting Seat Belt....167
Adjusting Lever Stand....168
Adjusting Mirrors....169
Final Checks Before Starting Engine....170
Starting Engine....172
Normal Starting....172
Starting in Cold Weather....174
Automatic Warming-Up Operation....175
Operations and Checks After Starting Engine....176
Checks After Starting Engine....176
Breaking in the Machine....177
Normal Operation....177
Stopping Engine....179
Check After Stopping Engine....179
Moving the Machine (Directional, Speed), Stopping the Machine....180
Moving the Machine....180
Changing Gear Speed....183
Changing Direction....184
Stopping the Machine....186
Transmission Cutoff Function....187
Turning....189
Emergency Steering (if equipped)....190
Emergency Steering Self-Check Function....191
Operation of Work Equipment....192
Work Equipment Lock Lever....192
Lift Arm Control Lever....192
Bucket Control Lever....193
Work Possible Using Wheel Loader....195
Digging Operations....195
Loading Piled Soil or Blasted Rock....195
Digging and Loading on Level Ground....197
Leveling Operations....198
Pushing Operations....198
Load-and-Carry Operations....199
Loading Operations....200
Cross-Drive Loading....200
V-Shape Loading....200
Preparations for Loading, Gathering Rocks....201
Approaching Facing....201
Digging....202
Traveling in Reverse After Excavation....204
Approaching Dump Truck....205
Loading Dump Truck....206
Reversing Away From Dump Truck....207
Precautions During Work Operations....208
Piling Up Loads....208
Handling Blasted Rock....208
Loosened Boulders....212
Pit Excavation....212
Cutting Face Operations....212
Switching Between Forward and Reverse....212
Turning When Tires Are Stationary....213
Wheel Brake Does Not Work....213
Braking Function....213
Lower the Center of Gravity when Turning....214
Permissible Water Depth....214
Driving Up or Down Slopes....214
Driving the Machine....215
Adjusting Work Equipment....216
Adjusting Boom Kickout....216
Adjusting Bucket Positioner....217
Bucket Level Indicator....218
Measuring Dump Angle....219
Measuring Bucket Dump Angle....219
Measuring Coupler Dump Angle....222
Parking the Machine....225
Checks After Completion of Operation....227
Before Stopping Engine....227
After Stopping Engine....227
Locking the Machine....228
HANDLING TIRES....230
Precautions When Handling Tires....230
Tire Pressure....231
Precautions for Using Load-and-Carry Method....232
TRANSPORTATION....233
Transportation Procedure....233
Loading and Unloading Trailers....234
Loading Machine....234
Securing Machine....235
Unloading Machine....237
LIFTING MACHINE....238
Lifting Position....238
Lifting Procedure....239
COLD WEATHER OPERATION....240
Precautions for Low Temperature....240
Fuel and Lubricants....240
Coolant....240
Battery....241
Precautions After Completion of Work....241
After Cold Weather....241
LONG-TERM STORAGE....242
Before Storage....242
During Storage....242
After Storage....242
AUTOMATIC AIR CONDITIONER....243
Control Panel....243
Main Power Switch....244
Fan Switch....244
Air Conditioner Switch....245
Auto Switch....246
Temperature Switch....246
FRESH/RECIRC Selector Switch....246
Mode Selector Switch....247
Method of Operation....248
Cooling Operation....248
Heating Operation....248
Drying-Heating and Demisting Operation....249
When Not Using the Air Conditioner Regularly....249
Precautions When Using Air Conditioner....249
Inspection and Maintenance....250
Cool Box....250
KOMTRAX....251
Basic Precautions....251
TROUBLESHOOTING....252
When Machine Runs Out of Fuel....252
Towing the Machine....252
When Engine Can Be Used....253
When Engine Cannot Be Used....253
Releasing Parking Brake....254
Emergency Travel Operation....256
If Battery is Discharged....257
Precautions....257
Removal and Installation of Battery....257
Precautions for Charging Battery....258
Starting Engine With Booster Cables....259
Precautions When Connecting or Disconnecting Booster Cable....259
Connecting Booster Cable....259
Starting Engine....260
Disconnecting Booster Cable....260
Lowering Work Equipment When Engine Has Stopped....261
Other Troubleshooting....262
Electrical System....262
Chassis....263
Engine....265
MAINTENANCE....267
GUIDES TO MAINTENANCE....268
Check Service Meter....268
Komatsu Genuine Replacement Parts....268
Komatsu Genuine Oils....268
Always Use Clean Washer Fluid....268
Always Use Clean Oil and Grease....268
Checking for Foreign Materials in Drained Oil and On Filters....268
Fuel Strainer....268
Welding Instructions....269
Do Not Drop Things Inside Machine....269
Dusty Work Sites....269
Avoid Mixing Oil....269
Locking Inspection Covers....269
Bleeding Air from Hydraulic Circuit....269
Precautions When Installing Hydraulic Hoses....270
Checks After Inspection and Maintenance....270
OUTLINES OF SERVICE....271
Handling Oil, Fuel, Coolant, and Performing Oil Clinic....271
Oil....271
Fuel....272
Coolant and Water for Dilution....272
Grease....273
Storing Oil and Fuel....273
Filters....273
Performing KOWA (Komatsu Oil Wear Analysis)....274
KOWA Analysis Items....274
Oil Sampling....274
Outline of Electric System....275
WEAR PARTS....276
Wear Parts List....276
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS....277
Fuel, Coolant, and Lubricant Ambient Temperature Chart....278
Recommended Brands, Other Than Komatsu Genuine Oil....279
Biodiesel Usage....280
Biodiesel Recommendation for Komatsu Engines....280
Biodiesel Terminology....280
Certification and Standards....281
Warranty and Use of Biodiesel Fuel in Komatsu Engines....281
Requirements for Using Biodiesel Fuel in Komatsu Engines....281
Properties of Biodiesel....282
Komatsu Biodiesel Blend Specification for B5 to B20....283
Summary of Recommendations....284
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....285
Torque List....285
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....287
Safety Critical Parts List....288
MAINTENANCE SCHEDULE CHART....290
SERVICE PROCEDURE....292
Initial 250 Hours Service....292
Initial 1000 Hours Service....292
When Required....293
Clean, Replace Air Cleaner Element....293
Clean Inside of Cooling System....297
Check Transmission Oil, Add Oil....301
Check Axle Oil Level, Add Oil....302
Clean Axle Case Breather....304
Clean Air Conditioner Condenser....305
Check Window Washing Fluid Level, Add Fluid....305
Clean Radiator Fins and Cooler Fins....306
Turn, Replace Bolt-On Cutting Edge....309
Replace Bucket Teeth (if equipped)....310
Check Air Conditioner....313
Replace Slow-Blow Fuse....315
Check Function of Accumulator....316
Select Tires....317
Check Tire Pressure....318
Check Before Starting....319
Every 50 Hours Service....320
Drain Water, Sediment from Fuel Tank....320
Every 100 Hours Service....321
Lubricate Rear Axle Pivot Pin....321
Check Oil Level in Hydraulic Tank, Add Oil....321
Clean Element in Air Conditioner Fresh Air Filter....322
Every 250 Hours Service....323
Check Battery Electrolyte Level....323
Check Parking Brake....324
Check Alternator Belt Tension, Adjust....325
Check Air Conditioner Compressor Belt Tension, Adjust....327
Check for Loose Wheel Hub Nuts, Tighten....329
Clean Element in Air Conditioner Recirculation Filter....329
Check Function of Brake Accumulator....330
Lubricating....331
Every 500 Hours Service....332
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge....332
Replace Fuel Prefilter Cartridge....334
Every 1000 Hours Service....336
Replace Fuel Main Filter Cartridge....336
Change Oil in Transmission Case, Replace Oil Filter Cartridge, Clean Strainer....338
Clean Transmission Case Breather....339
Lubricating....340
Check Engine Air Intake Piping Clamps for Looseness....340
Replace Corrosion Resistor Cartridge....340
Every 2000 Hours Service....341
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element....341
Replace Hydraulic Tank Breather Element....344
Change Axle Oil....345
Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter....346
Check Brake Disc Wear....347
Check Function of PPC Accumulator....349
Check Alternator....350
Check Engine Valve Clearance, Adjust....350
Check Starting Motor....350
Check Vibration Damper....350
Every 4000 Hours Service....351
Lubricating....351
Check Water Pump....353
Check Air Conditioner Compressor, Adjust....353
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber....354
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber....355
Every 8000 Hours Service....356
Replace High-Pressure Piping Clamps....356
Replace Fuel Spray Prevention Cap....356
SPECIFICATIONS....357
SPECIFICATIONS....358
OPTIONS, ATTACHMENTS....361
JOYSTICK STEERING SYSTEM....362
Structure and Function....362
Components....363
Shift UP, Shift DOWN Switches....364
Directional Selector Switch....364
Joystick Steering Lever....364
Joystick ON/OFF Switch....364
HI/LOW Selector Switch....365
Horn Switch....365
Console Tilt Lever....365
Console Fore-and-Aft Adjustment Lever....365
Joystick Pilot Lamp....366
Armrest Adjustment Lever....366
Steering with Joystick Lever or Steering Wheel....367
Precautions for Steering with Joystick....368
Operating the Joystick Steering System....369
Getting In and Out of Operators Cab....372
Adjustments....373
Adjusting Joystick Console....373
Adjusting Seat....374
TORQUE CONVERTER LOCKUP....377
Components....377
Torque Converter Lockup Switch....378
Torque Converter Lockup Pilot Lamp....378
Shift Indicator....378
Character Display....378
Method of Operation....379
Warning/Limit Functions for Travel Speed....380
Travel Speed Warning Function....380
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM....381
Sound System Components....383
Power Switch/Volume....383
Auto-Store/Preset Scan Button....383
Bass Control Knob....383
Treble Control Knob....384
Loudness Button....384
Time/Radio Display Selector Button....384
Tape Eject Button....385
Cassette Door....385
Fast-Forward, Rewind Buttons....385
Preset Buttons....385
Metal Tape Button....386
Manual Tuning Buttons....386
Seek Tuning Buttons....386
Band Selector Button....386
Method of Operation....387
Setting Preset Buttons....387
Using Auto-Preset....387
Using Manual Preset....387
Listening to Radio....388
Listening to Cassette Tape....388
Reversing the Tape....389
Precautions When Using....389
Handling Cassette Tape....389
MULTI-FUNCTION LEVER....390
Components....390
Work Equipment Lever....391
Kickdown Switch....391
Hold Switch....392
FNR Switch....392
Directional Selector Switch Actuation Switch....393
Directional Selector Pilot Lamp....393
Work Equipment Lock Switch....394
Using FNR Switch to Change Between Forward and Reverse....395
CENTRAL LUBRICATION SYSTEM....397
Automatic Greasing Circuit Diagram....397
WHEEL STOPPER....399
BATTERY DISCONNECTOR SWITCH....400
BUCKET AND TIRES....402
CEBM018601 - Wheel Loader WA450-6, WA480-6 Shop Manual....403
COVER....403
FOREWORD....404
CONTENTS....404
SAFETY....419
SAFETY NOTICE....419
IMPORTANT SAFETY NOTICE....419
GENERAL PRECAUTIONS....419
PREPARATIONS FOR WORK....419
PRECAUTIONS DURING WORK....419
GENERAL....421
HOW TO READ THE SHOP MANUAL....422
VOLUMES....422
DISTRIBUTION AND UPDATING....422
FILING METHOD....422
REVISED EDITION MARK....422
REVISIONS....422
SYMBOLS....422
HOISTING INSTRUCTIONS....423
HOISTING....423
WIRE ROPES....423
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD....424
COATING MATERIALS....426
STANDARD TIGHTENING TORQUE....428
Standard Tightening Torque of Bolts and Nuts....428
Tightening Torque of Hose Nuts....429
Tightening Torque of Split Flange Bolts....429
Tightening Torque for Flared Nuts....429
CONNECTING PUSH-PULL TYPE COUPLER....430
CONVERSION TABLES....433
Method of Using the Conversion Table....433
01 GENERAL....439
MACHINE SPECIFICATIONS....440
WEIGHT TABLE....443
FUEL, COOLANT AND LUBRICANTS....445
GENERAL ASSEMBLY DRAWING....446
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....447
SUPPORT, COOLING AND FAN SYSTEM....454
Engine and Transmission Mounting....454
Cooling System....455
Specifications....455
Cooling Fan Pump....456
Type: LPV30....456
Function....458
Structure....458
Operation....459
Control of Delivery....459
Servo Valve....460
Function....461
Cooling Fan Motor....462
Type: LMF28....462
Specifications....462
Motor....464
Function....464
Principle of Operation....464
Suction Valve....465
Function....465
Operation....465
Operation of Reversible Valve....466
Safety Valve....467
Function....467
Operation....467
POWER TRAIN SYSTEM....468
Drive Line Components....468
Outline....468
System Diagram....469
Outline....470
Drive Shaft System....471
Outline....471
Power Train Piping System....472
Torque Converter....473
Without Lockup Clutch....473
Power Transmitting Route....475
Oil Flow....475
With Lockup Clutch....476
Torque Flow....479
Lockup Clutch Disengaged....479
Lockup Clutch Engaged....479
Oil Flow....480
Transmission....481
Outline....482
Transmission with Lockup Clutch....484
F and R Clutch Packs....487
Without Lockup Clutch....487
With Lockup Clutch....488
1st and 4th Clutch....489
2nd and 3rd Clutch....490
Operation of Clutch Pack....491
When Clutch is Engaged....491
When Clutch is Disengaged....491
Transmission Torque Flow Route....492
Forward 1st Gear Speed....492
Forward 2nd Gear Speed....493
Forward 3rd Gear Speed....494
Forward 4th Gear Speed....495
Reverse 1st Gear Speed....496
Flow Control Valve....497
Operation....497
Valve Assembly....498
ECMV Operation Table....499
Electronic Control Modulation Valve (ECMV)....500
ECMV for Gear Speed Clutch....501
ECMV for Lockup Clutch....504
Operation....505
Main and Torque Converter Relief Valve System....507
Outline....508
Operation....508
DRIVE AXLE SYSTEM....509
Front and Rear Axles....509
Front Axle (WA450-6)....509
Front Axle (WA480-6)....510
Rear Axle (WA450-6....511
Rear Axle (WA480-6)....512
Differential....513
Front Differential....513
Rear Differential....515
Outline....517
When Traveling in a Straight Line....517
When Turning....517
Limited Slip Differential (if equipped)....518
Axle Carrier....519
WA450-6 and WA480-6 Front Carrier....520
WA450-6 Rear....521
WA480-6 Rear....522
Limited Slip Differential Operation....523
Generation of Braking Torque by Right / Left Side Gears (5)....523
When Traveling in a Straight Line....523
When Machine is Turning....524
Final Drives....525
WA450-6....525
WA480-6....527
Outline....530
STEERING SYSTEM....531
Steering Piping Diagram....531
Steering Column....532
Steering Pump....533
Type: LPV90....533
Pump Unit....534
Servo Valve....536
LS Valve....540
PC Valve....541
Steering Valve....545
Operation of Flow Amplifier....547
Operation of Flow Control Spool....549
Operation of Steering Valve....552
Orbit-roll Valve....559
Outline....560
Structure....560
Connection of Hand Pump and Sleeve....561
Role of Centering Spring....562
Stop Valve....563
Steering Relief Valve (if equipped)....564
Steering Cylinder....565
Emergency Steering Motor (if equipped)....567
Function....567
Emergency Steering Pump (if equipped)....568
Type: SBL (1) 21....568
SERVICE BRAKING SYSTEM....569
Brake Piping Diagram....569
Charge Valve....570
Function....571
Operation....572
Main Relief Valve (R1)....574
PPC Relief Valve (R3)....575
Sequence Valve (H1)....575
Shuttle Valve (S1)....575
Brake Valve....576
Outline....577
Operation....577
Accumulator for Brake....581
Between Charge Valve and Brake Valve....581
Between Brake Valve and Brake Cylinder....582
Slack Adjuster....583
Outline....584
Operation....584
Brakes....585
Front Brake....585
Rear Brake....587
Parking Brake System....590
Brake Control....590
Parking Brake....591
Parking Brake Solenoid Valve....593
Operation....594
Emergency Parking Brake Release Valve....595
UNDERCARRIAGE AND FRAME....596
Axle Mounting and Center Hinge Pin....596
Outline....596
Tires....600
Tire Structure and Characteristic Comparisons....600
HYDRAULIC SYSTEM....601
Piping Diagram....601
Outline....603
Work Equipment Control Lever System....604
Hydraulic Tank....605
Tank Vent System....606
Specifications....606
Power Train Pump....607
Type: SAL (4)125....607
Work Equipment Pump....608
Type: HPV95....608
Pump Unit....610
Pump Control Valve System....613
LS Valve....613
PC Valve....618
PC-EPC Valve....623
Work Equipment Control Valve....626
Sectional View of Valve (1 of 6)....628
Sectional View of Valve (2 of 6)....630
Sectional View of Valve (3 of 6)....632
Sectional View of Valve (4 of 6)....633
Sectional View of Valve (5 of 6)....634
Sectional View of Valve (6 of 6)....636
CLSS....637
Outline of CLSS....637
Basic Principle....638
Pressure Compensation Control....639
Function and Operation of Each Valve....640
Main Hydraulic Circuit Diagram of Valves....640
Pressure Compensation Valve....642
When a Heavy Load is Applied to the Lift Arm....642
During Compound Operation (Lift Arm Lower and Bucket Tilt)....643
Shuttle Valve in the Pressure Compensation Valve....644
Area Ratio of Pressure Compensation Valve....645
Supply of LS Pressure....646
LS Shuttle Valve....646
LS Bypass Plug....647
ECSS Control Valve....648
Function....648
Operation....648
Accumulator Pressure Relief Valve....648
Restriction on Lift Arm Raise Stroke....649
Function....650
Operation....650
Accumulator Charge Valve....651
When Valve is in Neutral and (P) is Low....653
When Load Pressure (P) is High....654
PPC Valve....655
Work Equipment PPC Valve....655
Operation in Neutral....657
Operations During Fine Control....658
At Full Stroke....659
When Lift Arm is Float....659
When Float State of Lift Arm is Reset....659
Accumulator for PPC Circuit....660
Accumulator for ECSS....660
WORK EQUIPMENT....661
Work Equipment Linkage....661
WA450-6....662
WA480-6....663
Bucket....664
Bucket Positioner and Boom Kick-out....665
Bucket Positioner....666
Boom Kick-out....666
Proximity Switch....667
When Bucket is Tilted....667
When Lift Arm is Raised....670
Work Equipment Cylinders....673
Lift Cylinder....673
Bucket Cylinder....673
CAB ENVIRONMENT....674
Cab....674
Air Conditioner....675
Air Conditioner Piping Diagram....675
Refrigerant Circuit Diagram....676
Air Conditioner Unit....678
Blower and Intake Unit....681
Refrigerant Compressor....683
Condenser....684
Receiver....685
Air Conditioner Panel....686
ELECTRICAL SYSTEM....690
Machine Monitor System....690
Outline....690
Operator Mode....690
Service Mode....691
System Circuit Diagram....692
Monitor Display Functions....694
List of Items Displayed on Monitor....695
Monitor Operational Switches....702
Setting the Machine Monitor System....703
Character Display Function....704
Operator Mode Function....705
Service Mode Functions....708
Input and Output Signals....713
Transmission Controller System....718
Gear Shifting Control....718
Transmission Controller Protection....724
Engine Control Function....726
Economy Operation Pilot Lamp Function....727
Cooling Fan Control Function....727
Fan Reverse Rotation Function....730
Work Equipment Swash Plate Control....733
Transmission Cut-off....735
ECSS Function....737
Electric Emergency Steering (if equipped)....739
System Circuit Diagram....741
Transmission Controller....743
Input and Output Signals....743
Electronic Transmission Control....745
Function....746
Combination Switch....747
Outline....747
Function....747
Operation....748
Kickdown and Hold Switch....749
Function....749
KOMTRAX Terminal System....750
KOMTRAX Terminal....751
Outline....751
Engine Starting Circuit....752
Function....752
Operation....753
Engine Stopping Circuit....754
Operation....754
Preheating Circuit....755
Outline....755
Operation....755
Engine Power Mode Selector Circuit....756
Function....756
Operation....756
Engine Output Derating....756
Automatic Warm-up....757
Parking Brake Circuit....757
Operation....757
When Starting Switch is Turned OFF....757
When Starting Switch is Turned ON....758
SENSORS....759
Speed Sensor....759
Torque Converter Oil Temperature Sensor....760
Hydraulic Oil Temperature Sensor....760
Transmission Oil Temperature Sensor....760
Brake Oil Temperature Sensor....760
Work Equipment Pump Oil Pressure Sensor....761
Steering Pump Oil Pressure Sensor....761
Transmission Cut-off Oil Pressure Sensor....762
Coolant Level Sensor....763
Fuel Level Sensor....764
Air Cleaner Clogging Sensor....765
Accelerator Pedal Sensor....766
Boom Kick-out Proximity Switch....767
Bucket Positioner Proximity Switch....767
20 TESTING, ADJUSTING AND TROUBLESHOOTING....769
STANDARD VALUE TABLE FOR ENGINE....774
STANDARD VALUE TABLE FOR CHASSIS....775
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....784
ENGINE COMPONENTS....787
Exhaust Smoke....787
Exhaust Temperature....787
Valve Clearance....787
Compression Pressure....787
Crankcase Pressure....787
Engine Oil Pressure....787
Boost Pressure....787
Fuel Pressure....787
Engine Speed Sensor....787
Bleeding Air from Fuel System....787
Engine Speed....788
Low Idling and High Idling....788
Measuring Torque Converter Stall Speed....788
Measuring Hydraulic Stall Speed....789
Measuring Torque Converter Stall and Hydraulic Stall (Full Stall) Speed....789
TRANSMISSION SPEED SENSOR....790
REFRIGERANT COMPRESSOR BELT....791
Testing....791
Adjusting....791
ALTERNATOR BELT TENSION....792
Testing....792
Adjusting....793
ADJUSTING DIRECTIONAL LEVER LENGTH....794
ADJUSTING GEAR SHIFT LEVER LENGTH....794
MEASURING DIRECTIONAL LEVER....795
Special Tools Required....795
Operating Effort of Directional Lever....795
Stroke of Directional Lever....795
POWER TRAIN OIL PRESSURES....796
Special Tools Required....798
Oil Pressure Measuring Position and Gauges....798
Transmission Hydraulic Operating Pressures....799
Measuring Main Relief Pressure....799
Measuring Torque Converter Relief Pressure (Inlet)....800
Measuring Torque Converter Outlet Pressure....801
Measuring Lockup Clutch Pressure (Lockup Clutch Specification)....802
Measuring F (Forward) Clutch Pressure....803
Measuring R (Reverse) Clutch Pressure....804
Measuring 1st Clutch Pressure....805
Measuring 2nd Clutch Pressure....806
Measuring 3rd Clutch Pressure....807
Measuring 4th Clutch Pressure....808
Measuring Lubrication Pressure....809
Measuring Parking Brake Pressure....810
Transmission Hydraulic Pressure Adjustments....811
Adjusting Transmission Main Relief Valve....811
Flushing Transmission System....812
Torque Converter, Transmission and Hydraulic Circuit....812
If Transmission Valve Fails....814
Moving Machine....814
Special Tools Required....814
Check Axle Drive for Oil Leakage....816
Check Drive Shafts for Looseness, Play and Damage....816
STEERING SYSTEM....817
Steering Stop Valve....817
Testing....817
Adjusting....817
Steering Wheel....819
Special Tools Required....819
Measuring Play in Steering Wheel....819
Measuring Operating Effort of Steering Wheel....819
Measuring Operating Time of Steering Wheel....820
Steering Oil Pressure....821
Special Tools Required....821
Measuring....821
Steering Relief Pressure....821
Steering Pilot Circuit Pressure....822
Adjusting....822
Steering Relief Pressure....822
Adjusting Steering Control Circuit Pressure....823
Bleeding Air from Steering Circuit....823
Bleeding Air from Steering Pump....823
Bleeding Air from Steering Cylinder Circuit....823
HYDRAULIC DRIVE FAN....824
Special Tools Required....824
Measuring Fan Speed....824
Tachometer Kit P1....825
Measuring Fan Drive Oil Pressure....825
Bleeding Air From Fan Circuit....826
Special Tools Required....826
Bleeding Air from Fan Pump....826
Bleeding Air from Fan Motor Circuit....826
WHEEL BRAKE SYSTEM....828
Measuring Brake Pedal....828
Measuring Pressing Angle of Pedal....828
Brake Pedal Linkage....829
Testing....829
Adjusting....829
Brake Performance....830
Accumulator Charge....831
Special Tools Required....831
Measuring....831
Accumulator Charge Cut-out Pressure....831
Wheel Brake Oil Pressure....832
Special Tools Required....832
Brake Test Kit....834
Wheel Brake Disc Wear....835
Special Tools Required....835
Bleeding Air from Brake Circuit....836
Releasing Residual Pressure in Brake Accumulator Circuit....837
PARKING BRAKE SYSTEM....838
Parking Brake Performance....838
Measuring Method....838
Parking Brake Oil Pressure....839
Special Tools Required....839
Parking Brake Disc Wear....841
Manual Release Method for Parking Brake....842
WORK EQUIPMENT SYSTEM....843
Control Levers....843
Special Tools Required....843
Operating Effort of Work Equipment Control Lever....843
Stroke of Work Equipment Control Lever....843
PPC Oil Pressure....844
Special Tools Required....844
Measuring PPC Pump Basic Pressure....844
PPC Valve Output Pressure....845
Adjusting....846
Hydraulic Pressure....847
Special Tools Required....847
Combination of Actuator and Valve....847
Preparation Work....847
Measuring Work Equipment Relief Pressure....848
Measuring Unload Pressure....848
Measuring Work Equipment LS Differential Pressure....849
Adjusting....850
Adjusting Work Equipment Relief Pressure....850
Adjusting LS Differential Pressure....850
Bleeding Air from Work Equipment Circuit....851
From Work Equipment Pump (Piston Pump)....851
Bleeding Air from Hydraulic Cylinder....851
Releasing Residual Pressure in Work Equipment Circuit....852
Between Hydraulic Cylinders and Control Valve....852
From ECSS (Travel Damper) Circuit....852
Bucket Positioners....854
Testing....854
Adjusting....854
Adjusting Mounting Position (Stopping Position)....854
Boom Kickout....855
Proximity Switch Operation Pilot Lamp....856
ELECTRICAL SYSTEM TROUBLESHOOTING....857
Procedure for Testing Diodes....857
When Using Digital-Type Circuit Tester....857
When Using Analog-Type Circuit Tester....857
Preparation for Troubleshooting Electrical System....858
Machine Monitor....858
Transmission Controller....859
Work Equipment Controller (if equipped)....860
KOMTRAX Controller....860
Ambient Pressure Sensor (AMBAIR PRESSURE)....861
Engine NE Speed Sensor (CRANK SENSOR)....861
Engine BKUP Speed Sensor (CAM SENSOR)....861
Engine Oil Pressure Switch (OIL PRESSURE SWITCH)....861
Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)....861
Supply Pump IMV Solenoid (FUEL REGULATOR)....861
Common Rail Pressure Sensor (FUEL RAIL PRESS)....862
Engine Coolant Temperature Sensor (COOLANT TEMP)....862
KOMTRAX TERMINAL SYSTEM OPERATION....863
KOMTRAX Terminal Installed at Plant....863
KOMTRAX Terminal Retrofitted....863
Station Opening Check in Machine Side....863
Application for the Start of Use....866
KOMTRAX Terminal Lamps....867
Check Antennas....868
Check Terminal Led Displays....868
MACHINE MONITOR SYSTEM....870
Machine Monitor....870
Adjusting Replaced, Reassembled or Added Sensor, Controller, etc. with Machine Monitor....871
Items to be Set When Sensor or Controller is Replaced, Reassembled or Added....871
Adjustment for User's Needs....872
Special Functions of Machine Monitor (EMMS)....873
Normal and Special Functions of Machine Monitor....873
Functions and Flow of Service Mode....874
Operator Mode....877
Service Meter/Clock Display Function....877
Load Meter Function (if Equipped)....877
Odometer Display Function....877
Maintenance Monitoring Function....878
Telephone Number Input Function....878
Language Selection Function....878
Monitor Brightness Adjustment Function....878
Time Adjustment Function....879
Travel Speed/Engine Speed Display Selecting Function....880
Travel Speed/Engine Speed Display/Non-Display Selecting Function....880
Action Code Display Function....880
Action Codes and Actions Alerted to Operator....881
Failure Code Display Function....881
Service Mode....882
Electrical System Fault History Display Function (ELECTRIC FAULT)....883
Mechanical System Fault History Display Function (MACHINE FAULT)....885
Real-time Monitoring Function (REAL-TIME MONITOR)....886
REAL-TIME MONITORING CODE TABLES....889
Monitor Panel Display (1)....889
Monitor Panel Display (2)....891
MON Mode....893
Transmission Display (1)....895
Transmission Display (1)....896
Transmission Display (2)....897
Transmission Display (2)....898
Transmission Display (3)....899
Transmission Display (3)....900
TM Mode....901
Engine Display....903
MONITOR USAGE....905
Cylinder Cut-out Function....905
No Injection Cranking Function....906
Adjustment Function (Tuning)....908
Adjustment Functions....908
Preparations for Transmission ECMV Current Adjustment....908
Confirmation of Transmission Oil Temperature Control....909
Adjustment of Transmission ECMV Current....910
Codes for Abnormal End....913
Setting of Transmission Initial Learning....913
Reset of Initial Learning....913
Preparations for Transmission Initial Learning....914
Implementation of Transmission Initial Learning....915
Confirmation of Completion of Transmission Initial Learning....916
Adjustment of Transmission L Mode Shift Point Function....916
Clearing an Adjusted Shift Point....916
Adjusting a Shift Point....917
Gear Shift Pattern Change Procedure....918
Adjustments Not Used....918
Adjustment of Fan Automatic Reverse Operation Interval (if equipped)....919
Adjustment of Fan Automatic Reverse Operation Continuance (if equipped)....921
Maintenance Monitoring Function....923
Changing Maintenance Interval Time....923
List of Maintenance Items....923
Selection Between Enabling or Disabling Timer by Item....925
Changing Set Default Value....926
Selection Between Timer Stop for All Items and Enable by Item....927
Operating Information Display Function....929
Fuel Consumption Ratio and Average Fuel Consumption Screen....929
Cumulative Fuel Consumption and Travel Distance....929
Cumulative Fuel Consumption and Elapsed Time....930
Loaded Volume and Loading Frequency Screen....930
Deleting Display Data....930
Setting Gain Correction....930
Optional Select Function....932
Optional Component Setting Table....932
Change or Settlement of BOOM TYPE OPTION SELECT....935
Option Setting/Not Setting Selection....935
Setting Tire Deflection Option....935
Storing Option Selection....936
Machine Serial Number Input Function....936
Machine Model Select Function (MACHINE)....936
Implementing the Model Change....937
Storing Model Change....937
Initialize Function....938
PM-CLINIC INSPECTION TABLES....939
POINTS TO REMEMBER WHEN TROUBLESHOOTING....946
SEQUENCE OF EVENTS IN TROUBLESHOOTING....948
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....949
Precautions When Handling Electrical Equipment....949
Handling Electronic Control Unit....954
Points to Remember When Troubleshooting Electrical Circuits....955
ELECTRIC WIRE CODE....956
Classification by Thickness....956
Classification by Color and Code....956
How to Read Electric Wire Code....957
Points to Remember When Handling Hydraulic Equipment....959
CHECKS BEFORE TROUBLESHOOTING....961
Categories and Method of Using Troubleshooting Charts....962
Troubleshooting Individual Electrical Circuits....963
Chart Use....965
Chart Tips....965
Troubleshooting Individual Hydraulic Circuits....966
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....968
T-ADAPTER TABLE....993
MODE CHART....997
INFORMATION CONTAINED IN TESTING PROCEDURES....1005
FAILURE CODE CHART....1007
TABLE OF FUSE BOX AND SLOW BLOW FUSES....1017
VIEW OF FUSE LOCATIONS....1019
FAILURE CODE....1020
1500L0 Torqflow Transmission - Double Engagement Detected....1020
15SAL1 ECMV F Clutch....1021
When Command Current is Off, Fill Signal is On....1021
15SALH ECMV F Clutch....1023
When Command Current is On, Fill Signal is Off....1023
15SBL1 ECMV R Clutch....1025
When Command Current is Off, Fill Signal is On....1025
15SBLH ECMV R Clutch....1027
When Command Current is On, Fill Signal is Off....1027
15SEL1 ECMV 1st Clutch....1029
When Command Current is Off, Fill Signal is On....1029
15SELH ECMV 1st Clutch....1031
When Command Current is On, Fill Signal is Off....1031
15SFL1 ECMV 2nd Clutch....1033
When Command Current is Off, Fill Signal is On....1033
15SFLH ECMV 2nd Clutch....1035
When Command Current is On, Fill Signal is Off....1035
15SGL1 ECMV 3rd Clutch....1037
When Command Current is Off, Fill Signal is On....1037
15SGLH ECMV 3rd Clutch....1039
When Command Current is On, Fill Signal is Off....1039
15SHL1 ECMV 4th Clutch....1041
When Command Current is Off, Fill Signal is On....1041
15SHLH ECMV 4th Clutch....1043
When Command Current is On, Fill Signal is Off....1043
2F00MA Parking Brake Malfunction....1045
2G43ZG Accumulator Oil Pressure Low....1047
44K0L4 Bucket Positioner On/Off Signals Incorrect....1049
AA1ANX Air Cleaner Clogged Indication....1052
AB00L6 Alternator Signal Incorrect with Operating State of Engine....1054
AB00MA Alternator Malfunction....1056
B@BAZG Engine Power and Speed Derated by Low Oil Pressure....1058
B@BAZK Engine Oil Level Low Level....1060
B@BCNS Engine Coolant Overheating....1062
B@BCZK Coolant Level Low....1064
B@C7NS Brake Oil Overheating....1066
b@CENS Torque Converter Oil Overheating....1068
B@CENS Torque Converter Oil Overheating....1070
B@HANS Hydraulic Oil Overheating....1072
CA111 Abnormality in Engine Controller....1074
CA115 Engine Ne or Bkup Speed Sensor Error....1077
CA122 Charge Pressure Sensor Failure....1078
CA123 Charge Pressure Sensor Failure....1080
CA131 Throttle Sensor High Failure....1081
CA132 Throttle Sensor Low Failure....1083
CA135 Engine Oil Pressure Sensor High Error....1085
CA141 Engine Oil Pressure Sensor High Error....1087
CA144 Coolant Sensor High Failure....1088
CA145 Coolant Sensor Low Failure....1090
CA153 Charge Temperature Sensor High Failure....1092
CA154 Charge Temperature Sensor Low Failure....1094
CA187 Sensor Power Supply 2 Low Error....1096
CA221 Atmospheric Pressure Sensor High Failure....1097
CA222 Atmospheric Pressure Sensor Low Failure....1099
CA227 Sensor Power Supply 2 High Failure....1100
CA234 Engine Overspeed Detected....1103
CA238 Ne Speed Sensor Power Supply Error....1104
CA263 Fuel Temperature Sensor High Failure....1106
CA265 Fuel Temperature Sensor Low Failure....1108
CA271 PCV1 Short Circuit Detected....1109
CA272 PCV1 Open Circuit Detected....1111
CA273 PCV2 Short Circuit Detected....1113
CA274 PCV2 Open Circuit Detected....1115
CA322 Injector #1 (L/B#1) Has an Open/Short....1117
CA323 Injector #5 (L/B#5) Has an Open/Short....1119
CA324 Injector #3 (L/B#3) Has an Open/Short....1121
CA325 Injector #6 (L/B#6) Has an Open/Short....1123
CA331 Injector #2 (L/B#2) Has an Open/Short....1125
CA332 Injector #4 (L/B#4) Has an Open/Short....1127
CA342 Calibration Code Inconsistency....1129
CA351 Injectors Drive Circuit Error....1130
CA352 Sensor Power Supply 1 Low Failure....1133
CA386 Sensor Power Supply 1 High Failure....1134
CA431 Idle Validation Switch Error....1136
CA432 Idle Validation Switch Action Error....1138
CA435 Engine Oil Pressure Switch Error....1141
CA441 Low Battery Voltage Error....1143
CA442 High Battery Voltage Error....1146
CA449 Common Rail Pressure High Error 2....1148
CA451 Common Rail Pressure Sensor High Error....1149
CA452 Common Rail Pressure Sensor Low Error....1151
CA553 Common Rail Pressure High Error 1....1152
CA554 Common Rail Pressure Sensor In-range Error....1153
CA559 Supply Pump Pressure Very Low Error....1154
Check Sheet For No-pressure Feed....1155
WA450-6 Specifications....1156
WA480-6 Specifications....1157
CA689 Ne Speed Sensor Error....1158
CA731 Engine Bkup Speed Sensor Phase Error....1160
CA757 All Continuous Data Loss Error....1160
CA778 Engine Bkup Speed Sensor Error....1161
CA1228 EGR Valve Servo Error 1....1163
CA1625 EGR Valve Servo Error 2....1164
CA1633 KOMNET Data Link Time Out Error....1165
CA2185 Throttle Sensor Supply Voltage High Failure....1167
CA2186 Throttle Sensor Supply Voltage Low Failure....1169
CA2249 Supply Pump Pressure Very Low Error....1171
CA2271 EGR Valve Lift Sensor High Error....1172
CA2272 EGR Valve Lift Sensor Low Error....1174
CA2351 EGR Valve Solenoid Showing Short Circuit Error....1175
CA2352 EGR Valve Solenoid Showing Open Circuit Error....1177
CA2555 Intake Heater Relay Open Error....1178
CA2556 Intake Heater Relay Short Error....1180
D150KA Emergency Steering Relay Open....1182
D150KB Emergency Steering Relay Shorted....1184
D150KY Emergency Steering Relay Shorted with Power Supply....1186
D160KA Backup Lamp Relay Open....1188
D160KB Backup Lamp Relay Shorted....1190
D191KA Joystick Steering Neutral Safety Relay: Disconnection....1192
D191KB Joystick Steering Neutral Safety Relay Shorted....1194
D191KY Joystick Steering Neutral Safety Relay Shorted....1196
D192KA ECSS Solenoid Open....1198
D192KB ECSS Solenoid Shorted....1200
D192KY ECSS Solenoid Power Supply Error....1202
D193KA Joystick Steering Solenoid Cut Relay Shorted....1204
D193KB Joystick Steering Solenoid Cut Relay Shorted....1206
D193KY Joystick Steering Solenoid Cut Relay Shorted....1208
D5ZHKA Terminal C Signal Open....1211
D5ZHKB Terminal C Signal Shorted....1215
D5ZHKZ Terminal C Signal: Disconnection or Short Circuit....1219
D5ZHL6 Terminal C Signal Does Not Match Engine Running or Stopped....1223
DA80L4 Auto Grease Controller On/Off Signals Disagree....1227
DAF3KK Machine Monitor Low Voltage Input....1230
DAF5KP Machine Monitor Low Output Voltage....1232
DAFRKR CAN Communication with Machine Monitor Defective....1235
DAQ0KK Transmission Controller Low Voltage Source....1237
DAQ0KT Transmission Controller Defective....1239
DAQ2KK Transmission Controller Low Voltage Source Input....1240
DAQ9KQ Transmission Controller Model Selection Disagreement....1242
DAQRKR CAN Communication with Transmission Controller Abnormal....1243
DAQRMA Transmission Controller Option Setting Malfunction....1246
DB2RKR CAN Communication with Engine Controller Abnormal....1247
DB90KK Work Equipment Controller Low Voltage Source....1250
DB90KT Work Equipment Controller Malfunction....1252
DB92KK Work Equipment Controller Low Voltage Input Source....1253
DB95KX Work Equipment Power Supply Output, Out of Range....1255
DB99KQ Work Equipment Controller Model Selection Disagreement....1259
DB9RKR CAN Communication with Work Equipment Controller Abnormal....1260
DB9RMA Work Equipment Controller Option Setting Malfunction....1263
DB9RMC Communication with Transmission Controller Defective....1266
DD15LD n Switch (Panel Switch 1) is Defective....1269
DD16LD Switch (Panel Switch 2) is Defective....1271
DD17LD < Switch (Panel Switch 3) is Defective....1273
DD18LD > Switch (Panel Switch 4) is Defective....1275
DD1ALD Remote Positioner Set Switch is Defective....1277
DD1BLD Remote Positioner Set Switch is Defective....1279
DD1CLD Load Meter Subtotal Switch Defective....1281
DD1FLD Load Meter Mode Selector Switch (A/B) is Defective....1283
DD1GLD Load Meter Mode Selector Switch (+/-) is Defective....1285
DD1HLD Load Meter Display Selector Switch is Defective....1287
DD1NLD Fan Reverse Selector Switch is Defective....1289
DD1NL4 Fan Reverse Selector Switch is Defective....1292
DDB6L4 Parking Brake Switch On/Off Signals Disagree....1295
DDD1LD Remote Bucket Positioner Switch is Defective....1298
DDE5MA Emergency Steering Drive Switch Malfunction....1301
DDK3KA Right FNR Switch Showing Open....1303
DDK4KA FNR Switch Showing Open....1306
DDK5L4 Joystick Steering Shift-up Switch On/Off Signal Error....1309
DDK6KA FNR Switch Showing Open....1311
DDK6KB FNR Switch Showing a Short....1314
DDS5KA Steering Pressure Switch Signal: Disconnected....1317
DDS5KB Steering Pressure Switch Signal: Short Circuit....1319
DDT0L4 Shift Mode Selector Switch On/Off Signals Incorrect....1321
DDT4LD Transmission Cut-off Switch is Defective....1324
DDW9LD Kick-down Switch Defective....1326
DDWLLD Hold Switch Defective....1328
DDY0LD Load Meter Cancel Switch Defective....1330
DF10KA Transmission Shift Lever Switch Open....1332
DF10KB Transmission Shift Lever Switch Shorted....1335
DGF1KA Transmission Oil Temperature Sensor Showing Open....1338
DGF1KB Transmission Oil Temperature Sensor Showing a Short....1340
DGH2KX Hydraulic Oil Temperature Sensor Out of Range....1342
DGR2KA Rear Brake Oil Temperature Sensor Open....1344
DGR2KX Rear Brake Oil Temperature Sensor Shorted....1346
DGT1KX Torque Converter Oil Temperature Sensor Out of Range....1348
DH21KA Loader Pump Pressure Sensor: Disconnection....1350
DH21KB Loader Pump Pressure Sensor: Power Supply Line Short....1352
DHPCKX Lift Arm Cylinder Bottom Pressure Sensor Out of Range....1354
DHPDKX Lift Arm Cylinder Head Pressure Sensor Out of Range....1356
DHT1KX Transmission Cut-off Pressure Sensor Out of Range....1358
DHT8KA Steering Pump Pressure Sensor Open....1360
DHT8KB Steering Pump Pressure Sensor Short Circuit....1362
DK59KA Lift Arm Epc Lever Showing Open....1364
DK59KY Lift Arm EPC Lever Showing a Short....1367
DK59L8 Lift Arm EPC Lever Showing Incorrect Signals....1370
DK5AKA Lift Arm Epc Lever Showing Open....1373
DK5AKY Lift Arm EPC Lever Shorted....1376
DK5BKA Bucket EPC Lever Showing Open....1379
DK5BKY Bucket EPC Lever System Shorted....1382
DK5BL8 Bucket EPC Lever Showing Incorrect Signals....1385
DK5CKA Bucket EPC Lever System Open....1388
DK5CKY Bucket EPC Lever System Shorted....1391
DK5DKA 3-Spool Attachment EPC Lever System Showing Open....1394
DK5DKY 3-Spool Attachment EPC Lever System Showing a Short....1397
DK5DL8 3-Spool EPC Lever Showing Incorrect Signals....1400
DK5EKA 3-Spool Attachment EPC Lever System Showing Open....1403
DK5EKY 3-Spool Attachment EPC Lever System Showing Short....1406
DK5FKA Joystick Steering EPC Lever System Showing Open....1409
DK5FKY Joystick Steering EPC Lever System Showing a Short....1412
DK5GKA Joystick Steering EPC Lever System Showing an Open....1415
DK5GKY Joystick Steering EPC Lever System Showing a Short....1418
DK5FL8 Joystick Steering EPC Lever System Incorrect Signals....1421
DKA0KA Lift Arm Angle Sensor System Showing an Open....1424
DKA0KY Lift Arm Angle Sensor System Showing a Short....1427
DKA0L0 Lift Arm Angle Sensor System Double Meshing....1430
DLT3KA Transmission Speed Sensor Open....1433
DLT3LC Transmission Speed Sensor Out of Range....1435
DT20KB Transmission Cut-off Indicator Lamp Shorted....1437
DUM1KB Remote Positioner Raise Set Indicator Shorted....1439
DUM2KB Remote Positioner Raise Set Indicator Shorted....1441
DV00KB Alarm Buzzer Shorted....1443
DW4PKA Lift Arm Raise EPC Solenoid Showing Open....1445
DW4PKB Lift Arm Raise EPC Solenoid Showing a Short Circuit....1447
DW4PKY Lift Arm Raise EPC Solenoid Showing a Short Circuit....1449
DW4QKA Lift Arm Lower EPC Solenoid Showing an Open....1451
DW4QKB Lift Arm Lower EPC Solenoid Showing a Short....1453
DW4QKY Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line....1455
DW4RKA Bucket Tilt EPC Solenoid Showing an Open....1457
DW4RKB Bucket Tilt EPC Solenoid Showing a Short....1459
DW4RKY Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line....1461
DW4SKA Bucket Dump EPC Solenoid Showing an Open....1463
DW4SKB Bucket Dump EPC Solenoid Showing a Short....1465
DW4SKY Bucket Dump EPC Solenoid Showing a Short....1467
DW7BKA Fan Reverse Solenoid Open....1469
DW7BKB Fan Reverse Solenoid Shorted....1471
DW7BKY Fan Reverse Solenoid Shorted....1473
DW7DKA Hydraulic Fan Neutral Solenoid Showing Open....1475
DW7DKB Hydraulic Fan Neutral Solenoid Shorted....1476
DW7DKY Hydraulic Fan Neutral Solenoid Showing Open....1477
DWM1KA Work Equipment Neutral Lock Solenoid Showing Open....1478
DWM1KB Work Equipment Neutral Lock Solenoid Shorted....1481
DWM1KY Work Equipment Neutral Lock Solenoid Shorted....1484
DWN6KA Lift Arm Raise Magnetic Detent Solenoid Showing Open....1487
DWN6KB Lift Arm Raise Magnetic Detent Solenoid is Shorted....1489
DWN6KY Lift Arm Raise Magnetic Detent Solenoid is Shorted....1491
DWN7KA Lift Arm Float Magnetic Detent Solenoid Showing Open....1493
DWN7KB Lift Arm Float Magnetic Detent Solenoid Showing Short....1495
DWN7KY Lift Arm Float Magnetic Detent Solenoid Showing Short....1497
DWN8KA Bucket Magnetic Detent Solenoid Showing Open....1499
DWN8KB Bucket Magnetic Detent Solenoid Shorted....1501
DWN8KY Bucket Magnetic Detent Solenoid Shorted....1503
DX16KA Fan Pump EPC Solenoid Open....1505
DX16KB Fan Pump EPC Solenoid Shorted....1507
DX16KY Fan Pump EPC Solenoid Shorted....1509
DXH1KA Lock-up ECMV Solenoid Open....1511
DXH1KB Lock-up ECMV Solenoid Shorted....1513
DXH1KY Lock-up ECMV Solenoid Shorted....1515
DXH4KA 1st Clutch ECMV Solenoid Open....1517
DXH4KB 1st Clutch ECMV Solenoid Shorted....1519
DXH4KY 1st Clutch ECMV Solenoid Shorted....1521
DXH5KA 2nd Clutch ECMV Solenoid Open....1523
DXH5KB 2nd Clutch ECMV Solenoid Shorted....1525
DXH5KY 2nd Clutch ECMV Solenoid Shorted....1527
DXH6KA 3rd Clutch ECMV Solenoid Open....1529
DXH6KB 3rd Clutch ECMV Solenoid Shorted....1531
DXH6KY 3rd Clutch ECMV Solenoid Shorted....1533
DXH7KA Reverse (R) Clutch ECMV Solenoid Open....1535
DXH7KB Reverse (R) Clutch ECMV Solenoid Shorted....1537
DXH7KY Reverse (R) Clutch ECMV Solenoid Shorted....1539
DXH8KA Forward (F) Clutch ECMV Solenoid Open....1541
DXH8KB Forward (F) Clutch ECMV Solenoid Shorted....1543
DXH8KY Forward (F) Clutch ECMV Solenoid Shorted....1545
DXHHKA 4th Clutch ECMV Solenoid Open....1547
DXHHKB 4th Clutch ECMV Solenoid Shorted....1549
DXHHKY 4th Clutch ECMV Solenoid Shorted....1551
DXHJKA 3-Spool Valve Extend EPC Solenoid Showing an Open....1553
DXHJKB 3-Spool Valve Extend EPC Solenoid Showing a Short....1555
DXHJKY 3-Spool Valve Extend EPC Solenoid Showing a Short....1557
DXHKKA 3-Spool Valve Retract EPC Solenoid Showing an Open....1559
DXHKKB 3-Spool Valve Extend EPC Solenoid Showing a Short....1561
DXHKKY 3-Spool Valve Extend EPC Solenoid Showing a Short....1563
DXHLKA Joystick Steering Right EPC Solenoid Showing Open....1565
DXHLKB Joystick Steering Right EPC Solenoid Shorted....1568
DXHLKY Joystick Steering Right EPC Solenoid Shorted....1571
DXHMKA Joystick Steering Left EPC Solenoid Showing Open....1574
DXHMKB Joystick Steering Left EPC Solenoid Shorted....1577
DXHMKY Joystick Steering Left EPC Solenoid Showing Open....1580
DY30MA Motor-driven Emergency Steering Pump Failure (During Operation of Machine)....1583
DY30MC Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)....1586
DY30ME Emergency Steering: Operating for More Than One Minute....1589
E-MODE (ELECTRICAL SYSTEM)....1594
Information Contained in Testing Procedures....1594
Table of Fuse Box and Slow Blow Fuses....1596
View of Fuse Locations....1598
E-1 Engine Will Not Crank....1599
E-2 Front Wiper Does Not Operate....1605
Rear Wiper Does Not Operate....1608
E-3 Windshield Washer Does Not Operate....1610
E-4 Head, Clearance, License and Tail Lamps Do Not Operate Correctly....1613
Head Lamps (High or Low Beams) Do Not Operate Correctly....1615
Head Lamp Low Beams Do Not Operate Correctly....1618
Head Lamp High Beams Do Not Operate Correctly....1621
Clearance Lamps Do Not Operate Correctly....1624
E-5 Work Lamps Do Not Operate Correctly....1626
Front Work Lamps....1626
Rear Work Lamps....1628
E-6 Hazard Lamps Do Not Operate Correctly....1630
Directional Lamps Do Not Operate Correctly....1633
Directional Lamps Work and Hazard Lamps Do Not Work....1636
E-7 Rear Brake Lamps Do Not Operate Correctly....1639
E-8 Backup Lamps Do Not Operate Correctly....1641
E-9 Backup Alarm Does Not Operate Correctly....1643
E-10 Horns Do Not Operate Correctly....1645
E-11 Alarm Buzzer Does Not Operate Correctly....1647
E-12 Air Conditioner Does Not Operate or Stop....1649
E-13 KOMTRAX System Does Not Operate Correctly....1652
S-MODE ENGINE SYSTEM....1655
H-MODE HYDRAULIC AND MECHANICAL SYSTEM....1658
Method of Using Troubleshooting Chart....1658
Failure Code and Cause Table....1662
H-1 The Machine Does Not Start....1666
Defective Clutch and ECMV (Check by Failure Code)....1667
H-2 Torque Converter Lockup Will Not Switch Off (if equipped)....1668
H-3 Torque Converter Lockup Will Not Switch On (if equipped)....1669
H-4 Slow Travel Speed, Weak Thrust Force and Uphill Travel and Gear Does Not Shift....1670
Defective Clutch and ECMV (Check by Failure Code)....1671
H-5 Strong Jerks Occur When Shifting Gears....1672
Defective Clutch and ECMV (Check by Failure Code)....1673
H-6 Extreme Time Lag Between Shifting Gears....1674
Defective Clutch and ECMV (Check by Failure Code)....1675
H-7 Torque Converter Oil Temperature is High....1676
H-8 Steering Does Not Turn....1677
H-9 Steering Does Not Turn (Joystick Steering)....1678
H-10 Steering Response is Poor....1679
H-11 Steering Response is Poor (Joystick Steering)....1680
H-12 Steering Feels Stiff....1681
H-13 Shaking or Jerking Occurs When Turning the Machine....1682
H-14 Shaking or Jerking Occurs When Turning the Machine (Joystick Steering)....1683
H-15 Wheel Brakes Do Not Work Properly....1684
H-16 Wheel Brakes Do Not Release Properly....1685
H-17 The Parking Brake Does Not Work Properly....1686
H-18 The Parking Brake Does Not Release Properly....1687
H-19 Lift Arm Does Not Rise....1688
H-20 Lift Arm Speed is Slow or Power is Insufficient....1689
H-21 When Rising, Lift Arm Moves Slowly at Specific Heights....1690
H-22 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)....1690
H-23 Hydraulic Drifts of the Lift Arm are Large....1690
H-24 The Lift Arm Wobbles During Operation....1690
H-25 Bucket Does Not Tilt Back....1691
H-25 Bucket Speed is Low or Tilt Back Force is Weak....1692
H-27 The Bucket Operates Slowly in The Midst of Tilting Back....1693
H-28 The Bucket Cylinder Cannot Hold Down the Bucket....1693
H-29 Hydraulic Drift of The Bucket is Large....1693
H-30 Bucket Wobbles During Travel Loaded (Work Equipment Valve is Set at Hold)....1693
H-31 Work Equipment Levers Move Hard....1694
H-32 During Operation, Engine Speed Lowers or Engine Stalls....1695
H-33 Strong Jerk is Felt When Work Equipment Starts and Stops....1695
H-34 When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves....1695
H-35 ECSS Does Not Operate, or Pitching and Bouncing Occur....1696
30 DISASSEBMLY AND ASSEMBLY....1697
HOW TO READ THIS MANUAL....1701
Removal and Installation of Assemblies....1701
Disassembly and Assembly of Assemblies....1703
COATING MATERIALS LIST....1705
SPECIAL TOOLS LIST....1708
SCHEMATIC DRAWINGS OF SPECIAL TOOLS....1712
CONNECTOR REPAIR PROCEDURES....1723
Stripping Insulation....1723
Wire Inspection....1723
Contact Terminal Removal (HD30 Type)....1724
Crimping Contact Terminal (HD30 Type)....1725
Insertion Of Contact Terminal (HD30 Type)....1726
Contact Terminal Removal (DT Type)....1727
Crimping Contact Terminal (DT Type)....1728
Insertion Of Contact Terminal (DT Type)....1729
ENGINE....1730
Alternator....1730
Engine Front Seal....1730
Engine Rear Seal....1730
Starting Motor....1730
Thermostat....1730
Turbocharger....1730
Water Pump....1730
ENGINE AND COOLING SYSTEM....1731
Engine....1731
Removal....1731
Installation....1735
Engine Hood....1737
Removal....1737
Installation....1740
Radiator....1741
Removal....1741
Installation....1744
Aftercooler....1745
Removal....1745
Installation....1746
Oil Cooler....1747
Removal....1747
Installation....1748
Cooling Fan and Drive Motor....1749
Removal....1749
Installation....1752
Fuel Supply Pump....1753
Special Tools....1753
Removal....1753
Installation....1756
Fuel Injector....1760
Removal....1760
Installation....1763
Cylinder Head....1766
Removal....1766
Installation....1774
Fuel Tank....1780
Removal....1780
Installation....1783
POWER TRAIN....1784
Torque Converter and Transmission....1784
Removal....1784
Installation....1790
Torque Converter - Standard Specifications....1792
Special Tools....1792
Disassembly....1792
Assembly....1794
Torque Converter - Lockup Specifications....1797
Special Tools....1797
Disassembly....1797
Assembly....1800
Transmission....1805
Special Tools....1805
Disassembly....1805
Assembly....1813
Transmission Clutch Pack....1823
Special Tools....1823
Disassembly....1823
Assembly....1830
Parking Brake....1845
Special Tools....1845
Disassembly....1845
Assembly....1848
Front Axle....1855
Removal....1855
Installation....1856
Rear Axle....1857
Removal....1857
Installation....1863
Axle Housing....1865
Special Tools....1865
Disassembly....1865
Assembly....1869
Differential....1876
Special Tools....1876
Disassembly....1876
Assembly....1884
UNDERCARRIAGE AND FRAME....1900
Center Hinge Pin....1900
Special Tools....1900
Removal....1900
Installation....1905
Counterweight....1910
Removal....1910
Installation....1912
HYDRAULIC SYSTEM....1913
Steering Demand Valve....1913
Removal....1913
Installation....1916
Work Equipment Valve....1917
Removal....1917
Installation....1920
Brake Charge Valve....1921
Removal....1921
Installation....1921
Hydraulic Tank....1922
Removal....1922
Installation....1924
Steering and Power Train Pump....1925
Removal....1925
Installation....1926
Work Equipment and Cooling Fan Pump....1927
Removal....1927
Installation....1928
WORK EQUIPMENT....1930
Work Equipment....1930
Removal....1930
Installation....1933
CAB AND ITS ATTACHMENTS....1935
Operator's Cab and Floor Frame....1935
Special Tools....1935
Removal....1935
Installation....1939
Operator's Cab Glass (Stuck Glass)....1940
Special Tools....1940
Removal....1940
Installation....1941
Operators Seat....1949
Disassembly....1949
Assembly....1956
ELECTRICAL SYSTEM....1962
Air Conditioner Unit....1962
Special Tools....1962
Removal....1962
Installation....1967
Engine Controller....1968
Removal....1968
Installation....1968
Transmission Controller....1969
Removal....1969
Installation....1969
KOMTRAX Controller....1970
Removal....1970
Installation....1970
90 DIAGRAMS AND SCHEMATICS....1971
ELECTRICAL SCHEMATICS....1973
IN CAB SWITCHES (VIEW 1 OF 47)....1973
IN CAB SWITCHES AND CONNECTORS (VIEW 2 OF 47)....1974
CAB HARNESS (VIEW 3 OF 47)....1975
TO MONITOR PANEL AND CONTROLLERS (VIEW 4 OF 47)....1976
THROTTLE PEDAL, PPC AND KICK-OUT SWITCHES (VIEW 5 OF 47)....1977
MONITOR PANEL AND OPTIONAL LOAD METER (VIEW 6 OF 47)....1978
TRANSNISSION AND FAN PUMP CONTROLLER HARNESS (VIEW 7 OF 47)....1979
LAMP SWITCHES AND MODE SELECTOR (VIEW 8 OF 47)....1980
SWITCH AND CONTROLER HARNESS (VIEW 9 OF 47)....1981
SYSTEM SWITCHES AND HARNESS (VIEW 10 OF 47)....1982
MODE SWITCHES AND HARNESS (VIEW 11 OF 47)....1983
KOMTRAX SYSTEM (VIEW 12 OF 47)....1984
DASH PANEL SWITCHES AND HARNESS (VIEW 13 OF 47)....1985
CAB REAR HARNESS (VIEW 14 OF 47)....1986
GROUND DRIVEN STEERING AND FAN SWITCH (VIEW 15 OF 47)....1987
TO REAR HARNESS (VIEW 16 OF 47)....1988
TO REAR HARNESS (VIEW 17 OF 47)....1989
MAIN HARNESS (VIEW 18 OF 47)....1990
FUSES AND HARNESS (VIEW 19 OF 47)....1991
SYSTEM HARNESS (VIEW 20 OF 47)....1992
FUSE BOX AND HARNESS (VIEW 21 OF 47)....1993
SYSTEM HARNESS (VIEW 22 OF 47)....1994
RELAY SYSTEM (VIEW 23 OF 47)....1995
RELAY SYETEM (VIEW 24 OF 47)....1996
TO FRONT HARNESS (VIEW 25 OF 47)....1997
ENGINE HARNESS (VIEW 26 OF 47)....1998
ENGINE CONTROL MODULE (VIEW 27 OF 47)....1999
LAMPS AND SWITCH IN HARNESS (VIEW 28 OF 47)....2000
ENGINE SENSORS (VIEW 29 OF 47)....2001
MACHINE LIGHTING SYSTEM AND SWITCHES (VIEW 30 OF 47)....2002
FUSES AND GROUND DRIVEN STEERING (VIEW 31 OF 47)....2003
SOLENOID AND SWITCH SYSTEMS (VIEW 32 OF 47)....2004
IN CAB CONTROL SYSTEMS (VIEW 33 OF 47)....2005
AIR CONDITIONING SYSTEM (VIEW 34 OF 47)....2006
AIR CONDITIONING SYSTEM (VIEW 35 OF 47)....2007
TO FLOOR HARNESS (VIEW 36 OF 47)....2008
ENGINE SYSTEM (VIEW 37 OF 47)....2009
ENGINE CONTROL MODULE (VIEW 38 OF 47)....2010
SWITCHES, RELAYS AND LAMPS (VIEW 39 OF 47)....2011
CONNECTING HARNESS VIEW (VIEW 40 OF 47)....2012
ENGINE ACCESSORIES (VIEW 41 OF 47)....2013
ENGINE CONTROL MODULE (VIEW 42 OF 47)....2014
GROUND DRIVEN STEERING (VIEW 43 OF 47)....2015
FRONT HARNESS AND LOAD METER (VIEW 44 OF 47)....2016
FUSES (VIEW 45 OF 47)....2017
ENGINE CONTROL MODULE HARNESS (VIEW 46 OF 47)....2018
ENGINE FUEL INJECTORS (VIEW 47 OF 47)....2019
HYDRAULIC CIRCUIT DIAGRAM....2020
POWER TRAIN HYDRAULIC CIRCURIT DIAGRAM....2021
WITH LOCKUP CLUTCH....2021
WITHOUT LOCKUP CLUTCH....2022
CONNECTOR LIST AND STEREOGRAM....2023
CHASSIS (VIEW 1 OF 3)....2023
ENGINE AND TRANSMISSION (VIEW 2 OF 3)....2024
OPERATOR'S COMPARTMENT (VIEW 3 OF 3)....2025
SEN00809-04 - Wheel Loader GALEO WA450-6, WA480-6 (KA Spec.) Shop Manual....2026
COVER PAGE....2026
00 Index and foreword....2028
Index....2028
Composition of shop manual....2029
Table of contents....2031
Foreword and general information....2046
Safety notice....2047
How to read the shop manual....2052
Explanation of terms for maintenance standard....2054
Handling electric equipment and hydraulic component....2056
Precautions when carrying out operation....2071
Method of disassembling and connecting push-pull type coupler....2074
Standard tightening torque table....2077
Conversion table....2081
01 Specification....2088
Specification and technical data....2088
Specification and technical data....2090
Specification dimension drawing....2090
Specifications....2091
Weight table....2095
Table of fuel, coolant and lubricants....2097
10 Structure, function and maintenance standard....2100
Engine and cooling system....2100
Engine and cooling system....2101
Engine mount and transmission mount....2101
Cooling system....2102
Cooling fan pump....2103
Cooling fan motor....2111
Power train....2118
Power train....2120
Power train....2120
Power train system diagram....2121
Drive shaft....2123
Power train piping diagram....2124
Torque converter....2125
Transmission....2133
Flow control valve....2150
Transmission control valve....2151
ECMV....2153
Main relief valve and torque converter relief valve....2159
Axle....2161
Differential....2165
Limited slip differential....2170
Final drive....2177
Steering system....2186
Steering system....2187
Steering piping diagram....2187
Steering column....2188
Steering pump....2189
Steering valve....2202
Orbit-roll valve....2217
Stop valve....2221
Steering relief valve....2222
Steering cylinder....2223
Emergency steering motor....2225
Emergency steering pump....2226
Brake system....2228
Brake system....2229
Brake piping diagram....2229
Charge valve....2230
Brake valve....2237
Accumulator (for brake)....2242
Slack adjuster....2243
Brake....2245
Parking brake control....2250
Parking brake....2251
Parking brake solenoid valve....2253
Emergency parking brake release valve....2255
Undercarriage and frame....2258
Undercarriage and frame....2259
Tires....2263
Hydraulic system, Part 1....2266
Hydraulic system, Part 1....2267
Hydraulic piping diagram....2267
Work equipment control lever linkage....2270
Hydraulic tank....2271
Power train pump....2273
Work equipment pump....2275
Work equipment control valve....2295
CLSS....2306
Each function and operation of each valve....2311
Hydraulic system, Part 2....2326
Hydraulic system, Part 2....2327
PPC valve....2327
Accumulator (for PPC circuit)....2333
Accumulator (for ECSS)....2334
Work equipment....2336
Work equipment....2337
Work equipment linkage....2337
Bucket....2340
Bucket positioner and boom kick-out....2341
Work equipment cylinder....2347
Cab and its attachments....2350
Cab and its attachments....2352
Cab....2352
Air conditioner....2353
Electrical system, Part 1....2372
Electrical system, Part 1....2373
Machine monitor system....2373
Machine monitor....2378
Electrical system, Part 2....2400
Electrical system, Part 2....2401
Electrical system (Transmission controller system)....2401
Transmission controller....2425
Electrical system, Part 3....2428
Electrical system, Part 3....2429
Electric transmission control....2429
Combination switch....2431
Kickdown switch and hold switch....2433
KOMTRAX terminal system....2435
Engine starting circuit....2437
Engine stopping circuit....2439
Preheating circuit....2440
Engine power mode selector circuit....2441
Engine output derating function....2442
Automatic warm-up function....2442
Parking brake circuit....2443
Sensor....2445
20 Standard value table....2454
Standard service value table....2455
Standard value table for engine....2455
Standard value table for chassis....2456
30 Testing and adjusting....2466
Testing and adjusting, Part 1....2466
Testing and adjusting, Part 1....2468
Tools for testing, adjusting, and troubleshooting....2468
Measuring engine speed....2471
Measuring exhaust gas color....2473
Measuring exhaust temperature....2474
Adjusting valve clearance....2476
Measuring compression pressure....2478
Measuring blow-by pressure....2480
Measuring engine oil pressure....2481
Measuring intake air (boost) pressure....2483
Handling fuel system equipment....2484
Releasing residual pressure in fuel system....2484
Testing fuel pressure....2485
Testing fuel return and leak amount....2486
Bleeding air from fuel circuit....2489
Testing fuel circuit for leakage....2491
Handling of reduced cylinder mode operation....2492
Handling of no injection cranking operation....2492
Handling controller voltage circuit....2493
Testing and adjusting air conditioner compressor belt tension....2496
Testing and adjusting alternator belt tension....2497
Adjusting transmission speed sensor....2498
Measuring directional lever....2500
Measuring and adjusting power train oil pressure....2501
Procedure for flushing torque converter and transmission hydraulic circuit....2516
Method of moving machine when transmission valve is broken....2517
Testing and adjusting steering stop valve....2520
Testing and adjusting steering wheel....2522
Testing steering oil pressure....2524
Bleeding air from steering circuit....2527
Testing and adjusting, Part 2....2530
Testing and adjusting, Part 2....2532
Testing hydraulic drive fan....2532
Bleeding air from hydraulic drive fan circuit....2534
Measuring brake pedal....2536
Measuring brake performance....2538
Testing and adjusting accumulator charge pressure....2539
Testing wheel brake oil pressure....2540
Measuring wear of wheel brake disc....2542
Bleeding air from wheel brake circuit....2543
Releasing residual pressure in brake accumulator circuit....2544
Testing parking brake performance....2544
Measuring parking brake oil pressure....2545
Manual release method for parking brake....2548
Measuring and adjusting work equipment control lever....2549
Measuring and adjusting work equipment PPC oil pressure....2550
Measuring and adjusting work equipment oil pressure....2553
Bleeding air from work equipment circuit....2557
Releasing residual pressure in work equipment circuit....2558
Testing and adjusting bucket positioner....2559
Testing and adjusting boom kick out....2561
Checking proximity switch operation pilot lamp....2562
Procedure for testing diodes....2563
Preparation work for troubleshooting for electrical system....2564
Starting KOMTRAX terminal operations....2567
Indicator lamps of KOMTRAX terminal....2571
Adjusting machine monitor....2574
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....2575
Testing and adjusting, Part 3....2578
Testing and adjusting, Part 3....2579
Special functions of machine monitor (EMMS)....2579
Pm-clinic inspection table....2642
40 Troubleshooting....2646
Failure code table and fuse locations....2646
Failure code table and fuse locations....2647
Failure code table....2647
Fuse locations....2659
General information on troubleshooting....2664
General information on troubleshooting....2665
Points to remember when troubleshooting....2665
Sequence of events in troubleshooting....2666
Testing before troubleshooting....2667
Classification and procedures of troubleshooting....2668
Information contained in troubleshooting table....2671
Connection table for connector pin numbers....2673
T-branch box and T-branch adapter table....2696
Troubleshooting by failure code (Display of code), Part 1....2700
Troubleshooting by failure code (Display of code), Part 1....2702
Failure code [1500L0] (TORQFLOW transmission: Double meshing)....2702
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)....2703
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)....2705
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)....2707
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)....2709
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)....2711
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)....2713
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)....2715
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)....2717
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)....2719
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)....2721
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)....2723
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)....2725
Failure code [2F00MA] (Parking brake: Malfunction)....2727
Failure code [2G43ZG] (Accumulator: Low oil pressure)....2729
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)....2731
Troubleshooting by failure code (Display of code), Part 2....2734
Troubleshooting by failure code (Display of code), Part 2....2737
Failure code [AA1ANX] (Air cleaner: Clogging)....2737
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)....2739
Failure code [AB00MA] (Alternator: Malfunction)....2741
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)....2743
Failure code [B@BAZK] (Engine oil: Low level)....2746
Failure code [B@BCNS] (Coolant: Overheating)....2747
Failure code [B@BCZK] (Coolant: Low level)....2749
Failure code [B@C7NS] (Brake oil: Overheating)....2751
Failure code [b@CENS] (Torque converter oil: Overheating)....2753
Failure code [B@CENS] (Torque converter oil: Overheating)....2755
Failure code [B@HANS] (Hydraulic oil: Overheating)....2757
Failure code [CA111] (Abnormality in engine controller)....2759
Failure code [CA115] (Engine Ne or Bkup speed sensor error)....2762
Failure code [CA122] (Charge pressure sensor high error)....2763
Failure code [CA123] (Charge pressure sensor low error)....2765
Failure code [CA131] (Throttle sensor high error)....2767
Failure code [CA132] (Throttle sensor low error)....2769
Failure code [CA135] (Engine oil pressure sensor high error)....2771
Failure code [CA141] (Engine oil pressure sensor low error)....2773
Failure code [CA144] (Coolant sensor high error)....2775
Failure code [CA145] (Coolant sensor low error)....2777
Failure code [CA153] (Charge temperature sensor high error)....2779
Failure code [CA154] (Charge temperature sensor low error)....2781
Failure code [CA187] (Sensor power supply 2 low error)....2783
Failure code [CA221] (Atmospheric pressure sensor high error)....2784
Failure code [CA222] (Atmospheric pressure sensor low error)....2786
Failure code [CA227] (Sensor power supply 2 high error)....2787
Failure code [CA234] (Engine overspeed)....2789
Failure code [CA238] (Ne speed sensor power supply error)....2791
Troubleshooting by failure code (Display of code), Part 3....2794
Troubleshooting by failure code (Display of code), Part 3....2797
Failure code [CA263] (Fuel temperature sensor high error)....2797
Failure code [CA265] (Fuel temperature sensor low error)....2799
Failure code [CA271] (PCV1 Short circuit)....2801
Failure code [CA272] (PCV1 Disconnection)....2803
Failure code [CA273] (PCV2 Short circuit)....2805
Failure code [CA274] (PCV2 Disconnection)....2807
Failure code [CA322] (Injector #1 (L/B #1) open/short error)....2809
Failure code [CA323] (Injector #5 (L/B #5) open/short error)....2811
Failure code [CA324] (Injector #3 (L/B #3) open/short error)....2813
Failure code [CA325] (Injector #6 (L/B #6) open/short error)....2815
Failure code [CA331] (Injector #2 (L/B #2) open/short error)....2817
Failure code [CA332] (Injector #4 (L/B #4) open/short error)....2819
Failure code [CA342] (Calibration code inconsistency)....2821
Failure code [CA351] (Injectors drive circuit error)....2822
Failure code [CA352] (Sensor power supply 1 low error)....2824
Failure code [CA386] (Sensor power supply 1 high error)....2825
Failure code [CA431] (Idle validation switch error)....2827
Failure code [CA432] (Idle validation action error)....2829
Failure code [CA441] (Battery voltage low error)....2831
Failure code [CA442] (Battery voltage high error)....2834
Failure code [CA449] Common rail pressure high error 2....2836
Failure code [CA451] (Common rail pressure sensor high error)....2837
Failure code [CA452] (Common rail pressure sensor low error)....2839
Failure code [CA553] (Common rail pressure high error 1)....2840
Failure code [CA554] (Common rail pressure sensor in-range error)....2841
Failure code [CA559] (Supply pump pressure very low error)....2842
Failure code [CA689] (Engine Ne speed sensor error)....2846
Failure code [CA731] (Engine Bkup speed sensor phase error)....2848
Failure code [CA757] (All continuous data lost error)....2848
Failure code [CA778] (Engine Bkup speed sensor error)....2849
Failure code [CA1228] (EGR valve servo error 1)....2851
Failure code [CA1625] (EGR valve servo error 2)....2852
Failure code [CA1633] (KOMNET datalink timeout error)....2853
Failure code [CA2185] (Throttle sensor supply voltage high error)....2855
Failure code [CA2186] (Throttle sensor power supply low error)....2856
Troubleshooting by failure code (Display of code), Part 4....2858
Troubleshooting by failure code (Display of code), Part 4....2860
Failure code [CA2249] (Supply pump pressure very low error 2)....2860
Failure code [CA2271] (EGR valve lift sensor high error)....2861
Failure code [CA2272] (EGR valve lift sensor low error)....2863
Failure code [CA2351] (EGR valve solenoid operation short circuit)....2864
Failure code [CA2352] (EGR valve solenoid operation disconnect)....2866
Failure code [CA2555] (Intake heater relay disconnection error)....2867
Failure code [CA2556] (Intake heater relay short circuit error)....2869
Failure code [D150KA] (Emergency steering relay: Disconnection)....2871
Failure code [D150KB] (Emergency steering relay: Short circuit)....2873
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)....2875
Failure code [D160KA] (Backup lamp relay: Disconnection)....2877
Failure code [D160KB] (Backup lamp relay: Short circuit)....2879
Failure code [D160KZ] (Backup lamp relay: Disconnection or shortcircuit)....2881
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)....2883
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)....2885
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)....2887
Failure code [D192KA] (ECSS solenoid: Disconnection)....2889
Failure code [D192KB] (ECSS solenoid: Short circuit)....2890
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)....2891
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)....2892
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)....2894
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)....2896
Failure code [D5ZHKA] (Terminal C signal: Disconnection)....2898
Failure code [D5ZHKB] (Terminal C signal: Short circuit)....2902
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)....2905
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)....2910
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)....2913
Failure code [DAF3KK] (Machine monitor: Low source voltage (input))....2915
Failure code [DAF5KP] (Machine monitor: Low output voltage)....2917
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))....2921
Troubleshooting by failure code (Display of code), Part 5....2924
Troubleshooting by failure code (Display of code), Part 5....2926
Failure code [DAQ0KK] (Transmission controller: Low source voltage)....2926
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)....2928
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))....2929
Failure code [DAQ9KQ] (Transmission controller model selection:Disagreement of model selection signals)....2931
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))....2932
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)....2934
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)....2935
Failure code [DB90KK] Work equipment controller: Low source voltage (input)....2937
Failure code [DB90KT] Work equipment controller: Abnormality in controller....2939
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)....2940
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range....2942
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)....2945
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system))....2946
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)....2948
Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation)....2949
Failure code [DD15LD] __ switch (Panel switch 1): Switch is kept pressed for long time....2953
Failure code [DD16LD] __ switch (Panel switch 2): Switch is kept pressed for long time....2955
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time....2957
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time....2959
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time....2961
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time....2963
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time....2965
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time....2967
Failure code [DD1GLD] Load meter mode selector switch (+/): Switch is kept pressed for long time....2969
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)....2971
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)....2973
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)....2975
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)....2977
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)....2981
Troubleshooting by failure code (Display of code), Part 6....2984
Troubleshooting by failure code (Display of code), Part 6....2987
Failure code [DDE5MA] (Emergency steering drive switch:Malfunction)....2987
Failure code [DDK3KA] (Right FNR switch: Disconnection)....2989
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)....2992
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)....2995
Failure code [DDK6KA] (FNR lever switch: Disconnection)....2997
Failure code [DDK6KB] (FNR lever switch: Short circuit)....3001
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)....3003
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)....3005
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)....3007
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for longtime)....3009
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)....3011
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)....3013
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)....3017
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)....3019
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)....3021
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)....3023
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)....3025
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)....3027
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)....3029
Troubleshooting by failure code (Display of code), Part 7....3032
Troubleshooting by failure code (Display of code), Part 7....3035
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)....3035
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out ofinput signal range)....3037
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)....3039
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)....3041
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)....3043
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)....3045
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)....3048
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)....3051
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)....3054
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)....3057
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)....3060
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)....3063
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)....3066
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)....3069
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)....3072
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)....3075
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)....3078
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)....3080
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)....3083
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)....3087
Troubleshooting by failure code (Display of code), Part 8....3090
Troubleshooting by failure code (Display of code), Part 8....3092
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)....3092
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)....3095
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)....3097
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)....3100
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)....3102
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)....3105
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)....3107
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)....3109
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)....3111
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)....3113
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)....3115
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)....3117
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)....3119
Failure code [DV00KB] (Alarm buzzer: Short circuit)....3121
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)....3123
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)....3125
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)....3127
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)....3129
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)....3130
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)....3131
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)....3133
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)....3134
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)....3135
Troubleshooting by failure code (Display of code), Part 9....3138
Troubleshooting by failure code (Display of code), Part 9....3140
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)....3140
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)....3141
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit withpower supply line)....3142
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)....3144
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)....3145
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)....3146
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)....3148
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)....3149
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)....3150
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)....3151
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)....3153
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)....3155
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)....3157
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)....3159
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)....3161
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)....3163
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)....3165
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)....3167
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)....3169
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)....3171
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)....3173
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)....3175
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)....3176
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)....3177
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)....3179
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)....3181
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)....3183
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)....3185
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)....3187
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit withpower supply line)....3189
Troubleshooting by failure code (Display of code), Part 10....3192
Troubleshooting by failure code (Display of code), Part 10....3195
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)....3195
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)....3197
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)....3199
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)....3201
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)....3203
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)....3205
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....3207
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....3209
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)....3211
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....3213
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....3215
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)....3217
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)....3219
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)....3221
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)....3223
Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection)....3225
Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit)....3227
Failure code [DXHJKY] (3-spool valve extend EPC solenoid: Short circuit with power supply line)....3229
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)....3231
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)....3233
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)....3235
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)....3237
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)....3239
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)....3241
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)....3243
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)....3245
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)....3247
Troubleshooting of electrical system (E-mode)....3250
Troubleshooting of electrical system (E-mode)....3252
Before carrying out troubleshooting for electrical system....3252
Information in troubleshooting table....3255
E-1 Engine does not start....3257
E-2 Wiper does not operate....3263
E-3 Windshield washer does not operate....3267
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not lightup or go off....3270
E-5 Working lamp does not light up or go off....3278
E-6 Turn signal lamp and hazard lamp do not light up or go off....3283
E-7 Brake lamp does not light or it keeps lighting up....3289
E-8 Backup lamp does not light or it keeps lighting up....3291
E-9 Backup buzzer does not sound or it keeps sounding....3293
E-10 Horn does not sound or it keeps sounding....3295
E-11 Alarm buzzer does not sound or it keeps sounding....3297
E-12 Air conditioner does not operate or stop....3299
E-13 The KOMTRAX system does not work properly....3302
Troubleshooting of hydraulic and mechanical system (H-mode)....3306
Troubleshooting of hydraulic and mechanical system (H-mode)....3308
Method of using troubleshooting chart....3308
Table of failure modes and causes....3311
H-1 The machine does not start....3315
H-2 Torque converter lockup is not switched off (engine stalls) [Machinewith lockup clutch (if equipped)]....3317
H-2 Torque converter lockup is not switched off (engine stalls) [Machinewith lockup clutch (if equipped)]....3317
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]....3317
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]....3318
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted....3319
H-5 Shocks are large at the times of starting and shifting gear....3321
H-6 Time lag is large at the times of starting and shifting gear....3323
H-7 The torque converter oil temperature is high....3325
H-8 Steering does not turn....3326
H-9 Steering does not turn [Machine with joystick steering (if equipped)]....3327
H-10 Steering response is low....3328
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]....3329
H-12 Steering is heavy....3330
H-13 When machine turns, it shakes or makes large shocks....3331
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]....3332
H-15 The wheel brake does not work or does not work well....3333
H-16 The wheel brake is not released or it drags....3334
H-17 The parking brake does not work or does not work well....3335
H-18 The parking brake is not released or it drags (including emergency release system)....3336
H-19 Lift arm does not rise....3337
H-20 Lift arm speed is low or rising force of lift arm is insufficient....3338
H-21 When rising, the lift arm comes to move slowly at specific height....3339
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)....3339
H-23 Hydraulic drifts of the lift arm is large....3339
H-24 The lift arm wobbles during operation....3339
H-25 Bucket does not tilt back....3340
H-26 Bucket speed is low or tilting back force is insufficient....3341
H-27 The bucket comes to operate slowly in the midst of tilting-back....3342
H-28 The bucket cylinder cannot hold down the bucket....3342
H-29 Hydraulic drifts of the bucket is large....3342
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to HOLD)....3342
H-31 Lift arm and bucket control levers do not move smoothly and are heavy....3343
H-32 During operation of the machine, engine speed lowers remarkablyor engine stalls....3344
H-33 Large shock is made when work equipment starts and stops....3344
H-34 When work equipment circuit is relieved singly, other work equipment moves....3344
H-35 ECSS does not operate, and pitching, bouncing occur....3345
Troubleshooting of engine (S-mode)....3348
Troubleshooting of engine (S-mode)....3350
Method of using troubleshooting chart....3350
S-1 Starting performance is poor....3353
S-2 Engine does not start....3355
S-3 Engine does not pick up smoothly....3359
S-4 Engine stops during operation....3360
S-5 Engine does not rotate smoothly....3361
S-6 Engine lacks output (or lacks power)....3362
S-7 Exhaust smoke is black (Incomplete combustion)....3363
S-8 Oil is consumed much (or exhaust gas color is blue)....3365
S-9 Engine oil becomes contaminated quickly....3366
S-10 Fuel consumption is excessive....3367
S-11 Coolant contains oil (blows back or reduces)....3368
S-12 Oil pressure drops....3369
S-13 Oil level rises (Water, fuel in oil)....3370
S-14 Coolant temperature rises too high (Overheating)....3372
S-15 Abnormal noise is made....3373
S-16 Vibration is excessive....3374
50 Disassembly and assembly....3376
General information on disassembly andassembly....3376
General information on disassembly and assembly....3377
How to read this manual....3377
Coating materials list....3379
Special tools list....3382
Sketches of special tools....3386
Engine and cooling system....3398
Engine and cooling system....3399
Removal and installation of engine assembly....3399
Removal and installation of hood....3403
Removal and installation of radiator assembly....3406
Removal and installation of aftercooler assembly....3409
Removal and installation of oil cooler assembly....3411
Removal and installation of cooling fan and drive motor assembly....3413
Removal and installation of fuel supply pump assembly....3416
Removal and installation of fuel injector assembly....3421
Removal and installation of cylinder head assembly....3426
Removal and installation of fuel tank assembly....3437
Power train, Part 1....3442
Power train, Part 1....3443
Removal and installation of torque converter and transmission assembly....3443
Disassembly and assembly of torque converter assembly (Standard specification)....3449
Disassembly and assembly of torque converter assembly (Lockup specification)....3453
Disassembly and assembly of transmission assembly....3460
Disassembly and assembly of transmission clutch pack assembly....3474
Disassembly and assembly of parking brake assembly....3491
Power train, Part 2....3500
Power train, Part 2....3501
Removal and installation of front axle assembly....3501
Removal and installation of rear axle assembly....3503
Disassembly and assembly of axle housing assembly....3509
Disassembly and assembly of differential assembly....3518
Undercarriage and frame....3538
Undercarriage and frame....3539
Removal and installation of centerhinge pin....3539
Removal and installation of counterweight....3547
Hydraulic system....3550
Hydraulic system....3551
Removal and installation of steering demand valve assembly....3551
Removal and installation of work equipment valve assembly....3554
Removal and installation of brake charge valve assembly....3557
Removal and installation of hydraulic tank assembly....3558
Removal and installation ofsteering and power train pump assembly....3560
Removal and installation of workequipment and cooling fan pump assembly....3562
Work equipment....3566
Work equipment....3567
Removal and installation of work equipment assembly....3567
Cab and its attachments....3572
Cab and its attachments....3573
Removal and installation of operator's cab and floor frame assembly....3573
Removal and installation of operator's cab glass (stuck glass)....3577
Disassembly and assembly of operator's seat assembly....3585
Electrical system....3596
Electrical system....3597
Removal and installation of air conditioner unit assembly....3597
Removal and installation of engine controller assembly....3601
Removal and installation of transmission controller assembly....3602
Removal and installation of KOMTRAX controller assembly....3603
90 Diagrams and drawings....3606
Hydraulic diagrams and drawings....3606
Hydraulic diagrams and drawings....3607
Power train hydraulic circuit diagram....3607
Hydraulic circuit diagram....3610
Electrical diagrams and drawings....3613
Electrical diagrams and drawings....3615
Electrical circuit diagram (1/2)....3615
Electrical circuit diagram (2/2)....3617
Connector arrangement diagram....3619
TEN00124-05 - Wheel Loader WA480-6 Operation & Maintenance Manual....3622
COVER....3622
FOREWORD....3623
BEFORE READING THIS MANUAL....3624
SAFETY INFORMATION....3627
INTRODUCTION....3628
USE OF MACHINE....3628
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....3629
NECESSARY INFORMATION....3630
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....3630
ENGINE SERIAL NO. PLATE....3630
POSITION OF SERVICE METER....3631
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....3631
CONTENTS....3632
SAFETY....3635
SAFETY....3636
SAFETY LABELS....3639
LOCATION OF SAFETY LABELS....3639
SAFETY LABELS....3640
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....3647
PRECAUTIONS BEFORE STARTING OPERATION....3647
PREPARATIONS FOR SAFE OPERATION....3647
FIRE PREVENTION....3649
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....3650
DO NOT GET CAUGHT IN ARTICULATING PORTION....3653
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....3653
UNAUTHORIZED MODIFICATION....3653
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....3653
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....3654
PRECAUTIONS FOR OPERATION....3655
PRECAUTIONS FOR JOBSITE....3655
STARTING ENGINE....3657
OPERATION....3659
TRANSPORTATION....3666
TOWING....3667
PRECAUTIONS FOR MAINTENANCE....3668
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....3668
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....3673
TIRES....3678
OPERATION....3681
GENERAL VIEW....3682
GENERAL VIEW OF MACHINE....3682
GENERAL VIEW OF CONTROLS AND GAUGES....3683
EXPLANATION OF COMPONENTS....3686
MACHINE MONITOR....3686
SWITCHES....3720
CONTROL LEVERS, PEDALS....3735
STEERING TILT LOCK LEVER....3740
CAP WITH LOCK....3740
FRAME LOCK BAR....3741
TOWING PIN....3742
GREASE PUMP....3742
OPENING, CLOSING CAB DOORS, WINDOWS....3743
BACKUP ALARM....3747
FUSE....3748
SLOW BLOW FUSE....3749
POWER OUTLET....3750
AM/FM RADIO....3751
AM/FM RADIO-CASSETTE STEREO....3757
HANDLING AUTO AIR CONDITIONER....3765
AIR CONDITIONER....3772
HANDLING CAB WIPER....3779
OPERATION....3780
CHECK BEFORE STARTING ENGINE, ADJUST....3780
STARTING ENGINE....3798
CHECKS AFTER STARTING ENGINE....3802
OPERATIONS AND CHECKS AFTER STARTING ENGINE....3803
STOPPING ENGINE....3805
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....3806
TURNING....3815
OPERATION OF WORK EQUIPMENT....3818
WORK POSSIBLE USING WHEEL LOADER....3820
PRECAUTIONS FOR OPERATION....3826
ADJUSTING WORK EQUIPMENT POSTURE....3828
PARKING MACHINE....3830
CHECKS AFTER COMPLETION OF OPERATION....3832
LOCKING....3833
HANDLING THE TIRES....3834
TRANSPORTATION....3836
TRANSPORTATION PROCEDURE....3836
LOADING, UNLOADING WORK WITH TRAILERS....3836
LIFTING MACHINE....3840
COLD WEATHER OPERATION....3842
PRECAUTIONS FOR LOW TEMPERATURE....3842
PRECAUTIONS AFTER COMPLETION OF WORK....3843
AFTER COLD WEATHER....3843
LONG-TERM STORAGE....3844
BEFORE STORAGE....3844
DURING STORAGE....3844
AFTER STORAGE....3844
TROUBLESHOOTING....3845
WHEN MACHINE RUNS OUT OF FUEL....3845
METHOD OF TOWING MACHINE....3845
IF BATTERY IS DISCHARGED....3850
OTHER TROUBLE....3853
MAINTENANCE....3859
GUIDES TO MAINTENANCE....3860
OUTLINES OF SERVICE....3862
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....3862
OUTLINE OF ELECTRIC SYSTEM....3865
WEAR PARTS....3866
WEAR PARTS LIST....3866
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....3867
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....3868
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....3869
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....3870
TORQUE LIST....3870
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....3871
MAINTENANCE SCHEDULE CHART....3873
MAINTENANCE SCHEDULE CHART....3873
SERVICE PROCEDURE....3875
INITIAL 250 HOURS SERVICE....3875
INITIAL 1000 HOURS SERVICE....3875
WHEN REQUIRED....3876
CHECK BEFORE STARTING....3896
EVERY 50 HOURS SERVICE....3897
EVERY 100 HOURS SERVICE....3898
EVERY 250 HOURS SERVICE....3900
EVERY 500 HOURS SERVICE....3908
EVERY 1000 HOURS SERVICE....3911
EVERY 2000 HOURS SERVICE....3916
EVERY 4000 HOURS SERVICE....3922
EVERY 8000 HOURS SERVICE....3925
SPECIFICATIONS....3927
SPECIFICATIONS....3928
ATTACHMENTS, OPTIONS....3929
SELECTING BUCKET AND TIRES....3930
HANDLING TORQUE CONVERTER LOCK-UP....3931
GENERAL LOCATIONS....3931
METHOD OF OPERATION....3932
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....3933
HANDLING JOYSTICK STEERING SYSTEM....3934
EXPLANATION OF COMPONENTS....3934
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....3938
GETTING IN OR OUT OF OPERATOR'S CAB....3939
SEAT ADJUSTMENT....3940
ADJUSTMENT OF JOYSTICK CONSOLE....3942
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL....3943
PRECAUTIONS FOR STEERING WITH JOYSTICK....3944
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....3944
HANDLING MULTI-FUNCTION LEVER....3947
EXPLANATION OF COMPONENTS....3947
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....3952
HANDLING MACHINES EQUIPPED WITH KOMTRAX....3954
BASIC PRECAUTIONS....3954
INDEX....3955
TEN00340-03 - Wheel Loader WA480-6 Operation & Maintenance Manual....3959
COVER....3959
FOREWORD....3960
BEFORE READING THIS MANUAL....3961
SAFETY INFORMATION....3962
INTRODUCTION....3963
USE OF MACHINE....3963
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....3964
VISIBILITY FROM OPERATOR'S SEAT....3964
NECESSARY INFORMATION....3965
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....3965
ENGINE SERIAL NO. PLATE....3965
POSITION OF SERVICE METER....3966
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....3966
CONTENTS....3967
SAFETY....3972
SAFETY....3973
SAFETY LABELS....3976
LOCATION OF SAFETY LABELS....3976
SAFETY LABELS....3977
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....3984
PRECAUTIONS BEFORE STARTING OPERATION....3984
PREPARATIONS FOR SAFE OPERATION....3984
FIRE PREVENTION....3986
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....3987
DO NOT GET CAUGHT IN ARTICULATING PORTION....3990
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....3990
UNAUTHORIZED MODIFICATION....3990
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....3991
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....3991
PRECAUTIONS FOR OPERATION....3992
PRECAUTIONS FOR JOBSITE....3992
STARTING ENGINE....3994
OPERATION....3997
TRANSPORTATION....4003
TOWING....4004
PRECAUTIONS FOR MAINTENANCE....4005
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....4005
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....4009
TIRES....4014
OPERATION....4016
GENERAL VIEW....4017
GENERAL VIEW OF MACHINE....4017
GENERAL VIEW OF CONTROLS AND GAUGES....4018
EXPLANATION OF COMPONENTS....4021
MACHINE MONITOR....4021
SWITCHES....4054
CONTROL LEVERS, PEDALS....4069
STEERING TILT LOCK LEVER....4074
CAP WITH LOCK....4075
FRAME LOCK BAR....4075
TOWING PIN....4076
GREASE PUMP....4076
OPENING, CLOSING CAB DOORS, WINDOWS....4077
BACKUP ALARM....4081
FUSE....4082
SLOW BLOW FUSE....4083
POWER OUTLET....4084
AM/FM RADIO-CASSETTE STEREO....4085
AM/FM RADIO....4093
AIR CONDITIONER....4099
HANDLING AUTO AIR CONDITIONER....4106
HANDLING CAB WIPER....4113
OPERATION....4114
CHECK BEFORE STARTING ENGINE, ADJUST....4114
STARTING ENGINE....4132
CHECKS AFTER STARTING ENGINE....4136
OPERATIONS AND CHECKS AFTER STARTING ENGINE....4137
STOPPING ENGINE....4139
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....4140
TURNING....4149
OPERATION OF WORK EQUIPMENT....4152
WORK POSSIBLE USING WHEEL LOADER....4154
PRECAUTIONS FOR OPERATION....4160
ADJUSTING WORK EQUIPMENT POSTURE....4162
PARKING MACHINE....4164
CHECKS AFTER COMPLETION OF OPERATION....4166
LOCKING....4167
HANDLING THE TIRES....4168
TRANSPORTATION....4170
TRANSPORTATION PROCEDURE....4170
LOADING, UNLOADING WORK WITH TRAILERS....4170
LIFTING MACHINE....4174
COLD WEATHER OPERATION....4176
PRECAUTIONS FOR LOW TEMPERATURE....4176
PRECAUTIONS AFTER COMPLETION OF WORK....4177
AFTER COLD WEATHER....4177
LONG-TERM STORAGE....4178
BEFORE STORAGE....4178
DURING STORAGE....4178
AFTER STORAGE....4178
TROUBLESHOOTING....4179
WHEN MACHINE RUNS OUT OF FUEL....4179
METHOD OF TOWING MACHINE....4179
IF BATTERY IS DISCHARGED....4184
OTHER TROUBLE....4187
MAINTENANCE....4192
GUIDES TO MAINTENANCE....4193
OUTLINES OF SERVICE....4195
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....4195
OUTLINE OF ELECTRIC SYSTEM....4198
WEAR PARTS....4199
WEAR PARTS LIST....4199
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....4200
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....4201
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....4202
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....4203
TORQUE LIST....4203
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....4204
MAINTENANCE SCHEDULE CHART....4206
MAINTENANCE SCHEDULE CHART....4206
SERVICE PROCEDURE....4208
INITIAL 250 HOURS SERVICE....4208
INITIAL 1000 HOURS SERVICE....4208
WHEN REQUIRED....4209
CHECK BEFORE STARTING....4233
EVERY 50 HOURS SERVICE....4234
EVERY 100 HOURS SERVICE....4235
EVERY 250 HOURS SERVICE....4237
EVERY 500 HOURS SERVICE....4245
EVERY 1000 HOURS SERVICE....4248
EVERY 2000 HOURS SERVICE....4253
EVERY 4000 HOURS SERVICE....4259
EVERY 8000 HOURS SERVICE....4263
SPECIFICATIONS....4264
SPECIFICATIONS....4265
ATTACHMENTS, OPTIONS....4266
SELECTING BUCKET AND TIRES....4267
HANDLING TORQUE CONVERTER LOCK-UP....4268
GENERAL LOCATIONS....4268
METHOD OF OPERATION....4269
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....4270
HANDLING JOYSTICK STEERING SYSTEM....4271
EXPLANATION OF COMPONENTS....4271
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....4275
GETTING IN OR OUT OF OPERATOR'S CAB....4276
SEAT ADJUSTMENT....4277
ADJUSTMENT OF JOYSTICK CONSOLE....4279
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL....4280
PRECAUTIONS FOR STEERING WITH JOYSTICK....4281
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....4281
HANDLING MULTI FUNCTION MONO-LEVER....4284
EXPLANATION OF COMPONENTS....4284
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....4289
HANDLING LOAD METER....4291
OUTLINE OF LOAD METER....4291
PRINCIPLE OF LOAD METER MEASUREMENT....4293
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY....4295
USING LOAD METER....4297
CENTRAL LUBRICATION SYSTEM....4328
OPERATING THE CENTRAL LUBRICATION SYSTEM....4328
DISPLAY AND CONTROL UNIT....4329
CHANGING THE LUBRICATION INTERVAL TIMES....4330
HANDLING WHEEL STOPPER....4331
HANDLING BATTERY DISCONNECTOR SWITCH....4332
EXPLANATION OF COMPONENTS....4332
HANDLING....4333
RADIO/CD....4334
CONTENTS....4334
OPERATING ELEMENTS....4336
IMPORTANT INFORMATION....4337
CODE THEFT PROTECTION....4338
SWITCHING THE CAR AUDIO SYSTEM ON/OFF....4340
VOLUME CONTROL....4342
ADJUSTING THE TONE....4344
SETTING THE BALANCE AND FADER....4346
RADIO OPERATION....4347
TRAFFIC INFORMATION....4353
CD PLAYER OPERATION....4354
CD CHANGER OPERATION(OPTION)....4358
RC 10 P REMOTE CONTROL UNIT(OPTION)....4361
EXTERNAL AUDIO SOURCES....4363
SPECIFICATIONS....4364
ISO CONNECTOR....4365
HANDLING MACHINES EQUIPPED WITH KOMTRAX....4366
BASIC PRECAUTIONS....4366
INDEX....4368
