Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-24 – PDF DOWNLOAD

Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-24 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-24 – PDF DOWNLOAD

Language : English
Pages : 2062
Downloadable : Yes
File Type : PDF
Size: 114 MB

DESCRIPTION:

Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-24 – PDF DOWNLOAD

SERIAL NUMBERS 55001 and up

General precautions:

• Before performing 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.• Locate a place in the repair workshop to keep the 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.• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer.Always wear the protective eyeglasses when grinding parts with a grinder, etc.• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.• Only qualified workers must perform the work and operation which require license or qualification.• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.• Before starting work, warm up your body thoroughly to start work under good condition.• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

How to read the shop manual :
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-24 – PDF DOWNLOAD

Cover 1
00 Index and foreword 0
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 0
Specification and technical data 63
Specification and technical data 64
Specification dimension drawing 64
Specifications 65
Weight table 68
Table of fuel, coolant and lubricants 70
10 Structure, function and maintenance standard 0
Engine and cooling system 73
Engine and cooling system 74
Cooling system 74
Engine mount and transmission mount 77
Joint 78
Cooling fan pump 80
Cooling fan motor 87
Power train, Part 1 95
Power train, Part 1 96
Power train 96
Power train system diagram 97
Drive shaft 99
Power train piping diagram 102
Torque converter 104
Torque converter regulator valve 122
Transmission 124
Transfer 144
Transmission control valve 146
ECMV 152
Main relief valve and torque converter relief valve 159
Lubrication relief valve 161
Power train, Part 2 163
Power train, Part 2 164
Torque converter oil cooler 164
Torque converter oil filter 165
Center support 168
Axle 170
Differential 172
Limited slip differential 181
Final drive 186
Steering system 191
Steering system 192
Steering piping diagram 192
Steering column 193
Steering control valve 194
Steering valve 205
Stop valve 209
Joystick steering lever linkage (if equipped) 210
Steering cylinder 211
Emergency steering piping diagram (if equipped) 214
Diverter valve 215
Brake system 221
Brake piping diagram 222
Brake valve 224
Slack adjuster 229
Accumulator charge valve 232
PPC relief valve 236
Accumulator (for brake) 238
Brake 240
Parking brake control 243
Parking brake 244
Parking brake solenoid valve 246
Emergency parking brake release valve 248
Undercarriage and frame 251
Undercarriage and frame 252
Axle mount 252
Center hinge pin 257
Hydraulic system, Part 1 261
Hydraulic system, Part 1 262
Hydraulic piping diagram 262
Work equipment control lever linkage 264
Hydraulic tank 265
Steering pump 267
Work equipment hydraulic pump 278
Hydraulic system, Part 2 299
Hydraulic system, Part 2 300
Control valve 300
CLSS 314
Each function and operation of each valve 319
Accumulator (for PPC circuit) 330
Work equipment electric lever 331
Work equipment 335
Work equipment 336
Work equipment linkage 336
Bucket 340
Bucket positioner and boom kick-out 342
Work equipment lubrication 343
Work equipment cylinder 345
Cab and its attachments 347
Cab and its attachments 348
ROPS cab 348
Air conditioner 350
Electrical system, Part 1 359
Electrical system, Part 1 360
Machine monitor system 360
Machine monitor 368
Electrical system, Part 2 423
Electrical system, Part 2 424
Work equipment control system 424
Transmission controller system 458
Electrical system, Part 3 491
Electrical system, Part 3 492
Electric transmission control 492
Engine starting circuit 496
Engine stopping circuit 498
Preheating circuit 499
Parking brake circuit 501
Backup and stop lamp circuits 506
Small lamp and head lamp circuits 508
Working lamp circuit 509
Horn circuit 510
Wiper and window washer circuits 511
Sensor 514
KOMTRAX system 532
20 Standard value table 0
Standard service value table 535
Standard service value table 536
Standard service value table for engine 536
Standard service value table for chassis 537
30 Testing and adjusting 0
Testing and adjusting, Part 1 547
Tools for testing, adjusting, and troubleshooting 549
Measuring engine speed 553
Measuring exhaust gas color 555
Measuring exhaust temperature 557
Adjusting valve clearance 559
Testing compression pressure 560
Measuring blow-by pressure 562
Measuring engine oil pressure 563
Measuring intake air (boost) pressure 564
Handling fuel system equipment 566
Releasing residual pressure in fuel system 566
Testing fuel pressure 567
Testing return rate and leakage 568
Bleeding air from fuel circuit 571
Testing leakage in fuel system 573
Handling reduced cylinder mode operation 574
Handling no injection cranking operation 574
Handling controller voltage circuit 575
Testing and adjusting alternator belt tension 576
Testing and adjusting air conditioner compressor belt tension 577
Adjusting transmission speed sensor 578
Measuring directional lever (Steering wheel specification) 580
Testing and adjusting power train oil pressure 581
Flushing procedure for torque converter and transmission hydraulic circuit 594
Method of moving machine when transmission valve is broken 597
Testing and adjusting, Part 2 601
Testing and adjusting steering stop valve 603
Testing and adjusting steering wheel 605
Testing steering oil pressure 607
Bleeding air from steering cylinder circuit 610
Testing hydraulic drive fan 611
Bleeding air from hydraulic drive fan circuit 614
Measuring brake pedal 616
Measuring brake performance 617
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 618
Testing and adjusting accumulator charge pressure 625
Testing wheel brake oil pressure 627
Measuring wear of wheel brake disc 629
Bleeding air from brake circuit 630
Releasing residual pressure in brake accumulator circuit 632
Testing parking brake performance 633
Measuring parking brake oil pressure 634
Testing wear of parking brake disc 637
Method of releasing parking brake manually 638
Measuring and adjusting work equipment control lever 639
Testing and adjusting work equipment PPC oil pressure 640
Measuring work equipment oil pressure 642
Bleeding air from work equipment circuit 648
Releasing residual pressure in work equipment circuit 649
Method of moving machine when removing operator cab (when separate cab and floor specification) 650
Testing and adjusting bucket positioner 651
Testing and adjusting lift arm position detecting lever 653
Checking proximity switch operation indication lamp 654
Procedure for testing diodes 655
Preparations for work on troubleshooting of electrical system 656
Testing and adjusting, Part 3 661
Testing and adjusting, Part 3 662
How to start KOMTRAX terminal operations (if equipped) 662
Indicator lamps of KOMTRAX terminal (if equipped) 667
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller 670
Special functions of machine monitor (EMMS) 672
Testing and adjusting, Part 4 713
Testing and adjusting, Part 4 714
Special functions of machine monitor (EMMS) 714
Pm clinic inspection table 752
40 Troubleshooting 0
General information on troubleshooting 757
Points to remember when performing troubleshooting 758
How to proceed in troubleshooting 760
Testing before troubleshooting 762
Classification and procedures of troubleshooting 763
Information in troubleshooting table 767
Troubleshooting method for disconnecting wiring harness of pressure sensor system 769
Connection table for connector pin numbers 771
T- branch box and T- branch adapter table 807
Troubleshooting by failure code (Display of code), Part 1 811
Troubleshooting by failure code (Display of code), Part 1 813
Failure codes list 813
Before carrying out troubleshooting for electrical system 824
Information contained in troubleshooting table 826
Failure code [1500L0] (TORQFLOW transmission : Double meshing) 828
Failure code [15B0NX] (Transmission filter: Clogged) 830
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 832
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 834
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 836
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 838
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 840
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 842
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 844
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 846
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 848
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 850
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 852
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 854
Failure code [2F00MA] (Parking brake: Malfunction) 856
Failure code [2G42ZG] (Front accumulator: Low oil pressure) 858
Troubleshooting by failure code (Display of code), Part 2 861
Failure code [2G43ZG] Rear accumulator: Low oil pressure 864
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree 866
Failure code [AA1ANX] Air cleaner: Clogging 869
Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine 871
Failure code [AB00MA] Alternator: Malfunction 873
Failure code [B@BAZG] Low engine oil pressure 875
Failure code [B@BAZK] Engine oil: Low level 876
Failure code [B@BCNS] Coolant: Overheating 878
Failure code [B@BCZK] Coolant: Low level 880
Failure code [b@CENS] Torque converter oil: Overheating 882
Failure code [B@CENS] Torque converter oil: Overheating 883
Failure code [B@GAZK] Battery electrolyte: Low level 884
Failure code [B@HANS] Hydraulic oil: Overheating 885
Failure code [CA111] Abnormality in engine controller 886
Failure code [CA115] Engine Ne or Bkup speed sensor error 889
Failure code [CA122] Charge (boost) pressure sensor high error 890
Failure code [CA123] Charge (boost) pressure sensor low error 892
Failure code [CA131] Throttle sensor high error 894
Failure code [CA132] Throttle sensor low error 897
Failure code [CA135] Engine oil pressure sensor high error 900
Failure code [CA141] Engine oil pressure sensor low error 902
Failure code [CA144] Coolant temperature sensor high error 904
Failure code [CA145] Coolant temperature sensor low error 906
Failure code [CA153] Charge (boost) temperature sensor high error 908
Failure code [CA154] Charge (boost) temperature sensor low error 910
Failure code [CA187] Sensor power supply 2 low error 912
Failure code [CA221] Atmospheric pressure sensor high error 916
Failure code [CA222] Atmospheric pressure sensor low error 918
Failure code [CA227] Sensor power supply 2 high error 920
Troubleshooting by failure code (Display of code), Part 3 923
Failure code [CA234] Engine overspeed 925
Failure code [CA238] Ne speed sensor power supply error 926
Failure code [CA263] Fuel Temp Sensor High Error 928
Failure code [CA265] Fuel Temp Sensor Low Error 930
Failure code [CA271] PCV1 Short circuit 932
Failure code [CA272] PCV1 Disconnection 933
Failure code [CA273] PCV2 Short circuit 934
Failure code [CA274] PCV2 Disconnection 935
Failure code [CA322] Injector #1 open/short error 936
Failure code [CA323] Injector #5 open/short error 938
Failure code [CA324] Injector #3 open/short error 940
Failure code [CA325] Injector #6 open/short error 942
Failure code [CA331] Injector #2 open/short error 944
Failure code [CA332] Injector #4 open/short error 946
Failure code [CA342] Calibration code inconsistency 948
Failure code [CA351] Injectors drive circuit error 949
Failure code [CA352] Sens Supply 1 Volt Low Error 950
Failure code [CA386] Sensor power supply 1 high error 952
Failure code [CA431] Idle validation switch error 953
Failure code [CA432] Idle validation action error 956
Failure code [CA441] Battery voltage low error 959
Failure code [CA442] Battery voltage high error 960
Failure code [CA449] Common rail pressure high error 2 961
Failure code [CA451] Rail Press Sensor High Error 962
Failure code [CA452] Rail Press Sensor Low Error 964
Failure code [CA553] Common rail pressure high error 1 966
Failure code [CA554] Common rail pressure sensor in range error 967
Failure code [CA559] Supply pump pressure very low error 1 968
Failure code [CA689] Engine Ne speed sensor error 972
Failure code [CA731] Engine Bkup speed sensor phase error 974
Failure code [CA757] All continuous data lost error 975
Failure code [CA778] Engine Bkup speed sensor error 976
Failure code [CA1228] EGR valve servo error 1 980
Failure code [CA1625] EGR valve servo error 2 981
Failure code [CA1626] Bypass valve solenoid current high error 982
Failure code [CA1627] Bypass valve solenoid current low error 984
Failure code [CA1628] Bypass Valve Servo Error 1 986
Failure code [CA1629] Bypass Valve Servo Error 2 987
Failure code [CA1631] Bypass valve lift sensor high error 988
Failure code [CA1632] Bypass valve lift sensor low error 990
Failure code [CA1633] KOMNET datalink timeout error 992
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor 994
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor 996
Troubleshooting by failure code (Display of code), Part 4 999
Failure code [CA2185] Throttle sensor supply voltage high error 1002
Failure code [CA2186] Throttle sensor power supply low error 1004
Failure code [CA2249] Supply pump pressure very low error 2 1006
Failure code [CA2271] EGR valve lift sensor high error 1008
Failure code [CA2272] EGR valve lift sensor low error 1010
Failure code [CA2351] EGR valve solenoid operation short circuit 1012
Failure code [CA2352] EGR valve solenoid operation disconnect 1014
Failure code [CA2555] Intake air heater relay open circuit error 1016
Failure code [CA2556] Intake air heater relay short circuit error 1018
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit 1020
Failure code [D191KA] Joystick steering neutral safety relay: Disconnection 1022
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit 1024
Failure code [D192KA] ECSS solenoid: Disconnection 1026
Failure code [D192KB] ECSS solenoid: Short circuit 1027
Failure code [D192KY] ECSS solenoid: Short circuit with power supply line 1028
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection 1030
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit 1032
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit with power supply line 1034
Failure code [D5ZHKA] Terminal C signal: Disconnection 1036
Failure code [D5ZHKB] Terminal C signal: Short circuit 1040
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit 1042
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine running or stopped state 1044
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree 1047
Failure code [DAF3KK] Machine monitor: Low source voltage (input) 1050
Failure code [DAF5KP] Machine monitor: Low output voltage 1052
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system) 1054
Failure code [DAQ0KK] Transmission controller: Low source voltage 1055
Failure code [DAQ0KT] Transmission controller: Abnormality in controller 1058
Failure code [DAQ2KK] Transmission controller load power supply line: Low source voltage (input) 1059
Failure code [DAQ9KQ] Transmission controller model selection: Disagreement of model selection signals 1062
Troubleshooting by failure code (Display of code), Part 5 1065
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system) 1068
Failure code [DAQRMA] Transmission controller option setting: Malfunction 1073
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system) 1075
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 1080
Failure code [DB90KT] Work equipment controller: Abnormality in controller 1083
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) 1084
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range 1088
Failure code [DB99KQ] Work equipment controller model selection: Disagreement of model selection signals 1090
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system) 1091
Failure code [DB9RMA] Work equipment controller option setting: Malfunction 1092
Failure code [DB9RMC] CAN communication with work equipment controller: Defective operation 1093
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time 1094
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time 1096
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 1098
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 1100
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time 1102
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time 1104
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time 1106
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time 1108
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time 1110
Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time 1112
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree 1114
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit 1116
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit 1119
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree 1122
Troubleshooting by failure code (Display of code), Part 6 1127
Troubleshooting by failure code (Display of code), Part 6 1130
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time) 1130
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 1132
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1134
Failure code [DDK3KB] (Right FNR switch: Short circuit) 1136
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1138
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) 1140
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 1142
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1144
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1148
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 1150
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 1152
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 1154
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 1156
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 1158
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) 1160
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1164
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) 1166
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 1168
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 1170
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) 1172
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 1174
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 1176
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) 1178
Troubleshooting by failure code (Display of code), Part 7 1181
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) 1184
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 1186
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 1188
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) 1190
Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine) 1192
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 1194
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) 1197
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 1200
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 1204
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) 1207
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 1210
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) 1213
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 1216
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 1220
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) 1223
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection) 1226
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line) 1229
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree) 1231
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection) 1234
Troubleshooting by failure code (Display of code), Part 8 1239
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line) 1242
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 1244
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) 1246
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 1248
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) 1250
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) 1252
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1256
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 1258
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 1260
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 1262
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 1264
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) 1266
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) 1268
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range) 1270
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 1272
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 1274
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 1276
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1278
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1280
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1281
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 1282
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1284
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1285
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 1286
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1288
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1290
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 1292
Troubleshooting by failure code (Display of code), Part 9 1295
Troubleshooting by failure code (Display of code), Part 9 1297
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1297
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1298
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) 1300
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1302
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1304
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 1306
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) 1308
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) 1308
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) 1309
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 1310
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 1312
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) 1314
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 1316
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 1318
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) 1320
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 1322
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 1324
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) 1326
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 1328
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 1330
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 1332
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1334
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1335
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 1336
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) 1337
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) 1338
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1339
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1340
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 1342
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1344
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1346
Troubleshooting by failure code (Display of code), Part 10 1349
Troubleshooting by failure code (Display of code), Part 10 1352
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 1352
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1354
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1356
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 1358
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1360
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1362
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 1364
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1366
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1368
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 1370
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1372
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1374
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 1376
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1378
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1380
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 1382
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) 1384
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit) 1385
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line) 1386
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) 1387
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) 1388
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line) 1389
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 1390
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 1392
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) 1394
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 1396
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 1398
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) 1400
Troubleshooting of electrical system (E-mode) 1403
Before carrying out troubleshooting of electrical system 1405
Information in troubleshooting table 1408
E-1 Engine does not start 1409
E-2 Wiper does not operate 1414
E-3 Windshield washer does not operate 1418
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 1421
E-5 Working lamp does not light up or go off 1429
E-6 Turn signal lamp and hazard lamp do not light up or go off 1434
E-7 Brake lamp does not light or it keeps lighting up 1440
E-8 Backup lamp does not light or it keeps lighting up 1442
E-9 Backup buzzer does not sound or it keeps sounding 1444
E-10 Horn does not sound or it keeps sounding 1446
E-11 Alarm buzzer does not sound or it keeps sounding 1449
E-12 Air conditioner does not operate or stop 1451
E-13 KOMTRAX system does not work properly 1454
Troubleshooting of hydraulic and mechanical system (H-mode) 1457
Troubleshooting of hydraulic and mechanical system (H-mode) 1459
Method of using troubleshooting chart 1459
Table of failure modes and causes 1462
H-1 Machine does not start 1466
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)] 1468
H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)] 1469
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted 1470
H-5 Shocks are large at the times of starting and shifting gear 1472
H-6 Time lag is large at the times of starting and shifting gear 1474
H-7 Torque converter oil temperature is high 1476
H-8 Steering does not turn 1477
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1478
H-10 Steering response is low 1479
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)] 1480
H-12 Steering is heavy 1481
H-13 When machine turns, it shakes or makes large shocks 1482
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] 1483
H-15 Wheel brake does not work or does not work well 1484
H-16 Wheel brake is not released or it drags 1485
H-17 Parking brake does not work or does not work well 1486
H-18 Parking brake is not released or it drags (including emergency release system) 1487
H-19 Lift arm does not rise 1488
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1489
H-21 When rising, lift arm comes to move slowly at specific height 1490
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) 1490
H-23 Hydraulic drifts of lift arm occur often 1490
H-24 Lift arm wobbles during operation 1490
H-25 Bucket does not tilt back 1491
H-26 Bucket speed is low or tilting back force is insufficient 1492
H-27 Bucket comes to operate slowly in the midst of tilting-back 1493
H-28 Bucket cylinder cannot hold down the bucket 1493
H-29 Hydraulic drifts of bucket occur often 1493
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”) 1493
H-31 During operation of machine, engine speed lowers remarkably or engine stalls 1494
H-32 Large shocks are made when work equipment starts and stops 1494
H-33 When work equipment circuit is relieved singly, other work equipment moves 1494
H-34 ECSS does not operate, and pitching and bouncing occur 1495
Troubleshooting of engine (S-mode) 1497
Troubleshooting of engine (S-mode) 1499
Method of using troubleshooting chart 1499
S-1 Engine does not start easily 1502
S-2 Engine does not start 1504
S-3 Engine does not pick up smoothly 1508
S-4 Engine stops during operation 1509
S-5 Engine does not rotate smoothly (Engine hunts ) 1510
S-6 Engine lacks output (or lacks power) 1511
S-7 Exhaust smoke is black (Incomplete combustion) 1512
S-8 Oil is consumed much (or exhaust gas color is blue) 1514
S-9 Engine oil becomes contaminated quickly 1515
S-10 Fuel consumption is excessive 1516
S-11 Coolant contains oil (blows back or reduces) 1517
S-12 Oil pressure drops 1518
S-13 Oil level rises (Water, fuel in oil) 1519
S-14 Coolant temperature rises too high (Overheating) 1521
S-15 Abnormal noise is made 1522
S-16 Vibration is excessive 1523
50 Disassembly and assembly 0
General information on disassembly and assembly 1525
How to read this manual 1526
Coating materials list 1528
Special tool list 1531
Sketches of special tools 1535
Engine and cooling system, Part 1 1543
Removal and installation of engine assembly 1544
Removal and installation of radiator assembly 1554
Removal and installation of air aftercooler 1558
Removal and installation of cooling fan and fan motor assembly 1561
Removal and installation of radiator guard and cooling fan motor assembly 1565
Removal and installation of fuel tank assembly 1570
Removal and installation of hood 1574
Engine and cooling system, Part 2 1579
Removal and installation of fuel supply pump assembly 1580
Removal and installation of cylinder head assembly 1587
Removal and installation of fuel injector assembly 1601
Removal and installation of engine front seal 1605
Removal and installation of engine rear seal 1609
Power train, Part 1 1617
Removal and installation of torque converter and transmission assembly 1618
Disconnection and connection of power train unit 1628
Disassembly and assembly of input transfer assembly 1635
Disassembly and assembly of torque converter assembly (lockup specification) 1643
Disassembly and assembly of torque converter assembly (lockup-less specification) 1660
Power train, Part 2 1677
Disassembly and assembly of transmission assembly 1678
Disassembly and assembly of transfer and parking brake assembly 1712
Removal and installation of front axle assembly 1734
Removal and installation of rear axle assembly 1738
Power train, Part 3 1743
Removal and installation of front differential assembly 1744
Disassembly and assembly of differential assembly (LSD specification) 1747
Disassembly and assembly of differential assembly (LSD-less specification) 1764
Disassembly and assembly of final drive assembly (front and rear) 1778
Brake system 1787
Removal and installation of brake assembly (front and rear) 1788
Disassembly and assembly of brake assembly (front and rear) 1795
Disassembly and assembly of slack adjuster assembly 1804
Disassembly and assembly of brake accumulator charge valve assembly 1805
Undercarriage and frame 1809
Removal and installation of center hinge pin 1810
Hydraulic system 1821
Removal and installation of hydraulic tank assembly 1822
Removal and installation of hydraulic cooling pump assembly 1828
Removal and installation of cooling fan pump assembly 1831
Removal and installation of work equipment pump assembly 1834
Removal and installation of steering, torque converter charge and EPC pump assembly 1838
Removal and installation of work equipment valve assembly 1842
Disassembly and assembly of work equipment control valve assembly 1847
Disassembly and assembly of steering cylinder assembly 1851
Disassembly and assembly of lift arm and bucket cylinder assembly 1856
Removal and installation of steering control valve assembly 1865
Work equipment 1869
Removal and installation of work equipment assembly 1870
Removal and installation of large counterweight assembly 1875
Removal and installation of small counterweight assembly 1878
Cab and its attachments 1881
Removal and installation of operator’s cab assembly (separate cab and floor specification) 1882
Removal and installation of operator’s cab and floor frame assembly (cab-floor unit specification) 1890
Removal and installation of operator’s cab glass (stuck glass) 1897
Disassembly and assembly of operator’s seat assembly 1907
Electrical system 1943
Removal and installation of engine controller assembly 1944
Removal and installation of transmission controller assembly 1946
Removal and installation of work equipment controller assembly 1949
Removal and installation of KOMTRAX terminal assembly 1952
Removal and installation of air conditioner unit assembly 1953
80 Appendix 0
Air conditioner 1961
Precautions for refrigerant 1963
Troubleshooting procedure 1964
Circuit diagram and arrangement of connector pins 1966
System diagram 1971
Detail of air conditioner unit 1973
Parts and connectors layout 1975
Testing with self-diagnosis function (indication on control panel) 1979
Testing temperature control 1982
Testing vent (mode) changeover 1983
Testing Fresh/Recirc changeover 1985
Testing inside air temp sensor and outside air temp sensor 1987
Testing evaporator temperature sensor 1989
Testing sunlight sensor 1990
Testing relays 1991
Troubleshooting chart 1 1992
Troubleshooting chart 2 1993
Information in troubleshooting table 1996
Troubleshooting for power supply system (Air conditioner does not operate) 1997
Troubleshooting for compressor and refrigerant system (Air is not cooled) 2000
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2003
Troubleshooting for temperature control 2009
Troubleshooting for vent (mode) changeover 2012
Troubleshooting for Fresh/Recirc air changeover 2015
Troubleshooting with gauge pressure 2017
Connection of service tool 2019
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 2020
Handling of compressor oil 2022
90 Diagrams and drawings 0
Hydraulic diagrams and drawings 2025
Automatic greasing circuit diagram 2026
Power train hydraulic circuit diagram 2029
Brake hydraulic circuit diagram 2033
Work equipment hydraulic circuit diagram 2037
Electrical diagrams and drawings 2041
Engine electrical circuit diagram 2042
Air conditioner electrical circuit diagram 2043
Electrical circuit diagram 2045
Connector arrangement diagram 2059

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