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KOMATSU WA600-6 WHEEL LOADER SHOP MANUAL SEN00235-27 – PDF DOWNLOAD
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KOMATSU WA600-6 WHEEL LOADER SHOP MANUAL SEN00235-27 – PDF DOWNLOAD
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KOMATSU WA600-6 WHEEL LOADER SHOP MANUAL SEN00235-27 – PDF DOWNLOAD
Language : English
Pages : 2206
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA600-6 WHEEL LOADER SHOP MANUAL SEN00235-27 – PDF DOWNLOAD
Cover..................................................................................................................................................................................... 1 00 Index and foreword................................................................................................................................................................. 3 Index............................................................................................................................................................................. 3 Composition of shop manual.................................................................................................................................................... 4 Table of contents............................................................................................................................................................. 6 Foreword and general information ................................................................................................................................................. 21 Safety notice ................................................................................................................................................................ 22 How to read the shop manual .................................................................................................................................................. 27 Explanation of terms for maintenance standard ................................................................................................................................ 29 Handling of electric equipment and hydraulic component ....................................................................................................................... 31 Handling of connectors newly used for engines ................................................................................................................................ 40 How to read electric wire code ............................................................................................................................................... 43 Precautions when carrying out operation ...................................................................................................................................... 46 Method of disassembling and connecting push-pull type coupler ................................................................................................................ 49 Standard tightening torque table ............................................................................................................................................. 52 Conversion table.............................................................................................................................................................. 56 01 Specification...................................................................................................................................................................... 63 Specification and technical data.................................................................................................................................................. 63 Specification dimension drawing............................................................................................................................................... 64 Specifications................................................................................................................................................................ 65 Weight table.................................................................................................................................................................. 72 Table of fuel, coolant and lubricants......................................................................................................................................... 74 10 Structure, function and maintenance standard....................................................................................................................................... 77 Engine and cooling system......................................................................................................................................................... 77 Engine and cooling system..................................................................................................................................................... 78 Engine mount and transmission mount....................................................................................................................................... 78 Damper.................................................................................................................................................................... 80 Cooling system............................................................................................................................................................ 82 Cooling fan pump.......................................................................................................................................................... 86 Cooling fan motor......................................................................................................................................................... 94 Power train, Part 1............................................................................................................................................................... 101 Power train, Part 1........................................................................................................................................................... 102 Power train............................................................................................................................................................... 102 Power train system diagram................................................................................................................................................ 103 Torque converter and transmission piping diagram.......................................................................................................................... 104 Torque converter.......................................................................................................................................................... 106 Modulation clutch......................................................................................................................................................... 115 Torque converter regulator valve.......................................................................................................................................... 116 Transmission.............................................................................................................................................................. 118 Transfer.................................................................................................................................................................. 138 Transmission control valve................................................................................................................................................ 140 ECMV...................................................................................................................................................................... 143 Main relief valve and torque converter relief valve....................................................................................................................... 150 Lubrication relief valve.................................................................................................................................................. 152 Power train, Part 2............................................................................................................................................................... 155 Power train, Part 2........................................................................................................................................................... 156 Torque converter oil cooler............................................................................................................................................... 156 Torque converter oil filter............................................................................................................................................... 157 Drive shaft............................................................................................................................................................... 159 Center support............................................................................................................................................................ 162 Axle...................................................................................................................................................................... 164 Differential.............................................................................................................................................................. 168 Limited slip differential................................................................................................................................................. 177 Final drive............................................................................................................................................................... 182 Steering system................................................................................................................................................................... 187 Steering piping diagram....................................................................................................................................................... 190 Steering column............................................................................................................................................................... 192 Joystick steering lever linkage............................................................................................................................................... 193 Joystick EPC valve............................................................................................................................................................ 194 Lock valve.................................................................................................................................................................... 195 Steering valve................................................................................................................................................................ 196 Rotary valve.................................................................................................................................................................. 199 Steering control valve........................................................................................................................................................ 202 Two-way restrictor valve...................................................................................................................................................... 218 Stop valve.................................................................................................................................................................... 219 Steering pump................................................................................................................................................................. 220 Steering cylinder............................................................................................................................................................. 234 Emergency steering piping diagram............................................................................................................................................. 236 Diverter valve................................................................................................................................................................ 237 Emergency steering pump....................................................................................................................................................... 245 Brake system...................................................................................................................................................................... 247 Brake system.................................................................................................................................................................. 248 Brake piping diagram...................................................................................................................................................... 248 Brake..................................................................................................................................................................... 250 Brake valve............................................................................................................................................................... 254 Accumulator charge valve.................................................................................................................................................. 262 EPC relief valve.......................................................................................................................................................... 268 Accumulator (for brake)................................................................................................................................................... 270 Slack adjuster............................................................................................................................................................ 272 Parking brake............................................................................................................................................................. 276 Parking brake solenoid valve.............................................................................................................................................. 278 Emergency parking brake release valve..................................................................................................................................... 280 Brake cooling pump........................................................................................................................................................ 281 Undercarriage and frame........................................................................................................................................................... 283 Undercarriage and frame....................................................................................................................................................... 284 Axle mount................................................................................................................................................................ 284 Center hinge pin.......................................................................................................................................................... 289 Hydraulic system, Part 1.......................................................................................................................................................... 293 Hydraulic system, Part 1...................................................................................................................................................... 294 Hydraulic piping diagram.................................................................................................................................................. 294 Work equipment control lever linkage...................................................................................................................................... 296 Hydraulic tank............................................................................................................................................................ 298 Work equipment hydraulic pump............................................................................................................................................. 300 Hydraulic system, Part 2.......................................................................................................................................................... 321 Hydraulic system, Part 2...................................................................................................................................................... 322 Control valve............................................................................................................................................................. 322 CLSS...................................................................................................................................................................... 336 Each function and operation of each valve................................................................................................................................. 341 Accumulator (for PPC circuit)............................................................................................................................................. 360 Accumulator (for ECSS).................................................................................................................................................... 361 Triple pump............................................................................................................................................................... 362 Work equipment.................................................................................................................................................................... 365 Work equipment................................................................................................................................................................ 366 Work equipment linkage.................................................................................................................................................... 366 Bucket.................................................................................................................................................................... 370 Bucket positioner and boom kick-out....................................................................................................................................... 375 Work equipment lubrication................................................................................................................................................ 376 Work equipment cylinder................................................................................................................................................... 378 Cab and its attachments........................................................................................................................................................... 381 Cab and its attachments....................................................................................................................................................... 382 ROPS cab.................................................................................................................................................................. 382 Air conditioner........................................................................................................................................................... 384 Electrical system, Part 1......................................................................................................................................................... 389 Machine monitor system........................................................................................................................................................ 390 Machine monitor............................................................................................................................................................... 396 Electrical system, Part 2......................................................................................................................................................... 453 Electrical system, Part 2..................................................................................................................................................... 454 Work equipment control system............................................................................................................................................. 454 Transmission controller system............................................................................................................................................ 490 Electrical system, Part 3......................................................................................................................................................... 523 Electric transmission control................................................................................................................................................. 524 Engine starting/stopping circuit.............................................................................................................................................. 526 Parking brake circuit......................................................................................................................................................... 529 Sensor........................................................................................................................................................................ 533 VHMS controller related....................................................................................................................................................... 556 Work equipment electric lever................................................................................................................................................. 560 20 Standard value table............................................................................................................................................................... 565 Standard service value table...................................................................................................................................................... 565 Standard service value table for engine....................................................................................................................................... 566 Standard service value table for chassis...................................................................................................................................... 567 30 Testing and adjusting.............................................................................................................................................................. 577 Testing and adjusting, Part 1..................................................................................................................................................... 577 Precautions before work....................................................................................................................................................... 579 Tools for testing, adjusting, and troubleshooting............................................................................................................................. 580 Sketches of special tools..................................................................................................................................................... 586 Measuring engine speed........................................................................................................................................................ 587 Measuring exhaust gas color................................................................................................................................................... 589 Measuring exhaust temperature................................................................................................................................................. 590 Adjusting valve clearance..................................................................................................................................................... 592 Testing compression pressures................................................................................................................................................. 594 Measuring blow-by pressure.................................................................................................................................................... 597 Measuring engine oil pressure................................................................................................................................................. 598 Testing EGR valve and bypass valve drive oil pressure......................................................................................................................... 599 Measuring intake air (boost) pressure......................................................................................................................................... 601 Handling fuel system equipment................................................................................................................................................ 602 Releasing residual pressure in fuel system.................................................................................................................................... 602 Testing fuel pressures........................................................................................................................................................ 603 Testing return rate and leakage............................................................................................................................................... 604 Bleeding air from fuel circuit................................................................................................................................................ 607 Testing leakage in fuel system................................................................................................................................................ 609 Handling reduced cylinder mode operation...................................................................................................................................... 610 Handling no-injection cranking operation...................................................................................................................................... 610 Handling controller voltage circuit........................................................................................................................................... 611 Replacing and adjusting alternator and air conditioner compressor belt tension................................................................................................ 612 Adjusting modulation clutch speed sensor and speed sensor..................................................................................................................... 613 Measuring directional lever and gear shift lever (Steering wheel specification)............................................................................................... 615 Testing and adjusting power train oil pressure................................................................................................................................ 616 Flushing procedure for torque converter and transmission hydraulic circuit.................................................................................................... 630 Method of moving machine when transmission valve is broken.................................................................................................................... 632 Adjusting steering stop valve................................................................................................................................................. 634 Testing and adjusting, Part 2..................................................................................................................................................... 637 Measuring operating effort of AJSS lever (AJSS specification)................................................................................................................. 639 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)..................................................................................... 640 Testing and adjusting steering stopper bolt (AJSS specification).............................................................................................................. 642 Testing and adjusting steering wheel (Steering wheel specification)........................................................................................................... 644 Testing steering oil pressure................................................................................................................................................. 646 Bleeding air from steering cylinder circuit................................................................................................................................... 650 Testing hydraulic drive fan................................................................................................................................................... 651 Bleeding air from hydraulic drive fan circuit................................................................................................................................. 654 Measuring brake pedal......................................................................................................................................................... 656 Measuring brake performance................................................................................................................................................... 657 Testing and adjusting accumulator charge pressure............................................................................................................................. 658 Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas................................................................... 660 Testing wheel brake oil pressure.............................................................................................................................................. 668 Measuring wear of wheel brake disc............................................................................................................................................ 670 Bleeding air from wheel brake circuit......................................................................................................................................... 671 Releasing residual pressure in brake accumulator circuit...................................................................................................................... 672 Testing parking brake performance............................................................................................................................................. 673 Measuring parking brake oil pressure.......................................................................................................................................... 674 Testing wear of parking brake disc............................................................................................................................................ 677 Method of releasing parking brake manually.................................................................................................................................... 678 Measuring and adjusting work equipment control lever.......................................................................................................................... 679 Measuring work equipment oil pressure......................................................................................................................................... 680 Bleeding air from work equipment circuit...................................................................................................................................... 685 Releasing residual pressure in work equipment circuit......................................................................................................................... 686 Testing of accumulator nitrogen gas pressure and procedure for charging ECSS accumulator with nitrogen gas.................................................................... 688 Moving machine for removing operator cab...................................................................................................................................... 696 Testing and adjusting bucket positioner....................................................................................................................................... 698 Testing and adjusting lift arm position detecting lever....................................................................................................................... 700 Checking proximity switch operation indication lamp........................................................................................................................... 701 Preparations for work on troubleshooting of electric system................................................................................................................... 702 Procedure for testing diodes.................................................................................................................................................. 706 Testing and adjusting, Part 3..................................................................................................................................................... 709 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller......................................... 710 Special functions of machine monitor (EMMS)................................................................................................................................... 713 Testing and adjusting, Part 4..................................................................................................................................................... 789 VHMS controller initial setting procedure (ORBCOMM installation specification)................................................................................................ 790 VHMS controller initial setting procedure (IRIDIUM installation specification)................................................................................................ 812 Precautions for replacing VHMS controller..................................................................................................................................... 834 Pm-clinic inspection table.................................................................................................................................................... 840 40 Troubleshooting.................................................................................................................................................................... 843 Failure code table and fuse locations............................................................................................................................................. 843 Failure codes list............................................................................................................................................................ 844 Fuse locations................................................................................................................................................................ 857 General information on troubleshooting............................................................................................................................................ 861 Precautions before work....................................................................................................................................................... 862 Points to remember when performing troubleshooting............................................................................................................................ 863 How to proceed in troubleshooting............................................................................................................................................. 865 Testing before troubleshooting................................................................................................................................................ 867 Classification and procedures of troubleshooting.............................................................................................................................. 869 Information in troubleshooting table.......................................................................................................................................... 873 Troubleshooting method for disconnecting wiring harness of pressure sensor system............................................................................................. 875 Phenomena looking like troubles and troubleshooting Nos....................................................................................................................... 878 Connection table for connector pin numbers.................................................................................................................................... 880 T- branch box and T- branch adapter table..................................................................................................................................... 915 Troubleshooting by failure code (Display of code), Part 1......................................................................................................................... 919 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................................................. 921 Failure code [15B0NX] (Transmission filter: Clogged).......................................................................................................................... 922 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)......................................................................................... 924 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)......................................................................................... 926 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)......................................................................................... 928 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)......................................................................................... 930 Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON).............................................................................................. 932 Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF).............................................................................................. 934 Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON).............................................................................................. 936 Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF).............................................................................................. 938 Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON).............................................................................................. 940 Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF).............................................................................................. 942 Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON).............................................................................................. 944 Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF).............................................................................................. 946 Failure code [15W0NT] (Transmission modulation clutch: Overheating)........................................................................................................... 948 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................................................ 949 Failure code [2G42ZG] (Front accumulator: Low oil pressure)................................................................................................................... 952 Troubleshooting by failure code (Display of code), Part 2......................................................................................................................... 955 Failure code [2G43ZG] (Rear accumulator: Low oil pressure).................................................................................................................... 958 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................................................ 960 Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) (Engine: Overrun).................................................................................................... 963 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................................................. 964 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)........................................................................................... 966 Failure code [AB00MA] (Alternator: Malfunction)............................................................................................................................... 968 Failure code [B@BAZG] (Engine oil pressure: Low error)........................................................................................................................ 970 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................................................. 971 Failure code [B@BCNS] (Engine coolant temperature: Overheating)............................................................................................................... 972 Failure code [B@BCZK] (Coolant: Low level).................................................................................................................................... 974 Failure code [B@C7NS] (Brake oil: Overheating)................................................................................................................................ 976 Failure code [b@CENS] (Torque converter oil: Overheating)..................................................................................................................... 977 Failure code [B@CENS] (Torque converter oil: Overheating)..................................................................................................................... 978 Failure code [B@GAZK] (Battery electrolyte: Low level)........................................................................................................................ 979 Failure code [B@HANS] (Hydraulic oil: Overheating)............................................................................................................................ 981 Failure code [CA111] (Abnormality in engine controller)....................................................................................................................... 982 Failure code [CA115] (Engine Ne or Bkup speed sensor error)................................................................................................................... 985 Failure code [CA122] (Charge (boost) pressure sensor high error).............................................................................................................. 986 Failure code [CA123] (Charge (boost) pressure sensor low error)............................................................................................................... 988 Failure code [CA131] (Throttle sensor high error)............................................................................................................................. 990 Failure code [CA132] (Throttle sensor low error).............................................................................................................................. 993 Failure code [CA135] (Engine oil pressure sensor high error).................................................................................................................. 996 Failure code [CA141] (Engine oil pressure sensor low error)................................................................................................................... 998 Failure code [CA144] (Coolant temperature sensor high error)..................................................................................................................1000 Failure code [CA145] (Coolant temperature sensor low error)...................................................................................................................1002 Failure code [CA153] (Charge (boost) temperature sensor high error)...........................................................................................................1004 Failure code [CA154] (Charge (boost) temperature sensor low error)............................................................................................................1006 Failure code [CA187] (Sensor power supply 2 low error)........................................................................................................................1008 Failure code [CA212] (Engine oil temperature sensor high error)...............................................................................................................1010 Failure code [CA213] (Engine oil temperature sensor low error)................................................................................................................1012 Failure code [CA221] (Atmospheric pressure sensor high error).................................................................................................................1014 Failure code [CA222] (Atmospheric pressure sensor low error)..................................................................................................................1016 Failure code [CA227] (Sensor power supply 2 high error).......................................................................................................................1018 Troubleshooting by failure code (Display of code), Part 3.........................................................................................................................1021 Failure code [CA234] (Engine overspeed).......................................................................................................................................1023 Failure code [CA238] (Ne speed sensor power supply error).....................................................................................................................1024 Failure code [CA263] (Fuel temperature sensor high error).....................................................................................................................1026 Failure code [CA265] (Fuel temperature sensor low error)......................................................................................................................1028 Failure code [CA271] (PCV1 Short circuit).....................................................................................................................................1030 Failure code [CA272] (PCV1 Disconnection).....................................................................................................................................1031 Failure code [CA273] (PCV2 Short circuit).....................................................................................................................................1032 Failure code [CA274] (PCV2 Disconnection).....................................................................................................................................1033 Failure code [CA322] (Injector #1 open/short error)...........................................................................................................................1034 Failure code [CA323] (Injector #5 open/short error)...........................................................................................................................1036 Failure code [CA324] (Injector #3 open/short error)...........................................................................................................................1038 Failure code [CA325] (Injector #6 open/short error)...........................................................................................................................1040 Failure code [CA331] (Injector #2 open/short error)...........................................................................................................................1042 Failure code [CA332] (Injector #4 open/short error)...........................................................................................................................1044 Failure code [CA342] (Calibration code inconsistency).........................................................................................................................1046 Failure code [CA351] (Injectors drive circuit error)..........................................................................................................................1047 Failure code [CA352] (Sensor power supply 1 low error)........................................................................................................................1048 Failure code [CA386] (Sensor power supply 1 high error).......................................................................................................................1050 Failure code [CA431] (Idle validation switch error)...........................................................................................................................1051 Failure code [CA432] (Idle validation action error)...........................................................................................................................1054 Failure code [CA441] (Battery voltage low error)..............................................................................................................................1057 Failure code [CA442] (Battery voltage high error).............................................................................................................................1058 Failure code [CA449] Common rail pressure high error 2........................................................................................................................1059 Failure code [CA451] (Common rail pressure sensor high error).................................................................................................................1060 Failure code [CA452] (Common rail pressure sensor low error)..................................................................................................................1062 Failure code [CA553] (Common rail pressure high error 1)......................................................................................................................1064 Failure code [CA554] Common rail pressure sensor in range error...............................................................................................................1065 Failure code [CA559] (Supply pump pressure very low error 1)..................................................................................................................1066 Failure code [CA689] (Engine Ne speed sensor error)...........................................................................................................................1070 Failure code [CA731] (Engine Bkup speed sensor phase error)...................................................................................................................1072 Failure code [CA757] (All continuous data lost error).........................................................................................................................1073 Failure code [CA778] (Engine Bkup speed sensor error).........................................................................................................................1074 Failure code [CA1228] (EGR valve servo error 1)...............................................................................................................................1076 Failure code [CA1625] (EGR valve servo error 2)...............................................................................................................................1077 Failure code [CA1626] (Bypass valve solenoid current high error)..............................................................................................................1078 Failure code [CA1627] (Bypass valve solenoid current low error)...............................................................................................................1080 Failure code [CA1628] (Bypass valve servo error 1)............................................................................................................................1082 Failure code [CA1629] (Bypass valve servo error 2)............................................................................................................................1083 Failure code [CA1631] (Bypass valve lift sensor high error)...................................................................................................................1084 Failure code [CA1632] (Bypass valve lift sensor low error)....................................................................................................................1086 Failure code [CA1633] (KOMNET datalink timeout error).........................................................................................................................1088 Troubleshooting by failure code (Display of code), Part 4.........................................................................................................................1091 Failure code [CA2185] Throttle sensor supply voltage high error...............................................................................................................1094 Failure code [CA2186] Throttle sensor power supply low error..................................................................................................................1096 Failure code [CA2249] Supply pump pressure very low error 2...................................................................................................................1098 Failure code [CA2271] EGR valve lift sensor high error........................................................................................................................1100 Failure code [CA2272] EGR valve lift sensor low error.........................................................................................................................1102 Failure code [CA2351] EGR valve solenoid operation short circuit..............................................................................................................1104 Failure code [CA2352] EGR valve solenoid operation disconnect.................................................................................................................1106 Failure code [CA2555] Intake air heater relay open circuit error..............................................................................................................1108 Failure code [CA2556] Intake air heater relay short circuit error.............................................................................................................1110 Failure code [D191KA] AJSS neutral safety relay open circuit..................................................................................................................1112 Failure code [D191KB] AJSS neutral safety relay short circuit.................................................................................................................1114 Failure code [D192KA] ECSS solenoid: Disconnection............................................................................................................................1116 Failure code [D192KB] ECSS solenoid: Short circuit............................................................................................................................1117 Failure code [D192KY] ECSS solenoid: Short circuit with power supply line.....................................................................................................1118 Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection................................................................................................1119 Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit................................................................................................1120 Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply line.........................................................................1121 Failure code [D5ZHKA] Terminal C signal open circuit..........................................................................................................................1122 Failure code [D5ZHKB] Terminal C signal short circuit.........................................................................................................................1124 Failure code [D5ZHKZ] Terminal C signal open or short circuit.................................................................................................................1126 Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine.................................................................................................1128 Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal...................................................................................................1130 Failure code [DAF3KK] Machine monitor: Source voltage low (input).............................................................................................................1132 Failure code [DAF5KP] Machine monitor: Output voltage low.....................................................................................................................1134 Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system)....................................................1136 Failure code [DAQ0KK] Transmission controller: Source voltage low.............................................................................................................1137 Failure code [DAQ0KT] Transmission controller: Defect in controller...........................................................................................................1140 Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)..............................................................................1141 Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement............................................................................1144 Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system)............................................1145 Failure code [DAQRMA] Transmission controller (Option setting): Malfunction...................................................................................................1150 Troubleshooting by failure code (Display of code), Part 5.........................................................................................................................1153 Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system)..................................................1156 Failure code [DB90KK] Work equipment controller: Source voltage low (input)...................................................................................................1159 Failure code [DB90KT] Work equipment controller: Defect in controller.........................................................................................................1162 Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input)............................................................................1163 Failure code [DB95KX] Work equipment controller power supply output: Out of range.............................................................................................1166 Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement..........................................................................1168 Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system)..........................................1169 Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction.................................................................................................1170 Failure code [DB9RMC] CAN communication with transmission controller: Malfunction.............................................................................................1171 Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source voltage low (input))...........................................................1172 Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller: Disagreement of model selection signals)..............................................1174 Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery power supply: Source voltage low (input))......................................1176 Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V power supply output: Output voltage low)...........................................1178 Failure code [DBB6KP] or change of VHMS_LED display from "n9" to "02" (VHMS controller 24V power supply output: Output voltage low)...........................................1180 Failure code [DBB7KP] or change of VHMS_LED display from "n9" to "03" (VHMS controller 12V power supply output: Output voltage low)...........................................1182 Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of VHMS controller: Communication error (Abnormality in target component system))....1184 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time.........................................................................................1186 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time.........................................................................................1188 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time.........................................................................................1190 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time.........................................................................................1192 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time..................................................................1194 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time..................................................................1196 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................................................................................1198 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time.............................................................................1200 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time.............................................................................1202 Troubleshooting by failure code (Display of code), Part 6.........................................................................................................................1205 Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time................................................................................1208 Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree..........................................................................................................1210 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit...........................................................................................1212 Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit.........................................................................................1215 Failure code [DDD1LD] Remote positioner bucket angle set switch: Switch is kept pressed for long time.........................................................................1218 Failure code [DDDBKA] Traction adjustment dial: Disconnection.................................................................................................................1222 Failure code [DDDBKB] Traction adjustment dial: Short circuit.................................................................................................................1224 Failure code [DDE5MA] Emergency steering drive switch: Malfunction............................................................................................................1226 Failure code [DDK4KA] AJSS FNR switch: Disconnection..........................................................................................................................1228 Failure code [DDK4KB] AJSS FNR switch: Short circuit..........................................................................................................................1230 Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree......................................................................................................1232 Failure code [DDK6KA] FNR lever switch: Disconnection.........................................................................................................................1235 Failure code [DDK6KB] FNR lever switch: Short circuit.........................................................................................................................1238 Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection....................................................................................1240 Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree.....................................................................................................1242 Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time..................................................................................................1244 Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time.......................................................................................................1246 Failure code [DDY0LD] Load meter cancel switch: Switch is kept pressed for long time..........................................................................................1248 Failure code [DF10KA] Transmission shift lever switch: Disconnection..........................................................................................................1250 Failure code [DF10KB] Transmission shift lever switch: Short circuit..........................................................................................................1254 Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor: Out of input signal range............................................................1256 Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection......................................................................................................1258 Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit......................................................................................................1260 Troubleshooting by failure code (Display of code), Part 7.........................................................................................................................1263 Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range.............................................................................................1266 Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection........................................................................................................1268 Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range............................................................................................1270 Failure code [DGT1KA] (Torque converter oil temperature sensor: Disconnection)................................................................................................1272 Failure code [DGT1KB] (Torque converter oil temperature sensor: Short circuit)................................................................................................1273 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range).....................................................................................1274 Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12") Exhaust gas temperature sensor (F): Disconnection....................................................................1276 Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11") Exhaust gas temperature sensor (F): Short circuit....................................................................1279 Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22") Exhaust gas temperature sensor (R): Disconnection....................................................................1282 Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21") Exhaust gas temperature sensor (R): Short circuit....................................................................1285 Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection..................................................................................................1288 Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit..................................................................................................1290 Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit...............................................................................1292 Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with power supply line........................................................1294 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...................................................................................1296 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).....................................................................................1299 Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine....................................................................1302 Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input signal range..............................................................1304 Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection....................................................................................................1308 Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit....................................................................................................1310 Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of input signal range.......................................................1312 Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of input signal range........................................................1314 Failure code [DK30KA] AJSS lever angle sensor: Disconnection..................................................................................................................1316 Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line...........................................................................................1318 Troubleshooting by failure code (Display of code), Part 8.........................................................................................................................1321 Failure code [DK59KA] Lift arm EPC lever potentiometer (Main): Disconnection..................................................................................................1323 Failure code [DK59KY] Lift arm EPC lever potentiometer (Main): Short circuit with power supply line...........................................................................1326 Failure code [DK59L8] Lift arm EPC lever potentiometer (Main): Analog signals disagree........................................................................................1328 Failure code [DK5AKA] Lift arm EPC lever potentiometer (Sub): Disconnection...................................................................................................1332 Failure code [DK5AKY] Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line............................................................................1335 Failure code [DK5BKA] Bucket EPC lever potentiometer (Main): Disconnection....................................................................................................1338 Failure code [DK5BKY] Bucket EPC lever potentiometer (Main): Short circuit with power supply line.............................................................................1341 Failure code [DK5BL8] Bucket EPC lever potentiometer (Main): Analog signals disagree..........................................................................................1343 Failure code [DK5CKA] Bucket EPC lever potentiometer (Sub): Disconnection.....................................................................................................1347 Failure code [DK5CKY] Bucket EPC lever potentiometer (Sub): Short circuit with power supply line..............................................................................1350 Failure code [DK5DKA] 3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection................................................................................1353 Failure code [DK5DKY] 3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line.........................................................1356 Failure code [DK5DL8] 3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree......................................................................1358 Failure code [DK5EKA] 3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection.................................................................................1361 Failure code [DK5EKY] 3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line.......................................................................1364 Failure code [DKA0KA] Lift arm angle sensor: Disconnection....................................................................................................................1366 Failure code [DKA0KX] Lift arm angle sensor: Out of input signal range........................................................................................................1369 Failure code [DKA0KY] Lift arm angle sensor: Short circuit with power supply line.............................................................................................1370 Failure code [DKA0L0] Lift arm angle sensor: Improper position................................................................................................................1372 Troubleshooting by failure code (Display of code), Part 9.........................................................................................................................1375 Failure code [DKD0KA] (Frame angle sensor: Disconnection).....................................................................................................................1378 Failure code [DKD0KY] (Frame angle sensor: Short circuit with power supply line)..............................................................................................1380 Failure code [DKD0KZ] (AJSS lever and frame angle sensor: Disconnection or short circuit).....................................................................................1382 Failure code [DLFAKA] (Modulation clutch output shaft speed sensor: Disconnection)............................................................................................1386 Failure code [DLFALC] (Modulation clutch output shaft speed sensor: Speed signals disagree)...................................................................................1388 Failure code [DLT3KA] (Transmission output shaft speed sensor (2): Disconnection).............................................................................................1390 Failure code [DLT3LC] (Transmission output shaft speed sensor (2): Speed signals disagree)....................................................................................1392 Failure code [DLT4KB] (Transmission output shaft speed sensor (1): Short circuit).............................................................................................1394 Failure code [DLT4KX] (Transmission output shaft speed sensor (1): Out of input signal range).................................................................................1396 Failure code [DUM1KB] (Remote positioner raise indicator lamp: Short circuit).................................................................................................1398 Failure code [DUM2KB] (Remote positioner lower indicator lamp: Short circuit).................................................................................................1400 Failure code [DV00KB] (Alarm buzzer: Short circuit)...........................................................................................................................1402 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)............................................................................................................1404 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)............................................................................................................1406 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line).....................................................................................1407 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)............................................................................................................1408 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)............................................................................................................1409 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line).....................................................................................1410 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...............................................................................................................1411 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...............................................................................................................1412 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)........................................................................................1413 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...............................................................................................................1414 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...............................................................................................................1415 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)........................................................................................1416 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...................................................................................................................1418 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...................................................................................................................1420 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)............................................................................................1422 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)...................................................................................................1423 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)...................................................................................................1424 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)............................................................................1425 Troubleshooting by failure code (Display of code), Part 10........................................................................................................................1427 Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection.....................................................................................................1430 Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit.....................................................................................................1432 Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line..............................................................................1434 Failure code [DWN6KA] Lift arm raise magnet detent solenoid: Disconnection....................................................................................................1436 Failure code [DWN6KB] Lift arm raise magnet detent solenoid: Short circuit....................................................................................................1438 Failure code [DWN6KY] Lift arm raise magnet detent solenoid: Short circuit with power supply line.............................................................................1440 Failure code [DWN7KA] Lift arm float magnet detent solenoid: Disconnection....................................................................................................1442 Failure code [DWN7KB] Lift arm float magnet detent solenoid: Short circuit....................................................................................................1444 Failure code [DWN7KY] Lift arm float magnet detent solenoid: Short circuit with power supply line.............................................................................1446 Failure code [DWN8KA] Bucket tilt magnet detent solenoid: Disconnection.......................................................................................................1448 Failure code [DWN8KB] Bucket tilt magnet detent solenoid: Short circuit.......................................................................................................1450 Failure code [DWN8KY] Bucket tilt magnet detent solenoid: Shorted with the power source.......................................................................................1452 Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection...............................................................................................1454 Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit...............................................................................................1456 Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source line........................................................................1458 Failure code [DX16KA] Fan pump EPC solenoid: Disconnection....................................................................................................................1460 Failure code [DX16KB] Fan pump EPC solenoid: Short circuit....................................................................................................................1461 Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line.............................................................................................1462 Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection.....................................................................................................................1463 Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit.....................................................................................................................1464 Failure code [DXF0KA] AJSS EPC solenoid: Disconnection........................................................................................................................1465 Failure code [DXF0KB] AJSS EPC solenoid: Short circuit........................................................................................................................1466 Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection.....................................................................................................................1468 Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit.....................................................................................................................1470 Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line..............................................................................................1472 Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection.................................................................................................................1474 Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit.................................................................................................................1476 Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1478 Troubleshooting by failure code (Display of code), Part 11........................................................................................................................1481 Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection.................................................................................................................1484 Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.................................................................................................................1486 Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1488 Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection.................................................................................................................1490 Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit.................................................................................................................1492 Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1494 Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection...................................................................................................................1496 Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit...................................................................................................................1498 Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line............................................................................................1500 Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection...................................................................................................................1502 Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit...................................................................................................................1504 Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line............................................................................................1506 Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection.................................................................................................................1508 Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit.................................................................................................................1510 Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line..........................................................................................1512 Failure code [DXHJKA] 3-spool valve extract EPC solenoid: Disconnection.......................................................................................................1514 Failure code [DXHJKB] 3-spool valve extract EPC solenoid: Short circuit.......................................................................................................1516 Failure code [DXHJKY] 3-spool valve extract EPC solenoid: Short circuit with power supply line................................................................................1517 Failure code [DXHKKA] 3-spool valve retract EPC solenoid: Disconnection.......................................................................................................1518 Failure code [DXHKKB] 3-spool valve retract EPC solenoid: Short circuit.......................................................................................................1520 Failure code [DXHKKY] 3-spool valve retract EPC solenoid: Short circuit with power supply line................................................................................1521 Failure code [DXHPKA] Modulation clutch solenoid: Disconnection...............................................................................................................1522 Failure code [DXHPKB] Modulation clutch solenoid: Short circuit...............................................................................................................1524 Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line........................................................................................1526 Failure code [DXHPMA] Modulation clutch solenoid: Malfunction.................................................................................................................1528 Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) Blow-by pressure: High error.........................................................................................1530 Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust gas temperature (F): Abnormal heat...........................................................................1532 Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F): Overheat................................................................................1534 Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust gas temperature (R): abnormal heat...........................................................................1536 Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat.................................................................................1538 Troubleshooting of electrical system (E-mode).....................................................................................................................................1541 Before carrying out troubleshooting of electrical system......................................................................................................................1543 Information in troubleshooting table..........................................................................................................................................1546 E-1 Engine does not start.....................................................................................................................................................1547 E-2 Wiper does not operate....................................................................................................................................................1557 E-3 Windshield washer does not operate........................................................................................................................................1565 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...........................................................................................1571 E-5 Working lamp does not light up or go off..................................................................................................................................1587 E-6 Step lamp does not light up or go off.....................................................................................................................................1594 E-7 Turn signal lamp and hazard lamp do not light up or go off................................................................................................................1597 E-8 Brake lamp does not light or it keeps lighting up.........................................................................................................................1607 E-9 Backup lamp does not light or it keeps lighting up........................................................................................................................1610 E-10 Backup buzzer does not sound or it keeps sounding........................................................................................................................1614 E-11 Horn does not sound or it keeps sounding.................................................................................................................................1618 E-12 Alarm buzzer does not sound or it keeps sounding.........................................................................................................................1622 E-13 Air conditioner does not operate or stop.................................................................................................................................1624 E-14 Electric priming pump does not operate or does not stop automatically....................................................................................................1626 E-15 When starting switch is turned to ON position, machine monitor displays nothing..........................................................................................1628 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................................................1633 Method of using troubleshooting chart.........................................................................................................................................1636 Table of failure modes and causes.............................................................................................................................................1638 H-1 Machine does not start....................................................................................................................................................1642 H-2 Torque converter lockup is not switched (engine stalls)...................................................................................................................1644 H-3 Torque converter lockup is not turned on..................................................................................................................................1645 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted....................................................................1646 H-5 Shocks are large at the times of starting and shifting gear...............................................................................................................1648 H-6 Time lag is large at the times of starting and shifting gear..............................................................................................................1650 H-7 Torque converter oil temperature is high..................................................................................................................................1652 H-8 Steering does not turn [machine with steering wheel]......................................................................................................................1653 H-9 Steering does not turn [machine with AJSS]................................................................................................................................1654 H-10 Turning, response of steering is poor [machine with steering wheel]......................................................................................................1655 H-11 Turning, response of AJSS is poor [machine with AJSS]....................................................................................................................1656 H-12 Steering is heavy [machine with steering wheel]..........................................................................................................................1657 H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel]........................................................................................1658 H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]..................................................................................................1659 H-15 Wheel brake does not work or does not work well..........................................................................................................................1660 H-16 Wheel brake is not released or it drags..................................................................................................................................1661 H-17 Parking brake does not work or does not work well........................................................................................................................1662 H-18 Parking brake is not released or it drags (including emergency release system)...........................................................................................1663 H-19 Lift arm does not rise...................................................................................................................................................1664 H-20 Lift arm speed is low or rising force of lift arm is insuff..............................................................................................................1665 H-21 When rising, lift arm comes to move slowly at specific height............................................................................................................1666 H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)................................................................................................................1666 H-23 Hydraulic drifts of lift arm occur often.................................................................................................................................1666 H-24 Lift arm wobbles during operation........................................................................................................................................1666 H-25 Bucket does not tilt back................................................................................................................................................1667 H-26 Bucket speed is low or tilting back force is insufficient................................................................................................................1668 H-27 Bucket comes to operate slowly in the midst of tilting-back..............................................................................................................1669 H-28 Bucket cylinder cannot hold down bucket..................................................................................................................................1669 H-29 Hydraulic drifts of bucket occur often...................................................................................................................................1669 H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)..........................................................................................1669 H-31 During operation of machine, engine speed lowers remarkably or engine stalls.............................................................................................1670 H-32 Large shocks are made when work equipment starts and stops...............................................................................................................1670 H-33 When work equipment circuit is relieved singly, other work equipment moves...............................................................................................1670 H-34 ECSS does not operate, and pitching bouncing occurs......................................................................................................................1671 H-35 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats).................................................................................1672 Troubleshooting of engine (S-mode)................................................................................................................................................1675 Method of using troubleshooting chart.........................................................................................................................................1677 S-1 Engine does not start easily..............................................................................................................................................1680 S-2 Engine does not start.....................................................................................................................................................1682 S-3 Engine does not pick up smoothly..........................................................................................................................................1686 S-4 Engine stops during operation.............................................................................................................................................1687 S-5 Engine does not rotate smoothly (Hunting occurs)..........................................................................................................................1688 S-6 Engine lacks output (or lacks power)......................................................................................................................................1689 S-7 Exhaust smoke is black (Incomplete combustion)............................................................................................................................1690 S-8 Oil is consumed much (or exhaust gas color is blue).......................................................................................................................1692 S-9 Engine oil becomes contaminated quickly...................................................................................................................................1693 S-10 Fuel consumption is excessive............................................................................................................................................1694 S-11 Coolant contains oil (blows back or reduces).............................................................................................................................1695 S-12 Oil pressure drops.......................................................................................................................................................1696 S-13 Oil level rises (Water, fuel in oil).....................................................................................................................................1698 S-14 Coolant temperature rises too high (Overheating).........................................................................................................................1700 S-15 Abnormal noise is made...................................................................................................................................................1701 S-16 Vibration is excessive...................................................................................................................................................1702 S-17 Air cannot be bled from fuel circuit.....................................................................................................................................1704 50 Disassembly and assembly...........................................................................................................................................................1707 General information on disassembly andassembly....................................................................................................................................1707 Precautions before work.......................................................................................................................................................1708 How to read this manual.......................................................................................................................................................1709 Coating materials list........................................................................................................................................................1711 Special tools list............................................................................................................................................................1714 Sketches of special tools.....................................................................................................................................................1724 Engine and cooling system, Part 1.................................................................................................................................................1733 Removal and installation of engine assembly...................................................................................................................................1734 Removal and installation of radiator assembly.................................................................................................................................1739 Removal and installation of air aftercooler assembly..........................................................................................................................1747 Removal and installation of cooling fan and fan motor assembly................................................................................................................1749 Removal and installation of damper assembly...................................................................................................................................1751 Disassembly and assembly of damper assembly...................................................................................................................................1755 Removal and installation of fuel tank assembly................................................................................................................................1760 Removal and installation of engine hood assembly..............................................................................................................................1764 Removal and installation of bulkhead assembly.................................................................................................................................1767 Engine and cooling system, Part 2.................................................................................................................................................1773 Removal and installation of fuel supply pump assembly.........................................................................................................................1774 Removal and installation of cylinder head assembly............................................................................................................................1782 Removal and installation of fuel injector assembly............................................................................................................................1803 Removal and installation of engine front seal.................................................................................................................................1809 Removal and installation of engine rear seal..................................................................................................................................1813 Power train, Part 1...............................................................................................................................................................1819 Removal and installation of parking brake assembly............................................................................................................................1820 Removal and installation of torque converter and transmissionassembly.........................................................................................................1822 Power train, Part 2...............................................................................................................................................................1833 Disassembly and assembly of torque converter assembly.........................................................................................................................1834 Disassembly and assembly of transmission assembly.............................................................................................................................1868 Disassembly and assembly of transfer assembly.................................................................................................................................1906 Disassembly and assembly of parking brake assembly............................................................................................................................1927 Power train, Part 3...............................................................................................................................................................1939 Removal and installation of front axle assembly...............................................................................................................................1940 Removal and installation of rear axle assembly................................................................................................................................1943 Removal and installation of center support assembly...........................................................................................................................1946 Disassembly and assembly of center support assembly...........................................................................................................................1948 Disassembly and assembly of differential assembly.............................................................................................................................1952 Power train, Part 4...............................................................................................................................................................1973 Removal and installation of final drive carrier assembly......................................................................................................................1974 Disassembly and assembly of final drive carrier assembly......................................................................................................................1977 Removal and installation of front final drive brake assembly..................................................................................................................1979 Disassembly and assembly of final drive assembly..............................................................................................................................1982 Brake system......................................................................................................................................................................1987 Disassembly and assembly of brake assembly....................................................................................................................................1988 Removal and installation of brake valve assembly..............................................................................................................................1999 Disassembly and assembly of accumulator and charge valveassembly..............................................................................................................2001 Disassembly and assembly of slack adjustor assembly...........................................................................................................................2004 Undercarriage and frame...........................................................................................................................................................2009 Removal and installation of center hinge pin..................................................................................................................................2010 Removal and installation of counterweight assembly............................................................................................................................2021 Hydraulic system..................................................................................................................................................................2023 Removal and installation of hydraulic tank assembly...........................................................................................................................2024 Removal and installation of hydraulic pump assembly...........................................................................................................................2028 Removal and installation of control valve assembly............................................................................................................................2035 Disassembly and assembly of control valve assembly............................................................................................................................2039 Removal and installation of steering valve assembly...........................................................................................................................2045 Removal and installation of ECSS accumulator assembly.........................................................................................................................2048 Disassembly and assembly of hydraulic cylinder assembly.......................................................................................................................2050 Work equipment....................................................................................................................................................................2059 Removal and installation of work equipment assembly...........................................................................................................................2060 Cab and its attachments...........................................................................................................................................................2069 Removal and installation of operator's cab assembly...........................................................................................................................2070 Removal and installation of operator's cab glass (stuck glass)................................................................................................................2076 Removal and installation of floor frame assembly..............................................................................................................................2085 Disassembly and assembly of operator’s seat assembly..........................................................................................................................2090 Removal and installation of air conditioner unit assembly.....................................................................................................................2119 Removal and installation of AJSS lever switch assembly........................................................................................................................2123 Electrical system.................................................................................................................................................................2131 Removal and installation of engine controller assembly........................................................................................................................2132 Removal and installation of transmission controller assembly..................................................................................................................2134 Removal and installation of loader controller assembly........................................................................................................................2136 Removal and installation of VHMS controller assembly..........................................................................................................................2138 Removal and installation of monitor assembly..................................................................................................................................2140 90 Diagrams and drawings..............................................................................................................................................................2145 Hydraulic diagrams and drawings...................................................................................................................................................2145 Power train hydraulic circuit diagram.........................................................................................................................................2146 Brake hydraulic circuit diagram...............................................................................................................................................2147 Work equipment hydraulic circuit diagram......................................................................................................................................2149 Electrical diagrams and drawings..................................................................................................................................................2159 Air conditioner electrical circuit diagram....................................................................................................................................2161 Steering wheel specification..................................................................................................................................................2163 Electrical circuit diagram (1/10).........................................................................................................................................2163 Electrical circuit diagram (2/10).........................................................................................................................................2165 Electrical circuit diagram (3/10).........................................................................................................................................2167 Electrical circuit diagram (4/10).........................................................................................................................................2169 Electrical circuit diagram (5/10).........................................................................................................................................2171 Electrical circuit diagram (6/10).........................................................................................................................................2173 Electrical circuit diagram (7/10).........................................................................................................................................2175 Electrical circuit diagram (8/10).........................................................................................................................................2177 Electrical circuit diagram (9/10).........................................................................................................................................2179 Electrical circuit diagram (10/10)........................................................................................................................................2181 AJSS (Advanced Joystick Steering System) specification........................................................................................................................2183 Electrical circuit diagram (1/10).........................................................................................................................................2183 Electrical circuit diagram (2/10).........................................................................................................................................2185 Electrical circuit diagram (3/10).........................................................................................................................................2187 Electrical circuit diagram (4/10).........................................................................................................................................2189 Electrical circuit diagram (5/10).........................................................................................................................................2191 Electrical circuit diagram (6/10).........................................................................................................................................2193 Electrical circuit diagram (7/10).........................................................................................................................................2195 Electrical circuit diagram (8/10).........................................................................................................................................2197 Electrical circuit diagram (9/10).........................................................................................................................................2199 Electrical circuit diagram (10/10)........................................................................................................................................2201 Connector arrangement diagram.................................................................................................................................................2203
DESCRIPTION:
KOMATSU WA600-6 WHEEL LOADER SHOP MANUAL SEN00235-27 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only the approved personnel can do the work in a closed environment or in a prohibited area.
6) Only qualified workers must carry out work and operation which require license or qualification.
7) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
8) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
9) Before starting work, warm up your body thoroughly to start work under good condition.
10) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
11) When you work in high places, use a platform.
12) Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
13) Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
14) Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
15) When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
16) If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.
S.S 29/12/24
