Komatsu WHEEL LOADER WA470-6 WA480-6 Shop Manual SEN04409-16 PDF

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Komatsu WHEEL LOADER WA470-6 WA480-6 Shop Manual SEN04409-16 – PDF DOWNLOAD

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Komatsu WHEEL LOADER WA470-6 WA480-6 Shop Manual SEN04409-16 – PDF DOWNLOAD

Language : English
Pages :1954
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu WHEEL LOADER WA470-6 WA480-6 Shop Manual SEN04409-16 – PDF DOWNLOAD

SERIAL NUMBERS WA470-90001
WA480-90001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu WHEEL LOADER WA470-6 WA480-6 Shop Manual SEN04409-16 – PDF DOWNLOAD

SERIAL NUMBERS WA470-90001
WA480-90001 and up

Cover 1
00 Index and foreword 3
100 Index 3
Composition of shop manual 4
Table of contents 6
200 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
100 Specification and technical data 63
Specification dimension drawing 65
Specifications 66
Weight table 70
Table of fuel, coolant and lubricants 72
10 Structure, function and maintenance standard 75
100 Engine and cooling system 75
Engine mount and transmission mount 76
Cooling system 77
Cooling fan pump 78
Cooling fan motor 86
200 Power train 93
Power train 95
Power train system diagram 96
Drive shaft 98
Power train piping diagram 99
Torque converter 100
Transmission 108
Transmission control valve 126
ECMV 130
Main relief valve and torque converter relief valve 142
Axle 144
Differential 148
Limited slip differential 153
Final drive 160
300 Steering system 167
Steering component layout drawing 168
Steering column 169
Steering pump 170
Steering valve 183
Orbit-roll valve 200
Stop valve 208
Steering relief valve 209
Steering cylinder 210
Emergency steering motor 212
Emergency steering pump 213
Joystick steering lever linkage 214
Electrical steering lever 215
Joystick EPC valve 216
400 Brake system 219
Brake component layout drawing 220
Component layout of brake cooling system 221
Brake cooling control system 222
Charge valve 223
Brake valve 230
Accumulator (for brake) 235
Slack adjuster 236
Brake 238
Parking brake control 243
Parking brake 244
Parking brake solenoid valve 246
Emergency parking brake release valve 248
Brake cooling oil cooler 249
Brake cooling pump motor 250
Brake cooling fan 251
500 Undercarriage and frame 253
Axle mount and center hinge pin 254
Tires 258
601 Hydraulic system, Part 1 261
Hydraulic component layout drawing 262
Work equipment control lever linkage 265
Hydraulic tank 268
Power train pump 270
Work equipment pump 272
Work equipment control valve 292
CLSS 309
Each function and operation of each valve 316
602 Hydraulic system, Part 2 331
PPC valve 332
Accumulator (for PPC circuit) 340
Accumulator (for power train circuit) 341
Accumulator (for ECSS) 342
Work equipment PPC cut-off solenoid valve 343
700 Work equipment 347
Work equipment linkage 348
Bucket 351
Bucket positioner and boom kick-out 352
Work equipment cylinder 358
800 Cab and its attachments 361
Cab 363
Air conditioner 364
901 Electrical system, Part 1 383
Machine monitor system 384
Machine monitor 388
902 Electrical system, Part 2 421
Electrical system (Transmission controller system) 422
Transmission controller 462
Electrical system (Work equipment controller system) 464
Work equipment controller 470
903 Electrical system, Part 3 473
Electric transmission control 474
Kickdown switch and hold switch 478
Load meter cancel switch and load meter subtotal switch 478
Multi-function knob 479
Joystick steering knob 480
KOMTRAX system 482
Engine starting circuit 484
Engine stopping circuit 486
Preheating circuit 487
Engine power mode selector circuit 488
Engine output derating function 489
Automatic warm-up function 489
Parking brake circuit 490
Sensor 492
20 Standard value table 503
100 Standard service value table 503
Standard value table for engine 504
Standard value table for chassis 505
30 Testing and adjusting 515
101 Testing and adjusting, Part 1 515
Precautions before work 517
Tools for testing, adjusting, and troubleshooting 518
Testing engine speed 524
Testing exhaust gas color 526
Testing exhaust temperature 528
Adjusting valve clearance 530
Testing compression pressure 532
Testing blow-by pressure 533
Testing engine oil pressure 534
Testing EGR valve drive pressure 535
Testing intake air (boost) pressure 536
Handling fuel system equipment 537
Releasing residual pressure in fuel system 537
Testing fuel pressure 538
Testing fuel return and leak amount 539
Bleeding air from fuel circuit 542
Testing fuel circuit for leakage 544
Handling of reduced cylinder mode operation 545
Handling of no injection cranking operation 545
Handling of controller voltage circuit 546
Check of muffler and muffler stack for looseness and damage 547
Check of muffler function 547
Check of installed condition of cylinder head and manifolds 548
Check of engine piping for damage and looseness 548
Testing and adjusting air conditioner compressor belt tension 549
Testing and adjusting alternator belt tension 550
Adjusting transmission speed sensor 551
Adjusting directional lever length 552
Adjusting gear shift lever length 552
Testing FNR lever and gear shift lever 553
Testing and adjusting power train oil pressure 554
Procedure for flushing torque converter and transmission hydraulic circuit 568
Method of moving machine when transmission valve is broken 570
Check of axle final drive for oil leakage 573
Check of drive shafts for looseness, play and damage 573
Testing and adjusting steering stop valve 574
Testing and adjusting steering wheel 576
Testing steering oil pressure 578
Bleeding air from steering circuit 581
102 Testing and adjusting, Part 2 583
Testing hydraulic drive fan 585
Adjustment of hydraulic fan speed sensor 587
Bleeding air from hydraulic drive fan circuit 588
Testing brake pedal 590
Testing and adjusting brake pedal linkage 591
Testing brake performance 592
Testing and adjusting accumulator charge pressure 593
Testing wheel brake oil pressure 595
Testing wear of wheel brake disc 597
Bleeding air from wheel brake circuit 598
Releasing residual pressure in brake accumulator circuit 599
Testing parking brake performance 599
Testing parking brake oil pressure 600
Testing wear of parking brake disc 602
Manual release method for parking brake 603
Testing and adjusting work equipment control lever 604
Testing and adjusting work equipment PPC oil pressure 605
Testing and adjusting work equipment oil pressure 608
Bleeding air from work equipment circuit 612
Releasing residual pressure in work equipment circuit 613
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator 614
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator 618
Testing and adjusting bucket positioner 624
Testing and adjusting boom kick-out 626
Checking proximity switch operation pilot lamp 627
Procedure for testing diodes 628
Preparation work for troubleshooting for electrical system 629
How to start KOMTRAX terminal operations 634
Indicator lamps of KOMTRAX terminal 639
103 Testing and adjusting, Part 3 643
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 644
Special functions of machine monitor (EMMS) 647
Pm-clinic inspection table 710
40 Troubleshooting 715
100 Failure code table and fuse locations 715
Precautions before work 716
Failure code table 717
Fuse locations 729
200 General information on troubleshooting 733
Points to remember when troubleshooting 734
Sequence of events in troubleshooting 735
Testing before troubleshooting 736
Classification and procedures of troubleshooting 737
Information contained in troubleshooting table 741
Connection table for connector pin numbers 743
T- branch box and T- branch adapter table 779
301 Troubleshooting by failure code (Display of code), Part 1 783
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 785
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 786
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 788
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 790
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 792
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 794
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 796
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 798
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 800
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 802
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 804
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 806
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 808
Failure code [2F00MA] (Parking brake: Malfunction) 810
Failure code [2G43ZG] (Accumulator: Low oil pressure) 812
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 814
302 Troubleshooting by failure code (Display of code), Part 2 819
Failure code [AA1ANX] (Air cleaner: Clogging) 822
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 824
Failure code [AB00MA] (Alternator: Malfunction) 826
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 828
Failure code [B@BAZK] (Engine oil: Low level) 831
Failure code [B@BCNS] (Coolant: Overheating) 832
Failure code [B@BCZK] (Coolant: Low level) 834
Failure code [B@C7NS] (Brake oil: Overheating) 836
Failure code [b@CENS] (Torque converter oil: Overheating) 838
Failure code [B@CENS] (Torque converter oil: Overheating) 840
Failure code [B@HANS] (Hydraulic oil: Overheating) 842
Failure code [CA111] (Abnormality in engine controller) 844
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 847
Failure code [CA122] (Charge pressure sensor high error) 848
Failure code [CA123] (Charge pressure sensor low error) 850
Failure code [CA131] (Throttle sensor high error) 852
Failure code [CA132] (Throttle sensor low error) 854
Failure code [CA135] (Engine oil pressure sensor high error) 856
Failure code [CA141] (Engine oil pressure sensor low error) 858
Failure code [CA144] (Coolant sensor high error) 860
Failure code [CA145] (Coolant sensor low error) 862
Failure code [CA153] (Charge temperature sensor high error) 864
Failure code [CA154] (Charge temperature sensor low error) 866
Failure code [CA187] (Sensor power supply 2 low error) 868
Failure code [CA221] (Atmospheric pressure sensor high error) 869
Failure code [CA222] (Atmospheric pressure sensor low error) 871
Failure code [CA227] (Sensor power supply 2 high error) 872
Failure code [CA234] (Engine overspeed) 874
Failure code [CA238] (Ne speed sensor power supply error) 876
303 Troubleshooting by failure code (Display of code), Part 3 879
Failure code [CA263] (Fuel temperature sensor high error) 882
Failure code [CA265] (Fuel temperature sensor low error) 884
Failure code [CA271] (PCV1 Short circuit) 886
Failure code [CA272] (PCV1 Disconnection) 888
Failure code [CA273] (PCV2 Short circuit) 890
Failure code [CA274] (PCV2 Disconnection) 892
Failure code [CA322] (Injector #1 open/short error) 894
Failure code [CA323] (Injector #5 open/short error) 896
Failure code [CA324] (Injector #3 open/short error) 898
Failure code [CA325] (Injector #6 open/short error) 900
Failure code [CA331] (Injector #2 open/short error) 902
Failure code [CA332] (Injector #4 open/short error) 904
Failure code [CA342] (Calibration code inconsistency) 906
Failure code [CA351] (Injectors drive circuit error) 907
Failure code [CA352] (Sensor power supply 1 low error) 909
Failure code [CA386] (Sensor power supply 1 high error) 910
Failure code [CA431] (Idle validation switch error) 912
Failure code [CA432] (Idle validation action error) 914
Failure code [CA441] (Battery voltage low error) 916
Failure code [CA442] (Battery voltage high error) 919
Failure code [CA449] Common rail pressure high error 2 921
Failure code [CA451] (Common rail pressure sensor high error) 922
Failure code [CA452] (Common rail pressure sensor low error) 924
Failure code [CA553] (Common rail pressure high error 1) 925
Failure code [CA554] (Common rail pressure sensor in-range error) 926
Failure code [CA559] (Supply pump pressure very low error) 927
Failure code [CA689] (Engine Ne speed sensor error) 931
Failure code [CA731] (Engine Bkup speed sensor phase error) 933
Failure code [CA757] (All continuous data lost error) 933
Failure code [CA778] (Engine Bkup speed sensor error) 934
Failure code [CA1228] (EGR valve servo error 1) 936
Failure code [CA1625] (EGR valve servo error 2) 937
Failure code [CA1633] (KOMNET datalink timeout error) 938
Failure code [CA2185] (Throttle sensor supply voltage high error) 940
Failure code [CA2186] (Throttle sensor power supply low error) 941
304 Troubleshooting by failure code (Display of code), Part 4 943
Failure code [CA2249] (Supply pump pressure very low error 2) 945
Failure code [CA2271] (EGR valve lift sensor high error) 946
Failure code [CA2272] (EGR valve lift sensor low error) 948
Failure code [CA2351] (EGR valve solenoid operation short circuit) 949
Failure code [CA2352] (EGR valve solenoid operation disconnect) 951
Failure code [CA2555] (Intake heater relay disconnection error) 952
Failure code [CA2556] (Intake heater relay short circuit error) 954
Failure code [D150KA] (Emergency steering relay: Disconnection) 956
Failure code [D150KB] (Emergency steering relay: Short circuit) 958
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 960
Failure code [D160KA] (Backup lamp relay output: Disconnection) 962
Failure code [D160KB] (Backup lamp relay output: Short circuit) 964
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 966
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 968
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) 970
Failure code [D192KA] (ECSS solenoid: Disconnection) 972
Failure code [D192KB] (ECSS solenoid: Short circuit) 973
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 974
Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection) 976
Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit) 978
Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line) 980
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 983
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 987
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 990
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 995
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 998
Failure code [DAF3KK] (Machine monitor: Low source voltage (input))1000
Failure code [DAF5KP] (Machine monitor: Low output voltage)1002
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))1006
305 Troubleshooting by failure code (Display of code), Part 51009
Failure code [DAQ0KK] (Transmission controller: Low source voltage)1012
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)1014
Failure code [DAQ1KA] (Terminal ACC input: Disconnection)1015
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))1018
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)1020
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))1021
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)1026
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)1027
Failure code [DB90KK] Work equipment controller: Low source voltage (input)1034
Failure code [DB90KT] Work equipment controller: Abnormality in controller1036
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)1038
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range1041
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)1044
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)1045
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)1050
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)1051
Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time1052
Failure code [DD16LD] ◇ switch (Panel switch 2): Switch is kept pressed for long time1054
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time1056
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time1058
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time1060
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time1062
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time1064
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time1066
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time1068
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)1070
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)1072
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)1074
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)1076
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)1080
306 Troubleshooting by failure code (Display of code), Part 61083
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)1086
Failure code [DDK3KA] (Right FNR switch: Disconnection)1088
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)1091
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)1094
Failure code [DDK6KA] (FNR lever switch: Disconnection)1096
Failure code [DDK6KB] (FNR lever switch: Short circuit)1100
Failure code [DDS5KA] (Steering pressure switch signal: Disconnected)1102
Failure code [DDS5KB] (Steering pressure switch signal: Short circuit)1104
Failure code [DDS5L6] (Steering: Low oil pressure)1106
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)1108
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)1110
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)1112
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)1114
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)1116
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)1118
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)1122
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)1124
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)1126
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)1128
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)1130
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)1132
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)1134
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)1136
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)1138
307 Troubleshooting by failure code (Display of code), Part 71141
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)1142
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)1144
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)1146
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)1148
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)1150
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)1152
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)1155
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)1158
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)1161
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)1164
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)1167
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)1170
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)1173
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)1176
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)1179
308 Troubleshooting by failure code (Display of code), Part 81183
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)1185
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)1188
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)1190
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)1193
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)1195
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)1198
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)1200
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)1202
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)1204
Failure code [DLF1KA] (Transmission input speed sensor: Disconnection)1206
Failure code [DLF1LC] (Transmission input speed sensor: Short circuit)1207
Failure code [DLM3KA] (Fan speed sensor: Disconnection)1208
Failure code [DLM3LC] (Fan speed sensor: Short circuit)1210
Failure code [DLT3KA] (Transmission output speed sensor: Disconnection)1212
Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range)1214
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)1216
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)1218
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)1220
Failure code [DV00KB] (Alarm buzzer: Short circuit)1222
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)1224
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)1226
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)1228
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)1230
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)1231
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)1232
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)1234
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)1235
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)1236
309 Troubleshooting by failure code (Display of code), Part 91239
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)1241
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)1242
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)1244
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)1246
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)1247
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)1248
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)1250
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)1252
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)1254
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)1256
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)1258
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)1260
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)1262
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)1264
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)1266
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)1268
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1270
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)1272
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)1274
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)1275
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)1276
Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection)1278
Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)1280
Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection)1282
Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit)1284
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)1286
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)1288
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)1290
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)1292
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)1294
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)1296
310 Troubleshooting by failure code (Display of code), Part 101299
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)1302
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)1304
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)1306
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)1308
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)1310
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)1312
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)1314
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)1316
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)1318
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)1320
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)1322
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)1324
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)1326
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)1328
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)1330
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)1332
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)1334
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)1336
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)1338
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)1340
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)1342
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)1344
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)1347
Failure code [DY30ME] Emergency steering: Operating for more than 1 minute1350
400 Troubleshooting of electrical system (E-mode)1355
Installing positions of fuses1357
Information in troubleshooting table1360
E-1 Engine does not start1362
E-2 Wiper does not operate1368
E-3 Windshield washer does not operate1372
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off1375
E-5 Working lamp does not light up or go off1383
E-6 Turn signal lamp and hazard lamp do not light up or go off1388
E-7 Brake lamp does not light or it keeps lighting up1394
E-8 Backup lamp does not light or it keeps lighting up1396
E-9 Backup buzzer does not sound or it keeps sounding1398
E-10 Horn does not sound or it keeps sounding1400
E-11 Alarm buzzer does not sound or it keeps sounding1402
E-12 Air conditioner does not operate or stop1404
E-13 The KOMTRAX system does not work properly1408
E-14 When kick-down switch is turned ON, kick-down operation does not start1410
E-15 When hold switch is pressed, holding operation does not start1412
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied1414
E-17 Transmission cut-off mode cannot be set or reset1416
E-18 Transmission cut-off set cannot be reset1418
E-19 FNR switch mode cannot be set or reset1420
E-20 Fan reverse function cannot be used or reset1422
E-21 Discharge from loader pump does not rise from minimum level1424
E-22 ECSS function cannot be used or reset1426
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up1428
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate1432
E-25 Air cleaner clogging indicator lamp does not light up1434
E-26 Radiator coolant level caution lamp does not light up1436
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up1437
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up1438
E-29 Steering oil pressure caution lamp does not light up1440
E-30 Abnormality in ■ switch (panel switch 1) input1442
E-31 Abnormality in ◇ switch (panel switch 1) input1444
E-32 Abnormality in < switch (panel switch 2) input1446
E-33 Abnormality in > switch (panel switch 2) input1448
500 Troubleshooting of hydraulic and mechanical system (H-mode)1451
Method of using troubleshooting chart1453
Table of failure and causes1456
H-1 The machine does not start1460
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]1462
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]1463
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted1464
H-5 Shocks are large at the times of starting and shifting gear1466
H-6 Time lag is large at the times of starting and shifting gear1468
H-7 The torque converter oil temperature is high1470
H-8 Steering does not turn1471
H-9 Steering does not turn [Machine with joystick steering (if equipped)]1472
H-10 Steering response is poor1473
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]1474
H-12 Steering is heavy1475
H-13 When machine turns, it shakes or makes large shocks1476
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]1477
H-15 The wheel brake does not work or does not work well1478
H-16 The wheel brake is not released or it drags1479
H-17 The parking brake does not work or does not work well1480
H-18 The parking brake is not released or it drags (including emergency release system)1481
H-19 Lift arm does not rise1482
H-20 Lift arm speed is low or rising force of lift arm is insufficient1483
H-21 When rising, the lift arm comes to move slowly at specific height1484
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)1484
H-23 Hydraulic drifts of the lift arm is large1484
H-24 The lift arm wobbles during operation1484
H-25 Bucket does not tilt back1485
H-26 Bucket speed is low or tilting back force is insufficient1486
H-27 The bucket comes to operate slowly in the midst of tilting-back1487
H-28 The bucket cylinder cannot hold down the bucket1487
H-29 Hydraulic drifts of the bucket is large1487
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)1487
H-31 Lift arm and bucket control levers do not move smoothly and are heavy1488
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls1489
H-33 Large shock is made when work equipment starts and stops1489
H-34 When work equipment circuit is relieved singly, other work equipment moves1489
H-35 ECSS does not operate, and pitching, bouncing occur1490
600 Troubleshooting of engine (S-mode)1493
Method of using troubleshooting chart1495
S-1 Starting performance is poor1498
S-2 Engine does not start1500
S-3 Engine does not pick up smoothly1504
S-4 Engine stops during operation1505
S-5 Engine does not rotate smoothly1506
S-6 Engine lacks output (or lacks power)1507
S-7 Exhaust smoke is black (Incomplete combustion)1508
S-8 Oil is consumed much (or exhaust gas color is blue)1509
S-9 Engine oil becomes contaminated quickly1510
S-10 Fuel consumption is excessive1511
S-11 Coolant contains oil (blows back or reduces)1512
S-12 Oil pressure drops1513
S-13 Oil level rises (Water, fuel in oil)1514
S-14 Coolant temperature rises too high (Overheating)1516
S-15 Abnormal noise is made1517
S-16 Vibration is excessive1518
50 Disassembly and assembly1521
100 General information on disassembly and assembly1521
Precautions before work1522
How to read this manual1523
Coating materials list1525
Special tools list1528
Sketches of special tools1533
200 Engine and cooling system1557
Removal and installation of engine assembly1558
Removal and installation of engine hood assembly1562
Removal and installation of radiator assembly1565
Removal and installation of aftercooler assembly1568
Removal and installation of oil cooler assembly1570
Removal and installation of cooling fan and drive motor assembly1572
Removal and installation of fuel supply pump assembly1576
Removal and installation of fuel injector assembly1583
Removal and installation of cylinder head assembly1589
Removal and installation of engine front oil seal1597
Removal and Installation of engine rear oil seal1600
Removal and installation of fuel tank assembly1605
301 Power train, Part 11609
Removal and installation of torque converter and transmission assembly1610
Disassembly and assembly of torque converter and transmission assembly1616
Disassembly and assembly of torque converter assembly (Standard specification)1650
Disassembly and assembly of torque converter assembly (Lockup specification)1655
Disassembly and assembly of clutch pack assembly1663
302 Power train, Part 21691
Removal and installation of front axle assembly1692
Removal and installation of rear axle assembly1694
Disassembly and assembly of axle housing assembly1700
Disassembly and assembly of differential assembly1711
400 Brake system1733
Removal and installation of parking brake disc and plate1734
500 Undercarriage and frame1739
Removal and installation of center hinge pin1740
Removal and installation of counterweight1748
600 Hydraulic system1753
Removal and installation of steering demand valve assembly1754
Removal and installation of work equipment valve assembly1757
Removal and installation of brake charge valve assembly1760
Removal and installation of hydraulic tank assembly1761
Removal and installation of steering and power train pump assembly1763
Removal and installation of work equipment and cooling fan pump assembly1764
Disassembly and assembly of hydraulic cylinder assembly1766
700 Work equipment1775
Removal and installation of work equipment assembly1776
800 Cab and its attachments1781
Removal and installation of operator’s cab and floor frame assembly1782
Removal and installation of operator’s cab glass (stuck glass)1786
Disassembly and assembly of operator’s seat assembly1794
Removal and installation of air conditioner unit assembly1837
900 Electrical system1843
Removal and installation of engine controller assembly1844
Removal and installation of transmission controller assembly1845
Removal and installation of KOMTRAX terminal assembly1846
80 Appendix1849
100 Air conditioner1849
Precautions before work1851
Precautions for refrigerant1852
Troubleshooting procedure1853
Circuit diagram and arrangement of connector pins1855
System diagram1860
Detail of air conditioner unit1862
Parts and connectors layout1864
Testing with self-diagnosis function (indication on control panel)1868
Testing temperature control1871
Testing vent (mode) changeover1872
Testing Fresh/Recirc changeover1874
Testing inside air temp sensor and outside air temp sensor1876
Testing evaporator temperature sensor1878
Testing sunlight sensor1879
Testing relays1880
Troubleshooting chart 11881
Troubleshooting chart 21882
Information in troubleshooting table1885
Troubleshooting for power supply system (Air conditioner does not operate)1886
Troubleshooting for compressor and refrigerant system (Air is not cooled)1889
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1892
Troubleshooting for temperature control1898
Troubleshooting for vent (mode) changeover1901
Troubleshooting for Fresh/Recirc air changeover1904
Troubleshooting with gauge pressure1906
Connection of service tool1908
Handling of compressor oil1909
90 Diagrams and drawings1913
100 Hydraulic diagrams and drawings1913
Power train hydraulic circuit diagram1914
Automatic greasing circuit diagram1916
Hydraulic circuit diagram1919
Hydraulic circuit diagram (brake cooling system)1923
200 Electrical diagrams and drawings1925
Electrical circuit diagram1927
Electrical circuit diagram (brake cooling system)1947
Work equipment controller system electrical circuit diagram1949
Connector list and stereogram1951

S.M 30/12/24