Komatsu Wheel Loader WA430 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA430, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA430 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: 13,857 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
Cover...1
00 Index and foreword...0
Index...3
Composition of shop manual...4
Table of contents...6
Foreword and general information...19
Safety notice...20
How to read the shop manual...25
Explanation of terms for maintenance standard...27
Handling of electric equipment and hydraulic component...29
Handling of connectors newly used for engines...38
How to read electric wire code...41
Precautions when carrying out operation...44
Method of disassembling and connecting push-pull type coupler...47
Standard tightening torque table...50
Conversion table...54
01 Specification...0
Specification and technical data...61
Specification dimension drawing...63
Specifications...64
Weight table...68
Table of fuel, coolant and lubricants...70
10 Structure, function and maintenance standard...0
Engine and cooling system...73
Engine mount and transmission mount...74
Cooling system...75
Cooling fan pump...76
Cooling fan motor...84
Power train...91
Power train...93
Power train system diagram...94
Drive shaft...96
Power train piping diagram...97
Torque converter...98
Transmission...106
Flow control valve...123
Transmission control valve...126
ECMV...130
Main relief valve and torque converter relief valve...136
Axle...138
Differential...140
Limited slip differential...146
Final drive...152
Steering system...159
Steering piping diagram...161
Steering column...162
Steering pump...163
Steering valve...175
Orbit-roll valve...190
Stop valve...194
Steering relief valve...195
Steering cylinder...196
Emergency steering motor...198
Emergency steering pump...199
Joystick steering lever linkage...200
Steering electric lever...201
Joystick EPC valve...202
Brake system...205
Brake piping diagram...206
Charge valve...207
Brake valve...214
Accumulator (for brake)...219
Brake...220
Parking brake control...225
Parking brake...226
Parking brake solenoid valve...228
Emergency parking brake release valve...230
Undercarriage and frame...233
Axle mount and center hinge pin...234
Tires...238
Hydraulic system, Part 1...241
Hydraulic piping diagram...242
Work equipment control lever linkage...245
Hydraulic tank...248
Power train pump...250
Work equipment pump...251
Work equipment control valve...262
CLSS...276
Each function and operation of each valve...280
Hydraulic system, Part 2...303
PPC valve...304
Stabilizer valve...312
Accumulator (for PPC circuit)...318
Accumulator (for ECSS)...319
Work equipment PPC cut-off solenoid valve...320
Work equipment...323
Work equipment linkage...324
Bucket...326
Bucket positioner and boom kick-out...327
Work equipment cylinder...333
Cab and its attachments...335
Cab...337
Air conditioner...338
Electrical system, Part 1...357
Machine monitor system...358
Machine monitor...362
Electrical system, Part 2...395
Electrical system (Transmission controller system)...396
Transmission controller...438
Electrical system (Work equipment controller system)...440
Work equipment controller...446
Electrical system, Part 3...449
Electric transmission control...450
Kickdown switch and hold switch...454
Load meter cancel switch and load meter subtotal switch...454
Multi-function knob...455
Joystick steering knob...456
KOMTRAX system...458
Engine starting circuit...460
Engine stopping circuit...462
Preheating circuit...463
Engine power mode selector circuit...464
Engine output derating function...465
Automatic warm-up function...465
Parking brake circuit...466
Sensor...468
20 Standard value table...0
Standard service value table...479
Standard value table for engine...480
Standard value table for chassis...481
30 Testing and adjusting...0
Testing and adjusting, Part 1...489
Tools for testing, adjusting, and troubleshooting...491
Testing engine speed...497
Testing exhaust gas color...499
Testing exhaust temperature...500
Adjusting valve clearance...502
Testing compression pressure...504
Testing blow-by pressure...508
Testing engine oil pressure...509
Testing intake air (boost) pressure...510
Handling fuel system equipment...511
Releasing residual pressure in fuel system...511
Testing fuel pressure...512
Testing fuel return and leak amount...518
Bleeding air from fuel circuit...520
Testing leakage in fuel system...521
Handling reduced cylinder mode operation...522
Handling no-injection cranking operation...522
Handling controller voltage circuit...523
Check of muffler and muffler stack for looseness and damage...524
Check of muffler function...524
Check of installed condition of cylinder head and manifolds...525
Check of engine piping for damage and looseness...525
Checking and replacing alternator belt...526
Checking and replacing auto- tensioner...528
Adjusting transmission speed sensor...530
Adjusting directional lever length...531
Adjusting gear shift lever length...531
Testing directional lever...532
Testing and adjusting power train oil pressure...533
Procedure for flushing torque converter and transmission hydraulic circuit...547
Method of moving machine when transmission valve is broken...548
Checking axle final drive for oil leakage...550
Checking drive shafts for looseness, play and damage...550
Testing and adjusting steering stop valve...551
Testing and adjusting steering wheel...553
Testing and adjusting steering oil pressure...555
Bleeding air from steering circuit...558
Testing and adjusting, Part 2...561
Testing hydraulic drive fan...563
Bleeding air from hydraulic drive fan circuit...565
Testing brake pedal...567
Testing and adjusting brake pedal linkage...568
Testing brake performance...569
Testing and adjusting accumulator charge pressure...570
Testing wheel brake oil pressure...571
Testing wear of wheel brake disc...573
Bleeding air from wheel brake circuit...574
Releasing residual pressure in brake accumulator circuit...575
Testing parking brake performance...576
Testing parking brake oil pressure...577
Testing wear of parking brake disc...579
Method of releasing parking brake manually...580
Testing and adjusting work equipment control lever...581
Testing and adjusting work equipment PPC oil pressure...582
Testing and adjusting work equipment oil pressure...585
Bleeding air from work equipment circuit...589
Releasing residual pressure in work equipment circuit...590
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator...591
Testing and adjusting bucket positioner...597
Testing and adjusting boom kickout...599
Checking proximity switch operation pilot lamp...600
Procedure for testing diodes...601
Preparation work for troubleshooting for electrical system...602
Starting KOMTRAX terminal operations...607
Indicator lamps of KOMTRAX terminal...612
Testing and adjusting, Part 3...617
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...618
Special functions of machine monitor (EMMS)...621
Pm-clinic inspection table...689
40 Troubleshooting...0
Failure code table and fuse locations...693
Failure code table...694
Fuse locations...705
General information on troubleshooting...709
Points to remember when troubleshooting...710
Sequence of events in troubleshooting...711
Testing before troubleshooting...712
Classification and procedures of troubleshooting...713
Information contained in troubleshooting table...716
Connection table for connector pin numbers...718
T- branch box and T- branch adapter table...754
Troubleshooting by failure code (Display of code), Part 1...759
Failure code [1500L0] (TORQFLOW transmission: Double meshing)...761
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...762
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...764
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...766
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...768
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...770
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...772
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...774
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...776
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...778
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...780
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...782
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...784
Failure code [2F00MA] (Parking brake: Malfunction)...786
Failure code [2G43ZG] (Accumulator: Low oil pressure)...788
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)...790
Troubleshooting by failure code (Display of code), Part 2...795
Failure code [AA1ANX] (Air cleaner: Clogging)...798
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...800
Failure code [AB00MA] (Alternator: Malfunction)...802
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...804
Failure code [B@BAZK] (Engine oil: Low level)...805
Failure code [B@BCNS] (Coolant: Overheating)...806
Failure code [B@BCZK] (Coolant: Low level)...808
Failure code [B@BEBF] (Water in fuel error)...810
Failure code [b@CENS] (Torque converter oil: Overheating)...812
Failure code [B@CENS] (Torque converter oil: Overheating)...814
Failure code [B@HANS] (Hydraulic oil: Overheating)...816
Failure code [CA111] (Abnormality in engine controller)...818
Failure code [CA115] (Engine Ne or Bkup speed sensor error)...819
Failure code [CA122] (Charge pressure sensor high error)...820
Failure code [CA123] (Charge pressure sensor low error)...822
Failure code [CA131] (Throttle sensor high error)...824
Failure code [CA132] (Throttle sensor low error)...826
Failure code [CA144] (Coolant sensor high error)...828
Failure code [CA145] (Coolant sensor low error)...830
Failure code [CA153] (Charge temperature sensor high error)...832
Failure code [CA154] (Charge temperature sensor low error)...834
Failure code [CA155] (Derating of speed by abnormally high charge temperature)...836
Failure code [CA187] (Sensor power supply 2 low error)...838
Failure code [CA221] (Atmospheric pressure sensor high error)...840
Failure code [CA222] (Atmospheric sensor low error)...842
Failure code [CA227] (Sensor power supply 2 high error)...844
Failure code [CA234] (Engine overspeed)...845
Failure code [CA238] (Ne speed sensor power supply error)...846
Troubleshooting by failure code (Display of code), Part 3...849
Failure code [CA271] (IMV/PCV1 Short circuit)...851
Failure code [CA272] (IMV/PCV1 Disconnection)...852
Failure code [CA281] High pressure pump error...854
Failure code [CA322] (Injector #1 open/short error)...856
Failure code [CA323] (Injector #5 open/short error)...858
Failure code [CA324] (Injector #3 open/short error)...860
Failure code [CA325] (Injector #6 open/short error)...862
Failure code [CA331] (Injector #2 open/short error)...864
Failure code [CA332] (Injector #4 open/short error)...866
Failure code [CA342] (Calibration code inconsistency)...868
Failure code [CA351] (Injectors drive circuit error)...870
Failure code [CA352] (Sensor power supply 1 low error)...872
Failure code [CA386] (Sensor power supply 1 high error)...874
Failure code [CA428] (Abnormally high level in water sensor)...875
Failure code [CA429] (Abnormally low level in water sensor)...876
Failure code [CA431] (Idle validation switch error)...878
Failure code [CA432] (Idle validation action error)...880
Failure code [CA435] (Engine oil pressure switch error)...882
Failure code [CA441] (Battery voltage low error)...883
Failure code [CA442] (Battery voltage high error)...886
Failure code [CA449] Common rail pressure high error 2...888
Failure code [CA451] (Common rail pressure sensor high error)...892
Failure code [CA452] (Common rail pressure sensor low error)...894
Failure code [CA488] (Derating of torque by abnormally high charge temperature)...896
Failure code [CA553] (Common rail pressure high error 1)...897
Failure code [CA559] (Supply pump pressure very low error)...898
Failure code [CA689] (Engine Ne speed sensor error)...900
Failure code [CA731] (Engine Bkup speed sensor phase error)...902
Failure code [CA757] (All continuous data lost error)...903
Failure code [CA778] (Engine Bkup speed sensor error)...906
Failure code [CA1633] (KOMNET datalink timeout error)...908
Failure code [CA2185] (Throttle sensor power supply voltage high error)...910
Failure code [CA2186] (Throttle sensor power supply voltage low error)...911
Troubleshooting by failure code (Display of code), Part 4...913
Failure code [CA2249] (Supply pump pressure very low error 2)...915
Failure code [CA2265] (Abnormally high level in electric lift pump)...916
Failure code [CA2266] (Abnormally low level in electric lift pump)...918
Failure code [CA2311] (Abnormality in IMV solenoid)...920
Failure code [CA2555] (Intake heater relay disconnection error)...922
Failure code [CA2556] (Intake heater relay short circuit error)...924
Failure code [D150KA] (Emergency steering relay: Disconnection)...926
Failure code [D150KB] (Emergency steering relay: Short circuit)...928
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...930
Failure code [D160KA] (Backup lamp relay: Disconnection)...932
Failure code [D160KB] (Backup lamp relay: Short circuit)...934
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)...936
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...938
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...940
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...942
Failure code [D192KA] (ECSS solenoid: Disconnection)...944
Failure code [D192KB] (ECSS solenoid: Short circuit)...945
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...946
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...948
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...950
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...952
Failure code [D5ZHKA] (Terminal C signal: Disconnection)...955
Failure code [D5ZHKB] (Terminal C signal: Short circuit)...959
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)...962
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...967
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...970
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...972
Failure code [DAF5KP] (Machine monitor: Low output voltage)...974
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)...978
Troubleshooting by failure code (Display of code), Part 5...981
Failure code [DAQ0KK] (Transmission controller: Low source voltage)...984
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...986
Failure code [DAQ1KA] (Terminal ACC input: Disconnection)...987
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)...990
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...992
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)...993
Failure code [DAQRMA] (Transmission controller option setting: Disagreement of option selection)...996
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...998
Failure code [DB90KK] Work equipment controller: Low source voltage (input)...1000
Failure code [DB90KT] Work equipment controller: Abnormality in controller...1002
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...1004
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...1006
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...1009
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)...1010
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...1012
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...1013
Failure code [DD15LD] ? switch (Panel switch 1): Switch is kept pressed for long time...1016
Failure code [DD16LD] ? switch (Panel switch 2): Switch is kept pressed for long time...1018
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...1020
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time...1022
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time...1024
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time...1026
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...1028
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time...1030
Failure code [DD1GLD] Load meter mode selector switch (+/?): Switch is kept pressed for long time...1032
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...1034
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...1036
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...1038
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...1040
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)...1044
Troubleshooting by failure code (Display of code), Part 6...1047
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)...1050
Failure code [DDK3KA] (Right FNR switch: Disconnection)...1052
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...1055
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...1058
Failure code [DDK6KA] (FNR lever switch: Disconnection)...1060
Failure code [DDK6KB] (FNR lever switch: Short circuit)...1064
Failure code [DDS5KA] (Steering pressure switch: Disconnected)...1066
Failure code [DDS5KB] (Steering pressure switch: Short-circuit)...1068
Failure code [DDS5L6] (Steering: Low oil pressure)...1070
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...1072
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...1074
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...1076
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...1078
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...1080
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...1082
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...1086
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...1088
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...1090
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...1092
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...1094
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...1096
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...1098
Troubleshooting by failure code (Display of code), Part 7...1101
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...1104
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)...1106
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...1108
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...1110
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...1112
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...1114
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...1116
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...1118
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...1121
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)...1124
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)...1127
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)...1130
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)...1133
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...1136
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...1139
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)...1142
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...1145
Troubleshooting by failure code (Display of code), Part 8...1149
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)...1151
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...1154
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...1156
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)...1160
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)...1162
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)...1166
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)...1168
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...1170
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)...1172
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...1174
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...1176
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...1178
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)...1180
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)...1182
Failure code [DV00KB] (Alarm buzzer: Short circuit)...1184
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...1186
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...1188
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)...1190
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...1192
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...1193
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)...1194
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...1196
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...1197
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...1198
Troubleshooting by failure code (Display of code), Part 9...1201
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...1203
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...1204
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...1206
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...1208
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...1209
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...1210
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)...1211
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)...1212
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)...1213
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)...1214
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...1216
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...1218
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)...1220
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)...1222
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...1224
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)...1226
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)...1228
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...1230
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)...1232
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)...1234
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)...1236
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)...1238
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)...1239
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...1240
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...1242
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...1244
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...1246
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...1248
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...1250
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...1252
Troubleshooting by failure code (Display of code), Part 10...1255
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...1258
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...1260
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...1262
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...1264
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...1266
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...1268
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...1270
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...1272
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...1274
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...1276
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...1278
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...1280
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...1282
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...1284
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...1286
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...1288
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)...1290
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...1292
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...1294
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...1296
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)...1298
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)...1300
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)...1303
Failure code [DY30ME] Emergency steering: Operating for more than 1 minute...1306
Troubleshooting of electrical system (E-mode)...1311
Installing positions of fuses...1313
Information in troubleshooting table...1316
E-1 Engine does not start...1318
E-2 Wiper does not operate...1324
E-3 Windshield washer does not operate...1328
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...1331
E-5 Working lamp does not light up or go off...1339
E-6 Turn signal lamp and hazard lamp do not light up or go off...1344
E-7 Brake lamp does not light or it keeps lighting up...1350
E-8 Backup lamp does not light or it keeps lighting up...1352
E-9 Backup buzzer does not sound or it keeps sounding...1354
E-10 Horn does not sound or it keeps sounding...1356
E-11 Alarm buzzer does not sound or it keeps sounding...1358
E-12 Air conditioner does not operate or stop...1360
E-13 The KOMTRAX system does not work properly...1363
E-14 When kick-down switch is turned ON, kick-down operation does not start...1366
E-15 When hold switch is pressed, holding operation does not start...1368
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...1370
E-17 Transmission cut-off mode cannot be set or reset...1372
E-18 Transmission cut-off set cannot be reset...1374
E-19 FNR switch mode cannot be set or reset...1376
E-20 Fan reverse function cannot be used or reset...1378
E-21 Discharge from loader pump does not rise from minimum level...1380
E-22 ECSS function cannot be used or reset...1382
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up...1384
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate...1388
E-25 Air cleaner clogging indicator lamp does not light up...1390
E-26 Radiator coolant level caution lamp does not light up...1392
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up...1393
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up...1394
E-29 Steering oil pressure caution lamp does not light up...1396
E-30 Abnormality in ? switch (panel switch 1) input...1398
E-31 Abnormality in ? switch (panel switch 2) input...1400
E-32 Abnormality in < switch (panel switch 3) input...1402
E-33 Abnormality in > switch (panel switch 4) input...1404
E-34 Air conditioner does not operate...1406
E-35 Air is not cooled...1410
E-36 No air comes out or air flow is abnormal...1414
E-37 Temperature cannot be controlled...1420
E-38 Spurting out mode cannot be switched...1424
E-39 Recirc/Fresh cannot be changed over...1428
Troubleshooting of hydraulic and mechanical system (H-mode)...1431
Method of using troubleshooting chart...1433
Table of failure modes and causes...1436
H-1 The machine does not start...1440
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...1442
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]...1443
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...1444
H-5 Shocks are large at the times of starting and shifting gear...1446
H-6 Time lag is large at the times of starting and shifting gear...1448
H-7 The torque converter oil temperature is high...1450
H-8 Steering does not turn...1451
H-9 Steering does not turn [Machine with joystick steering (if equipped)]...1452
H-10 Steering response is low...1453
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]...1454
H-12 Steering is heavy...1455
H-13 When machine turns, it shakes or makes large shocks...1456
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...1457
H-15 The wheel brake does not work or does not work well...1458
H-16 The wheel brake is not released or it drags...1459
H-17 The parking brake does not work or does not work well...1460
H-18 The parking brake is not released or it drags (including emergency release system)...1461
H-19 Lift arm does not rise...1462
H-20 Lift arm speed is low or rising force of lift arm is insufficient...1463
H-21 When rising, the lift arm comes to move slowly at specific height...1464
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...1464
H-23 Hydraulic drifts of the lift arm is large...1464
H-24 The lift arm wobbles during operation...1464
H-25 Bucket does not tilt back...1465
H-26 Bucket speed is low or tilting back force is insufficient...1466
H-27 The bucket comes to operate slowly in the midst of tilting-back...1467
H-28 The bucket cylinder cannot hold down the bucket...1467
H-29 Hydraulic drifts of the bucket is large...1467
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to ?HOLD?)...1467
H-31 Lift arm and bucket control levers do not move smoothly and are heavy...1468
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...1469
H-33 Large shock is made when work equipment starts and stops...1469
H-34 When work equipment circuit is relieved singly, other work equipment moves...1469
H-35 ECSS does not operate, and pitching, bouncing occur...1470
Troubleshooting of engine (S-mode)...1473
Method of using troubleshooting charts...1475
S-1 Engine does not start easily...1478
S-2 Engine does not start...1479
S-3 Engine does not pick up smoothly...1482
S-4 Engine stops during operations...1483
S-5 Engine does not rotate smoothly...1484
S-6 Engine lacks output (or lacks power)...1485
S-7 Exhaust smoke is black (Incomplete combustion)...1486
S-8 Oil consumption is excessive (or exhaust smoke is blue)...1487
S-9 Engine oil becomes contaminated quickly...1488
S-10 Fuel consumption is excessive...1489
S-11 Coolant contains oil (blows back or reduces)...1490
S-12 Oil pressure drops...1491
S-13 Oil level rises (Water, fuel in oil)...1492
S-14 Coolant temperature rises too high (Overheating)...1493
S-15 Abnormal noise is made...1494
S-16 Vibration is excessive...1495
50 Disassembly and assembly...0
General information on disassembly and assembly...1497
How to read this manual...1498
Coating materials list...1500
Special tools list...1503
Sketches of special tools...1506
Engine and cooling system...1521
Removal and installation of fuel supply pump assembly...1522
Removal and installation of fuel injector assembly...1525
Removal and installation of cylinder head assembly...1534
Removal and installation of engine hood and radiator guard assembly...1547
Removal and installation of radiator assembly...1549
Removal and installation of air aftercooler assembly...1551
Removal and installation of hydraulic oil cooler assembly...1553
Removal and installation of engine assembly...1554
Removal and installation of front seal assembly...1559
Removal and installation of rear oil seal assembly...1561
Removal and installation of cooling fan and fan motor assembly...1566
Removal and installation of fuel tank assembly...1569
Power train, Part 1...1573
Removal and installation of torque converter and transmission assembly...1574
Disassembly and assembly of torque converter assembly (Standard specification)...1579
Disassembly and assembly of torque converter assembly (Lock-up specification)...1583
Disassembly and assembly of transmission assembly...1590
Disassembly and assembly of transmission clutch pack assembly...1605
Disassembly and assembly of parking brake assembly...1621
Power train, Part 2...1631
Removal and installation of front axle assembly...1632
Removal and installation of rear axle assembly...1634
Disassembly and assembly of axle housing...1638
Disassembly and assembly of differential assembly...1647
Steering system...1669
Removal and installation of steering demand valve assembly...1670
Removal and installation of steering valve oil seal...1672
Brake system...1675
Removal and installation of parking brake disc and plate...1676
Undercarriage and frame...1681
Removal and installation of center hinge pin...1682
Removal and installation of counterweight...1690
Hydraulic system...1693
Removal and installation of work equipment control valve assembly...1694
Removal and installation of power train pump and work equipment pump assembly...1697
Removal and installation of steering pump and cooling fan pump assembly...1698
Removal and installation of hydraulic tank assembly...1699
Work equipment...1703
Removal and installation of work equipment assembly...1704
Disassembly and assembly of hydraulic cylinder assembly...1709
Cab and its attachments...1717
Removal and installation of operator's cab and floor frame assembly...1718
Removal and installation of operator's cab glass (stuck glass)...1722
Disassembly and assembly of operator's seat assembly (Standard specification)...1730
Disassembly and assembly of operator's seat assembly (Manufactured by GRAMMER)...1739
Removal and installation of air conditioner unit assembly...1772
Electrical system...1779
Removal and installation of engine controller assembly...1780
Removal and installation of KOMTRAX terminal assembly...1781
90 Diagrams and drawings...0
Hydraulic diagrams and drawings...1783
Power train hydraulic circuit diagram...1784
Automatic greasing circuit diagram...1788
Hydraulic circuit diagram...1791
Electrical diagrams and drawings...1794
Electrical circuit diagram...1796
Work equipment controller system electrical circuit diagram...1810
Connector list and sterogram...1811
