Komatsu WHEEL LOADER WD600-6 Shop Manual SEN04979-13 PDF

Description

Komatsu WHEEL LOADER WD600-6 Shop Manual SEN04979-13 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WHEEL LOADER WD600-6 Shop Manual SEN04979-13 – PDF DOWNLOAD

Language : English
Pages :1938
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WHEEL LOADER WD600-6 Shop Manual SEN04979-13 – PDF DOWNLOAD

SERIAL NUMBERS 55001 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 WD600-6 Shop Manual SEN04979-13 – PDF DOWNLOAD

SERIAL NUMBERS 55001 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 19
Safety notice 20
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling of electric equipment and hydraulic component 29
Handling of connectors newly used for engines 38
How to read electric wire code 41
Precautions when carrying out operation 44
Method of disassembling and connecting push-pull type coupler 47
Standard tightening torque table 50
Conversion table 54
01 Specification 61
100 Specification and technical data 61
Specification dimension drawing 62
Specifications 63
Weight table 66
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 71
100 Engine and cooling system 71
Engine mount and transmission mount 72
Damper 74
Cooling system 76
Cooling fan pump 80
Cooling fan motor 88
201 Power train, Part 1 95
Power train 96
Power train system diagram 97
Torque converter and transmission piping diagram 98
Torque converter 100
Modulation clutch 109
Torque converter regulator valve 110
Transmission 112
Transfer 132
Transmission control valve 134
ECMV 136
Main relief valve and torque converter relief valve 143
Lubrication relief valve 145
202 Power train, Part 2 147
Torque converter oil cooler 148
Torque converter oil filter 149
Drive shaft 151
Center support 154
Axle 156
Differential 160
Limited slip differential 169
Final drive 174
300 Steering system 179
Steering piping diagram 180
Steering column 182
Joystick steering lever linkage 183
Joystick EPC valve 184
Lock valve 185
Steering valve 186
Rotary valve 189
Steering control valve 192
Two-way restrictor valve 208
Stop valve 209
Steering pump 210
Steering cylinder 224
Emergency steering piping diagram 225
Diverter valve 226
Emergency steering pump 234
400 Brake system 237
Brake piping diagram 238
Brake 240
Brake valve 244
Accumulator charge valve 252
EPC relief valve 258
Accumulator (for brake) 260
Slack adjuster 262
Parking brake 266
Parking brake solenoid valve 268
Emergency parking brake release valve 270
Brake cooling pump 271
500 Undercarriage and frame 273
Axle mount 274
Center hinge pin 279
601 Hydraulic system, Part 1 283
Hydraulic piping diagram 284
Work equipment control lever linkage 286
Hydraulic tank 288
Work equipment pump 290
602 Hydraulic system, Part 2 311
Control valve 312
CLSS 326
Functions and operation by valve 330
Accumulator (for PPC circuit) 340
Triple pump 341
700 Work equipment 343
Work equipment linkage 344
Cutting edge and end bit 347
Work equipment lubrication 349
Hydraulic cylinder 352
800 Cab and its attachments 355
ROPS cab 356
Air conditioner 358
901 Electrical system, Part 1 363
Machine monitor system 364
Machine monitor 370
902 Electrical system, Part 2 419
Work equipment control system 420
Transmission controller system 446
903 Electrical system, Part 3 479
Electric transmission control 480
Engine starting/stopping circuit 482
Parking brake circuit 485
Sensor 489
VHMS controller related 510
Electric lever (Work equipment) 515
20 Standard value table 519
100 Standard service value table 519
Standard service value table for engine 520
Standard service value table for chassis 521
30 Testing and adjusting 531
101 Testing and adjusting, Part 1 531
Tools for testing, adjusting, and troubleshooting 533
Sketches of special tools 538
Measuring engine speed 539
Measuring exhaust gas color 541
Measuring exhaust temperature 542
Adjusting valve clearance 544
Testing compression pressures 546
Measuring blow-by pressure 549
Measuring engine oil pressure 550
Testing EGR valve and bypass valve drive oil pressure 551
Measuring intake air (boost) pressure 553
Handling fuel system equipment 554
Releasing residual pressure in fuel system 554
Testing fuel pressures 555
Testing return rate and leakage 556
Bleeding air from fuel circuit 559
Testing leakage in fuel system 561
Handling reduced cylinder mode operation 562
Handling no-injection cranking operation 562
Handling controller voltage circuit 563
Replacing and adjusting alternator and air conditioner compressor belt tension 564
Adjusting modulation clutch speed sensor and speed sensor 565
Measuring directional lever and gear shift lever (Steering wheel specification) 567
Testing and adjusting power train oil pressure 568
Flushing procedure for torque converter and transmission hydraulic circuit 582
Method of moving machine when transmission valve is broken 584
Moving method of machine disabled by short-to-power failure in work equipment potentiometer 586
Adjusting steering stop valve 588
102 Testing and adjusting, Part 2 591
Measuring operating effort of AJSS lever (AJSS specification) 593
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) 594
Testing and adjusting steering stopper bolt (AJSS specification) 596
Testing and adjusting steering wheel (Steering wheel specification) 598
Testing steering oil pressure 600
Bleeding air from steering cylinder circuit 604
Testing hydraulic drive fan 605
Bleeding air from hydraulic drive fan circuit 608
Measuring brake pedal 610
Measuring brake performance 611
Testing and adjusting accumulator charge pressure 612
Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas 614
Testing wheel brake oil pressure 622
Measuring wear of wheel brake disc 624
Bleeding air from wheel brake circuit 625
Releasing residual pressure in brake accumulator circuit 626
Testing parking brake performance 627
Measuring parking brake oil pressure 628
Testing wear of parking brake disc 631
Method of releasing parking brake manually 632
Measuring and adjusting work equipment control lever 633
Measuring work equipment oil pressure 634
Bleeding air from work equipment circuit 639
Moving machine for removing operator cab 640
Preparations for work on troubleshooting of electric system 642
Procedure for testing diodes 646
103 Testing and adjusting, Part 3 649
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller 650
Special functions of machine monitor (EMMS) 653
104 Testing and adjusting, Part 4 723
VHMS controller initial setting procedure (ORBCOMM installation specification) 724
VHMS controller initial setting procedure (IRIDIUM installation specification) 746
Precautions for replacing VHMS controller 768
Pm-clinic inspection table 774
40 Troubleshooting 777
100 Failure code table and fuse locations 777
Failure codes list 778
Fuse locations 790
200 General information on troubleshooting 793
Points to remember when performing troubleshooting 794
How to proceed in troubleshooting 796
Checks before troubleshooting 798
Classification and procedures of troubleshooting 799
Information in troubleshooting table 803
Troubleshooting method for disconnecting wiring harness of pressure sensor system 805
Phenomena looking like troubles and troubleshooting Nos 808
Connection table for connector pin numbers 810
T- branch box and T- branch adapter table 846
301 Troubleshooting by failure code (Display of code), Part 1 851
Failure code [1500L0] TORQFLOW transmission: Double meshing 853
Failure code [15B0NX] Transmission Oil Filter Clogging 854
Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON 856
Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF 858
Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON 860
Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF 862
Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON 864
Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF 866
Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON 868
Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF 870
Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON 872
Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF 874
Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON 876
Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF 878
Failure code [15W0NT] Transmission modulation clutch: Overheating 880
Failure code [2F00MA] Parking brake: Malfunction 881
Failure code [2G42ZG] Front Accumulator Oil Pressure Low 884
302 Troubleshooting by failure code (Display of code), Part 2 887
Failure code [2G43ZG] Rear Accumulator Oil Pressure Low 890
Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine: Overrun 893
Failure code [AA1ANX] Air Cleaner Clogging 894
Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine 896
Failure code [AB00MA] Alternator: Malfunction 898
Failure code [B@BAZG] Engine oil pressure: Low error 900
Failure code [B@BAZK] Eng Oil Level Low 901
Failure code [B@BCNS] Engine coolant temperature: Overheating 902
Failure code [B@BCZK] Engine coolant level low 904
Failure code [B@C7NS] Brake oil overheating 906
Failure code [b@CENS] Torque converter oil overheating 907
Failure code [B@CENS] Torque converter oil overheating 908
Failure code [B@GAZK] Low Battery Fluid Level 909
Failure code [B@HANS] Hyd Oil Overheat 910
Failure code [CA111] Abnormality in engine controller 912
Failure code [CA115] Engine Ne or Bkup speed sensor error 915
Failure code [CA122] Charge (boost) pressure sensor high error 916
Failure code [CA123] Charge (boost) pressure sensor low error 918
Failure code [CA131] Throttle sensor high error 920
Failure code [CA132] Throttle sensor low error 923
Failure code [CA135] Engine oil pressure sensor high error 926
Failure code [CA141] Engine oil pressure sensor low error 928
Failure code [CA144] Coolant temperature sensor high error 930
Failure code [CA145] Coolant temperature sensor low error 932
Failure code [CA153] Charge (boost) temperature sensor high error 934
Failure code [CA154] Charge (boost) temperature sensor low error 936
Failure code [CA187] Sensor power supply 2 low error 938
Failure code [CA212] Engine oil temperature sensor high error 940
Failure code [CA213] Engine oil temperature sensor low error 942
Failure code [CA221] Atmospheric pressure sensor high error 944
Failure code [CA222] Atmospheric pressure sensor low error 946
Failure code [CA227] Sensor power supply 2 high error 948
303 Troubleshooting by failure code (Display of code), Part 3 951
Failure code [CA234] Engine overspeed 953
Failure code [CA238] Ne speed sensor power supply error 954
Failure code [CA263] Fuel Temp Sensor High Error 956
Failure code [CA265] Fuel Temp Sensor Low Error 958
Failure code [CA271] PCV1 Short circuit 960
Failure code [CA272] PCV1 Disconnection 961
Failure code [CA273] PCV2 Short circuit 962
Failure code [CA274] PCV2 Disconnection 963
Failure code [CA322] Injector #1 open/short error 964
Failure code [CA323] Injector #5 open/short error 966
Failure code [CA324] Injector #3 open/short error 968
Failure code [CA325] Injector #6 open/short error 970
Failure code [CA331] Injector #2 open/short error 972
Failure code [CA332] Injector #4 open/short error 974
Failure code [CA342] Calibration code inconsistency 976
Failure code [CA351] Injectors drive circuit error 977
Failure code [CA352] Sens Supply 1 Volt Low Error 978
Failure code [CA386] Sensor power supply 1 high error 980
Failure code [CA431] Idle validation switch error 981
Failure code [CA432] Idle validation action error 984
Failure code [CA441] Battery voltage low error 987
Failure code [CA442] Battery voltage high error 988
Failure code [CA449] Common rail pressure high error 2 989
Failure code [CA451] Rail Press Sensor High Error 990
Failure code [CA452] Rail Press Sensor Low Error 992
Failure code [CA553] Common rail pressure high error 1 994
Failure code [CA554] Common rail pressure sensor in range error 995
Failure code [CA559] Supply pump pressure very low error 1 996
Failure code [CA689] Engine Ne speed sensor error1000
Failure code [CA731] Engine Bkup speed sensor phase error1002
Failure code [CA757] All continuous data lost error1003
Failure code [CA778] Engine Bkup speed sensor error1004
Failure code [CA1228] EGR valve servo error 11006
Failure code [CA1625] EGR valve servo error 21007
Failure code [CA1626] (Bypass valve solenoid current high error)1008
Failure code [CA1627] (Bypass valve solenoid current low error)1010
Failure code [CA1628] Bypass Valve Servo Error 11012
Failure code [CA1629] Bypass Valve Servo Error 21013
Failure code [CA1631] (Bypass valve lift sensor high error)1014
Failure code [CA1632] (Bypass valve lift sensor low error)1016
Failure code [CA1633] KOMNET datalink timeout error1018
304 Troubleshooting by failure code (Display of code), Part 41021
Failure code [CA2185] Throttle sensor supply voltage high error1024
Failure code [CA2186] Throttle sensor power supply low error1026
Failure code [CA2249] Supply pump pressure very low error 21028
Failure code [CA2271] EGR valve lift sensor high error1030
Failure code [CA2272] EGR valve lift sensor low error1032
Failure code [CA2351] EGR valve solenoid operation short circuit1034
Failure code [CA2352] EGR valve solenoid operation disconnect1036
Failure code [CA2555] Intake air heater relay open circuit error1038
Failure code [CA2556] Intake air heater relay short circuit error1040
Failure code [D191KA] AJSS neutral safety relay open circuit1042
Failure code [D191KB] AJSS neutral safety relay short circuit1044
Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection1046
Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit1047
Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply line1048
Failure code [D5ZHKA] Terminal C signal open circuit1050
Failure code [D5ZHKB] Terminal C signal short circuit1052
Failure code [D5ZHKZ] Terminal C signal open or short circuit1054
Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine1056
Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal1058
Failure code [DAF3KK] Machine monitor: Source voltage low (input)1060
Failure code [DAF5KP] Machine monitor: Output voltage low1062
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system)1064
Failure code [DAQ0KK] Transmission controller: Source voltage low1065
Failure code [DAQ0KT] Transmission controller: Defect in controller1068
Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)1070
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement1073
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system)1074
Failure code [DAQRMA] Transmission controller (Option setting): Malfunction1079
305 Troubleshooting by failure code (Display of code), Part 51081
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system)1084
Failure code [DB90KK] Work equipment controller: Source voltage low (input)1087
Failure code [DB90KT] Work equipment controller: Defect in controller1090
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input)1091
Failure code [DB95KX] Work equipment controller power supply output: Out of range1094
Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement1096
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system)1097
Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction1098
Failure code [DB9RMC] CAN communication with transmission controller: Malfunction1099
Failure code [DBB0KK] or change of VHMS_LED display from “n9” to “01” (VHMS controller: Source voltage low (input))1100
Failure code [DBB0KQ] or change of VHMS_LED display from “nF” to “11” (VHMS controller: Disagreement of model selection signals)1102
Failure code [DBB3KK] or change of VHMS_LED display from “n9” to “05” (VHMS controller battery power supply: Source voltage low (input))1104
Failure code [DBB5KP] or change of VHMS_LED display from “n9” to “04” (VHMS controller 5 V power supply output: Output voltage low)1106
Failure code [DBB6KP] or change of VHMS_LED display from “n9” to “02” (VHMS controller 24V power supply output: Output voltage low)1108
Failure code [DBB7KP] or change of VHMS_LED display from “n9” to “03” (VHMS controller 12V power supply output: Output voltage low)1110
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))1112
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time1114
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time1116
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time1118
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time1120
306 Troubleshooting by failure code (Display of code), Part 61123
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree1126
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit1128
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit1131
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree1134
Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed for long time1138
Failure code [DDDBKA] Traction adjustment dial: Disconnection1140
Failure code [DDDBKB] Traction adjustment dial: Short circuit1142
Failure code [DDE5MA] Emergency steering drive switch: Malfunction1144
Failure code [DDK4KA] AJSS FNR switch: Disconnection1146
Failure code [DDK4KB] AJSS FNR switch: Short circuit1148
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree1150
Failure code [DDK6KA] FNR lever switch: Disconnection1153
Failure code [DDK6KB] FNR lever switch: Short circuit1156
Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection1158
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree1160
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time1162
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time1164
Failure code [DF10KA] Transmission shift lever switch: Disconnection1166
Failure code [DF10KB] Transmission shift lever switch: Short circuit1170
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor: Out of input signal range1172
Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection1174
Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit1176
307 Troubleshooting by failure code (Display of code), Part 71179
Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range1182
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection1184
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range1186
Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection1188
Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit1190
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range)1192
Failure code [DGT4KA] (or VHMS_LED display: “n3” → “12”) Exhaust gas temperature sensor (F): Disconnection1194
Failure code [DGT4KB] (or VHMS_LED display: “n3” → “11”) Exhaust gas temperature sensor (F): Short circuit1197
Failure code [DGT5KA] (or VHMS_LED display: “n3” → “22”) Exhaust gas temperature sensor (R): Disconnection1200
Failure code [DGT5KB] (or VHMS_LED display: “n3” → “21”) Exhaust gas temperature sensor (R): Short circuit1203
Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection1206
Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit1208
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit1210
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with power supply line1212
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine1214
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input signal range1216
Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection1220
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit1222
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of input signal range1224
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of input signal range1226
Failure code [DK30KA] AJSS lever angle sensor: Disconnection1228
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line1230
308 Troubleshooting by failure code (Display of code), Part 81233
Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection1235
Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit with power supply line1238
Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree1240
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection1243
Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit with power supply line1246
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection1248
Failure code [DK5BKY] Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply line1252
Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree1254
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection1257
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply line1260
Failure code [DKD0KA] Frame angle sensor: Disconnection1262
Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line1264
Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit1266
Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection1270
Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree1272
Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection1274
Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree1276
Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit1278
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range1280
Failure code [DV00KB] Alarm buzzer: Short circuit1282
Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection1284
Failure code [DW4PKB] Blade raise EPC solenoid: Short circuit1286
Failure code [DW4PKY] Blade raise EPC solenoid: Short circuit with power supply line1287
Failure code [DW4QKA] Blade lower EPC solenoid: Disconnection1288
Failure code [DW4QKB] Blade lower EPC solenoid: Short circuit1289
Failure code [DW4QKY] Blade lower EPC solenoid: Short circuit with power supply line1290
Failure code [DW4RKA] Tilt & pitch EPC solenoid: Disconnection1291
Failure code [DW4RKB] Tilt & pitch EPC solenoid: Short circuit1292
Failure code [DW4RKY] Tilt & pitch EPC solenoid: Short circuit with power supply line1293
Failure code [DW4SKA] Tilt & pitch EPC solenoid: Disconnection1294
Failure code [DW4SKB] Tilt & pitch EPC solenoid: Short circuit1295
Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with power supply line1296
Failure code [DW7BKA] Fan reverse solenoid: Disconnection1298
Failure code [DW7BKB] Fan reverse solenoid: Short circuit1300
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line1302
309 Troubleshooting by failure code (Display of code), Part 91305
Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection1308
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit1310
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line1312
Failure code [DWN7KA] Blade float magnet detent solenoid: Disconnection1314
Failure code [DWN7KB] Blade float magnet detent solenoid: Short circuit1316
Failure code [DWN7KY] Blade float magnet detent solenoid: Short circuit with power supply line1318
Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection1320
Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit1322
Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source line1324
Failure code [DX16KA] Fan pump EPC solenoid: Disconnection1326
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit1327
Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line1328
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection1329
Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit1330
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection1331
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit1332
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection1334
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit1336
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line1338
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection1340
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit1342
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line1344
310 Troubleshooting by failure code (Display of code), Part 101347
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection1350
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit1352
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line1354
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection1356
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit1358
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line1360
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection1362
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit1364
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line1366
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection1368
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit1370
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line1372
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection1374
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit1376
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line1378
Failure code [DXHJKA] RH pitch REAR EPC solenoid: Disconnection1380
Failure code [DXHJKB] RH pitch REAR EPC solenoid: Short circuit1381
Failure code [DXHJKY] RH pitch REAR EPC solenoid: Short circuit with power supply line1382
Failure code [DXHKKA] RH pitch FORWARD EPC solenoid: Disconnection1383
Failure code [DXHKKB] RH pitch FORWARD EPC solenoid: Short circuit1384
Failure code [DXHKKY] RH pitch FORWARD EPC solenoid: Short circuit with power supply line1385
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection1386
Failure code [DXHPKB] Modulation clutch solenoid: Short circuit1388
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line1390
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction1392
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by pressure: High error1394
Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust gas temperature (F): Abnormal heat1396
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F): Overheat1398
Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust gas temperature (R): abnormal heat1400
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat1402
400 Troubleshooting of electrical system (E-mode)1405
Before carrying out troubleshooting of electrical system1406
Information in troubleshooting table1409
E-1 Engine does not start1410
E-2 Wiper does not operate1420
E-3 Windshield washer does not operate1428
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off1434
E-5 Working lamp does not light up or go off1450
E-6 Step lamp does not light up or go off1458
E-7 Turn signal lamp and hazard lamp do not light up or go off1460
E-8 Brake lamp does not light or it keeps lighting up1470
E-9 Backup lamp does not light or it keeps lighting up1474
E-10 Backup buzzer does not sound or it keeps sounding1478
E-11 Horn does not sound or it keeps sounding1482
E-12 Alarm buzzer does not sound or it keeps sounding1486
E-13 Air conditioner does not operate or stop1488
E-14 Electric priming pump does not operate or does not stop automatically1490
E-15 When starting switch is turned to ON position, machine monitor displays nothing1492
500 Troubleshooting of hydraulic and mechanical system (H-mode)1497
Method of using troubleshooting chart1500
Table of failure modes and causes1502
H-1 Machine does not start1506
H-2 Torque converter lockup is not switched (engine stalls)1508
H-3 Torque converter lockup is not turned on1509
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted1510
H-5 Shocks are large at the times of starting and shifting gear1512
H-6 Time lag is large at the times of starting and shifting gear1514
H-7 Torque converter oil temperature is high1516
H-8 Steering does not turn [machine with steering wheel]1517
H-9 Steering does not turn [machine with AJSS]1518
H-10 Turning, response of steering is poor [machine with steering wheel]1519
H-11 Turning, response of AJSS is poor [machine with AJSS]1520
H-12 Steering is heavy [machine with steering wheel]1521
H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel]1522
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]1523
H-15 Wheel brake does not work or does not work well1524
H-16 Wheel brake is not released or it drags1525
H-17 Parking brake does not work or does not work well1526
H-18 Parking brake is not released or it drags (including emergency release system)1527
H-19 Blade does not rise1528
H-20 Blade speed is low or rising force of lift is insufficient1529
H-21 When rising, blade comes to move slowly at specific height1530
H-22 Lift cylinder cannot hold down blade (Blade floats)1530
H-23 Hydraulic drifts of blade occur often1530
H-24 Blade wobbles during operation1530
H-25 Blade does not tilt and pitch1531
H-26 Blade speed is low or tilt and pitch force is insufficient1532
H-27 Blade comes to operate slowly in the midst of tilt and pitch1533
H-28 Tilt & pitch cylinder cannot hold down blade1533
H-29 Hydraulic drifts of blade occur often1533
H-30 Blade wobbles during travel when loaded (Work equipment valve is set to “HOLD”)1533
H-31 During operation of machine, engine speed lowers remarkably or engine stalls1534
H-32 Large shocks are made when work equipment starts and stops1534
H-33 When work equipment circuit is relieved singly, other work equipment moves1534
H-34 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats)1535
600 Troubleshooting of engine (S-mode)1537
Method of using troubleshooting chart1538
S-1 Engine does not start easily1542
S-2 Engine does not start1544
S-3 Engine does not pick up smoothly1548
S-4 Engine stops during operation1549
S-5 Engine does not rotate smoothly (Hunting occurs)1550
S-6 Engine lacks output (or lacks power)1551
S-7 Exhaust smoke is black (Incomplete combustion)1552
S-8 Oil is consumed much (or exhaust gas color is blue)1554
S-9 Engine oil becomes contaminated quickly1555
S-10 Fuel consumption is excessive1556
S-11 Coolant contains oil (blows back or reduces)1557
S-12 Oil pressure drops1558
S-13 Oil level rises (Water, fuel in oil)1560
S-14 Coolant temperature rises too high (Overheating)1562
S-15 Abnormal noise is made1563
S-16 Vibration is excessive1564
S-17 Air cannot be bled from fuel circuit1566
50 Disassembly and assembly1569
100 General information on disassembly and assembly1569
How to read this manual1570
Coating materials list1572
Special tools list1575
Sketches of special tools1579
201 Engine and cooling system, Part 11589
Removal and installation of engine assembly1590
Removal and installation of radiator assembly1594
Removal and installation of air aftercooler1599
Removal and installation of cooling fan and fan motor assembly1600
Removal and installation of damper assembly1602
Disassembly and assembly of damper assembly1604
Removal and installation of fuel tank assembly1608
Removal and installation of engine hood assembly1610
Removal and installation of bulkhead assembly1612
202 Engine and cooling system, Part 21617
Removal and installation of fuel supply pump assembly1618
Removal and installation of cylinder head assembly1624
Removal and installation of fuel injector assembly1640
Removal and installation of engine front seal1644
Removal and installation of engine rear seal1647
301 Power train, Part 11653
Removal and installation of parking brake assembly1654
Removal and installation of torque converter and transmission assembly1656
302 Power train, Part 21663
Disassembly and assembly of torque converter assembly1664
Disassembly and assembly of transmission assembly1691
Disassembly and assembly of transfer assembly1718
Disassembly and assembly of parking brake assembly1734
303 Power train, Part 31743
Removal and installation of front axle assembly1744
Removal and installation of rear axle assembly1746
Removal and installation of center support assembly1748
Disassembly and assembly of center support assembly1750
Disassembly and assembly of differential assembly1754
304 Power train, Part 41769
Removal and installation of final drive carrier assembly1770
Disassembly and assembly of final drive carrier assembly1772
Removal and installation of front final drive brake assembly1773
Disassembly and assembly of final drive assembly1775
400 Brake system1779
Disassembly and assembly of brake assembly1780
Removal and installation of brake valve assembly1788
Disassembly and assembly of accumulator and charge valve assembly1789
Disassembly and assembly of slack adjustor assembly1792
500 Undercarriage and frame1795
Removal and installation of center hinge pin1796
Removal and installation of counterweight assembly1803
600 Hydraulic system1805
Removal and installation of hydraulic tank assembly1806
Removal and installation of hydraulic pump assembly1808
Removal and installation of control valve assembly1812
Disassembly and assembly of control valve assembly1814
Removal and installation of steering valve assembly1819
Disassembly and assembly of hydraulic cylinder assembly1820
700 Work equipment1827
Removal and installation of work equipment assembly1828
800 Cab and its attachments1833
Removal and installation of operator’s cab assembly1834
Removal and installation of operator’s cab glass (stuck glass)1838
Removal and installation of floor frame assembly1846
Disassembly and assembly of operator’s seat assembly1849
Removal and installation of air conditioner unit assembly1882
Removal and installation of AJSS lever switch assembly1885
900 Electrical system1891
Removal and installation of engine controller assembly1892
Removal and installation of transmission controller assembly1894
Removal and installation of loader controller assembly1894
Removal and installation of VHMS controller assembly1895
Removal and installation of machine monitor assembly1896
90 Diagrams and drawings1901
100 Hydraulic diagrams and drawings1901
Power train hydraulic circuit diagram1902
Brake hydraulic circuit diagram1903
Work equipment hydraulic circuit diagram1905
200 Electrical diagrams and drawings1911
Air conditioner electrical circuit diagram1913
Electrical circuit diagram (1/10)1915
Electrical circuit diagram (2/10)1917
Electrical circuit diagram (3/10)1919
Electrical circuit diagram (4/10)1921
Electrical circuit diagram (5/10)1923
Electrical circuit diagram (6/10)1925
Electrical circuit diagram (7/10)1927
Electrical circuit diagram (8/10)1929
Electrical circuit diagram (9/10)1931
Electrical circuit diagram (10/10)1933
Connector list and stereogram1935

S.M 30/12/24