WD600-6 | SN: 55001 and up | Komatsu | Heavy Equipment Manual PDF

Compositionofshopmanual1

ThecontentsofthisshopmanualareshowntogetherwithFormNo.inalist.

SectionTitleFormNumber

ShopManual,contentsbinder,binderlabelandtabs.....................................................................SEN04979-15

00Indexandforeword....................................................................................................................SEN04980-15

100Index..................................................................................................................................SEN04981-15

200Forewordandgeneralinformation.....................................................................................SEN04982-03

01Specification...............................................................................................................................SEN04983-01

100Specificationandtechnicaldata.........................................................................................SEN04984-01

10Structure,functionandmaintenancestandard...........................................................................SEN04985-05

100Engineandcoolingsystem................................................................................................SEN04986-00

201Powertrain,Part1.............................................................................................................SEN04987-00

202Powertrain,Part2.............................................................................................................SEN04988-01

300Steeringsystem.................................................................................................................SEN04989-01

400Brakesystem.....................................................................................................................SEN04990-00

500Undercarriageandframe...................................................................................................SEN04991-00

601Hydraulicsystem,Part1....................................................................................................SEN04992-00

602Hydraulicsystem,Part2....................................................................................................SEN04993-00

700Workequipment.................................................................................................................SEN04994-00

800Cabanditsattachments....................................................................................................SEN04995-00

901Electricalsystem,Part1....................................................................................................SEN04996-02

902Electricalsystem,Part2....................................................................................................SEN04997-00

903Electricalsystem,Part3....................................................................................................SEN04998-02

20Standardvaluetable...................................................................................................................SEN04999-02

100Standardservicevaluetable..............................................................................................SEN05044-02

30Testingandadjusting.................................................................................................................SEN05000-09

101Testingandadjusting,Part1..............................................................................................SEN05045-05 102Testingandadjusting,Part2..............................................................................................SEN05046-01 103Testingandadjusting,Part3..............................................................................................SEN05047-02 104Testingandadjusting,Part4..............................................................................................SEN05048-06

40Troubleshooting..........................................................................................................................SEN05001-04

100Failurecodetableandfuselocations................................................................................SEN05049-01 200Generalinformationontroubleshooting.............................................................................SEN05050-02

301Troubleshootingbyfailurecode(Displayofcode),Part1.................................................SEN05051-01

302Troubleshootingbyfailurecode(Displayofcode),Part2.................................................SEN05052-02

303Troubleshootingbyfailurecode(Displayofcode),Part3.................................................SEN05053-02 304Troubleshootingbyfailurecode(Displayofcode),Part4.................................................SEN05054-02 305Troubleshootingbyfailurecode(Displayofcode),Part5.................................................SEN05055-02 306Troubleshootingbyfailurecode(Displayofcode),Part6.................................................SEN05056-03 307Troubleshootingbyfailurecode(Displayofcode),Part7.................................................SEN05057-01 308Troubleshootingbyfailurecode(Displayofcode),Part8.................................................SEN05058-01

309Troubleshootingbyfailurecode(Displayofcode),Part9.................................................SEN05059-01 310Troubleshootingbyfailurecode(Displayofcode),Part10...............................................SEN05060-01

400Troubleshootingofelectricalsystem(E-mode)..................................................................SEN05061-01

500Troubleshootingofhydraulicandmechanicalsystem(H-mode)........................................SEN05062-01

600Troubleshootingofengine(S-mode)..................................................................................SEN05063-00

50Disassemblyandassembly........................................................................................................SEN05002-06

100Generalinformationondisassemblyandassembly...........................................................SEN05141-01

201Engineandcoolingsystem,Part1.....................................................................................SEN05142-02

202Engineandcoolingsystem,Part2.....................................................................................SEN05143-02

301Powertrain,Part1..............................................................................................................SEN05144-01

302Powertrain,Part2..............................................................................................................SEN05145-02

303Powertrain,Part3..............................................................................................................SEN05146-01

304Powertrain,Part4..............................................................................................................SEN05147-00

400Brakesystem......................................................................................................................SEN05148-01

500Undercarriageandframe...................................................................................................SEN05149-01

600Hydraulicsystem................................................................................................................SEN05150-01

700Workequipment.................................................................................................................SEN05151-00

800Cabanditsattachments.....................................................................................................SEN05152-02

900Electricalsystem................................................................................................................SEN05153-00

90Diagramsanddrawings..............................................................................................................SEN05003-04

100Hydraulicdiagramsanddrawings......................................................................................SEN05004-01

200Electricaldiagramsanddrawings.......................................................................................SEN05005-03

Tableofcontents1

Testingandadjustingpowertrainoilpressure..............................................................................................39

Flushingprocedurefortorqueconverterandtransmissionhydrauliccircuit.................................................53

Methodofmovingmachinewhentransmissionvalveisbroken...................................................................55

Movingmethodofmachinedisabledbyshort-to-powerfailureinworkequipmentpotentiometer................57

Adjustingsteeringstopvalve........................................................................................................................59

102Testingandadjusting,Part2SEN05046-01

MeasuringoperatingeffortofAJSSlever(AJSSspecification)....................................................................3

TestingandadjustingAJSSleveranglesensorandframeanglesensor(AJSSspecification)....................4

Testingandadjustingsteeringstopperbolt(AJSSspecification)..................................................................6

Testingandadjustingsteeringwheel(Steeringwheelspecification)............................................................8

Testingsteeringoilpressure.........................................................................................................................10

Bleedingairfromsteeringcylindercircuit.....................................................................................................14

Testinghydraulicdrivefan.............................................................................................................................15

Bleedingairfromhydraulicdrivefancircuit..................................................................................................18

Measuringbrakepedal..................................................................................................................................20

Measuringbrakeperformance......................................................................................................................21

Testingandadjustingaccumulatorchargepressure.....................................................................................22

Testingofaccumulatornitrogengaspressureandprocedureforchargingbrake accumulatorwithnitrogengas................................................................................................................24

Testingwheelbrakeoilpressure...................................................................................................................32

Measuringwearofwheelbrakedisc.............................................................................................................34

Bleedingairfromwheelbrakecircuit............................................................................................................35

Releasingresidualpressureinbrakeaccumulatorcircuit.............................................................................36

Testingparkingbrakeperformance...............................................................................................................37

Measuringparkingbrakeoilpressure...........................................................................................................38

Testingwearofparkingbrakedisc................................................................................................................41

Methodofreleasingparkingbrakemanually.................................................................................................42

Measuringandadjustingworkequipmentcontrollever................................................................................43

Measuringworkequipmentoilpressure........................................................................................................44

Bleedingairfromworkequipmentcircuit.......................................................................................................49

Movingmachineforremovingoperatorcab..................................................................................................50

Preparationsforworkontroubleshootingofelectricsystem.........................................................................52

Procedurefortestingdiodes..........................................................................................................................56

103Testingandadjusting,Part3SEN05047-02

Machinemonitor-basedadjustmentatreplacement,disassemblyandassembly, andadditionalinstallationforeachsensorandcontroller........................................................................2

Specialfunctionsofmachinemonitor(EMMS)..............................................................................................5

104Testingandadjusting,Part4SEN05048-06

VHMScontrollerinitialsettingprocedure(ORBCOMMinstallationspecification).........................................2

VHMScontrollerinitialsettingprocedure(IRIDIUMinstallationspecification)..............................................24

PrecautionsforreplacingVHMScontroller....................................................................................................46 Pm-clinicinspectiontable..............................................................................................................................52

40Troubleshooting

100FailurecodetableandfuselocationsSEN05049-01

Failurecodeslist............................................................................................................................................2

Fuselocations...............................................................................................................................................14

200GeneralinformationontroubleshootingSEN05050-02

Precautionsbeforework................................................................................................................................2

Pointstorememberwhenperformingtroubleshooting..................................................................................3

Howtoproceedintroubleshooting................................................................................................................5

Checksbeforetroubleshooting......................................................................................................................7

Classificationandproceduresoftroubleshooting..........................................................................................8

Informationintroubleshootingtable..............................................................................................................12

Troubleshootingmethodfordisconnectingwiringharnessofpressuresensorsystem................................14

PhenomenalookingliketroublesandtroubleshootingNos...........................................................................17

Connectiontableforconnectorpinnumbers.................................................................................................19 T-branchboxandT-branchadaptertable...................................................................................................55

301Troubleshootingbyfailurecode(Displayofcode),Part1SEN05051-01

Failurecode[1500L0]TORQFLOWtransmission:Doublemeshing.............................................................3

Failurecode[15B0NX]TransmissionOilFilterClogging...............................................................................4

Failurecode[15SAL1]ECMVFclutch:WhencommandcurrentisOFF,fillsignalisON............................6

Failurecode[15SALH]ECMVFclutch:WhencommandcurrentisON,fillsignalisOFF...........................8

Failurecode[15SBL1]ECMVRclutch:WhencommandcurrentisOFF,fillsignalisON............................10

Failurecode[15SBLH]ECMVRclutch:WhencommandcurrentisON,fillsignalisOFF...........................12

Failurecode[15SEL1]ECMV(1):WhencommandcurrentisOFF,fillsignalisON.....................................14

Failurecode[15SELH]ECMV(1):WhencommandcurrentisON,fillsignalisOFF....................................16

Failurecode[15SFL1]ECMV(2):WhencommandcurrentisOFF,fillsignalisON.....................................18

Failurecode[15SFLH]ECMV(2):WhencommandcurrentisON,fillsignalisOFF....................................20

Failurecode[15SGL1]ECMV(3):WhencommandcurrentisOFF,fillsignalisON....................................22

Failurecode[15SGLH]ECMV(3):WhencommandcurrentisON,fillsignalisOFF...................................24

Failurecode[15SHL1]ECMV(4):WhencommandcurrentisOFF,fillsignalisON....................................26

Failurecode[15SHLH]ECMV(4):WhencommandcurrentisON,fillsignalisOFF...................................28

Failurecode[15W0NT]Transmissionmodulationclutch:Overheating.........................................................30

Failurecode[2F00MA]Parkingbrake:Malfunction.......................................................................................31

Failurecode[2G42ZG]FrontAccumulatorOilPressureLow.......................................................................34

302Troubleshootingbyfailurecode(Displayofcode),Part2SEN05052-02

Failurecode[2G43ZG]RearAccumulatorOilPressureLow........................................................................4

Failurecode[A000N1](orVHMS_LEDdisplay:“n2”“01”)Engine:Overrun............................................7

Failurecode[AA1ANX]AirCleanerClogging...............................................................................................8

Failurecode[AB00L6]Alternator:Signaldisagreeswithrunandstopofengine.........................................10

Failurecode[AB00MA]Alternator:Malfunction............................................................................................12

Failurecode[B@BAZG]Engineoilpressure:Lowerror...............................................................................14

Failurecode[B@BAZK]EngOilLevelLow..................................................................................................15

Failurecode[B@BCNS]Enginecoolanttemperature:Overheating.............................................................16

Failurecode[B@BCZK]Enginecoolantlevellow........................................................................................18

Failurecode[B@C7NS]Brakeoiloverheating.............................................................................................20

Failurecode[b@CENS]Torqueconverteroiloverheating...........................................................................21

Failurecode[B@CENS]Torqueconverteroiloverheating...........................................................................22

Failurecode[B@GAZK]LowBatteryFluidLevel.........................................................................................23

Failurecode[B@HANS]HydOilOverheat...................................................................................................24

Failurecode[CA111]Abnormalityinenginecontroller..................................................................................26

Failurecode[CA115]EngineNeorBkupspeedsensorerror......................................................................29

Failurecode[CA122]Charge(boost)pressuresensorhigherror................................................................30

Failurecode[CA123]Charge(boost)pressuresensorlowerror..................................................................32

Failurecode[CA131]Throttlesensorhigherror...........................................................................................34

Failurecode[CA132]Throttlesensorlowerror............................................................................................37

Failurecode[CA135]Engineoilpressuresensorhigherror........................................................................40

Failurecode[CA141]Engineoilpressuresensorlowerror..........................................................................42

Failurecode[CA144]Coolanttemperaturesensorhigherror......................................................................44

Failurecode[CA145]Coolanttemperaturesensorlowerror........................................................................46

Failurecode[CA153]Charge(boost)temperaturesensorhigherror...........................................................48

Failurecode[CA154]Charge(boost)temperaturesensorlowerror............................................................50

Failurecode[CA187]Sensorpowersupply2lowerror................................................................................52

Failurecode[CA212]Engineoiltemperaturesensorhigherror...................................................................54

Failurecode[CA213]Engineoiltemperaturesensorlowerror....................................................................56

Failurecode[CA221]Atmosphericpressuresensorhigherror....................................................................58

Failurecode[CA222]Atmosphericpressuresensorlowerror......................................................................60

Failurecode[CA227]Sensorpowersupply2higherror..............................................................................62 303Troubleshootingbyfailurecode(Displayofcode),Part3SEN05053-02

Failurecode[CA234]Engineoverspeed......................................................................................................3

Failurecode[CA238]Nespeedsensorpowersupplyerror.........................................................................4

Failurecode[CA263]FuelTempSensorHighError.....................................................................................6

Failurecode[CA265]FuelTempSensorLowError......................................................................................8

Failurecode[CA271]PCV1Shortcircuit......................................................................................................10

Failurecode[CA272]PCV1Disconnection..................................................................................................11

Failurecode[CA273]PCV2Shortcircuit......................................................................................................12

Failurecode[CA274]PCV2Disconnection..................................................................................................13

Failurecode[CA322]Injector#1open/shorterror........................................................................................14

Failurecode[CA323]Injector#5open/shorterror........................................................................................16

Failurecode[CA324]Injector#3open/shorterror........................................................................................18

Failurecode[CA325]Injector#6open/shorterror........................................................................................20

Failurecode[CA331]Injector#2open/shorterror........................................................................................22

Failurecode[CA332]Injector#4open/shorterror........................................................................................24

Failurecode[CA342]Calibrationcodeinconsistency...................................................................................26

Failurecode[CA351]Injectorsdrivecircuiterror..........................................................................................27

Failurecode[CA352]SensSupply1VoltLowError.....................................................................................28

Failurecode[CA386]Sensorpowersupply1higherror..............................................................................30

Failurecode[CA431]Idlevalidationswitcherror..........................................................................................31

Failurecode[CA432]Idlevalidationactionerror..........................................................................................34

Failurecode[CA441]Batteryvoltagelowerror............................................................................................37

Failurecode[CA442]Batteryvoltagehigherror...........................................................................................38

Failurecode[CA449]Commonrailpressurehigherror2.............................................................................39

Failurecode[CA451]RailPressSensorHighError.....................................................................................40

Failurecode[CA452]RailPressSensorLowError......................................................................................42

Failurecode[CA553]Commonrailpressurehigherror1.............................................................................44

Failurecode[CA554]Commonrailpressuresensorinrangeerror..............................................................45

Failurecode[CA559]Supplypumppressureverylowerror1......................................................................46

Failurecode[CA689]EngineNespeedsensorerror....................................................................................50

Failurecode[CA731]EngineBkupspeedsensorphaseerror.....................................................................52

Failurecode[CA757]Allcontinuousdatalosterror......................................................................................53

Failurecode[CA778]EngineBkupspeedsensorerror................................................................................54

Failurecode[CA1228]EGRvalveservoerror1...........................................................................................56

Failurecode[CA1625]EGRvalveservoerror2...........................................................................................57

Failurecode[CA1626](Bypassvalvesolenoidcurrenthigherror)...............................................................58

Failurecode[CA1627](Bypassvalvesolenoidcurrentlowerror).................................................................60

Failurecode[CA1628]BypassValveServoError1......................................................................................62

Failurecode[CA1629]BypassValveServoError2......................................................................................63

Failurecode[CA1631](Bypassvalveliftsensorhigherror)..........................................................................64

Failurecode[CA1632](Bypassvalveliftsensorlowerror)...........................................................................66

Failurecode[CA1633]KOMNETdatalinktimeouterror................................................................................68

304Troubleshootingbyfailurecode(Displayofcode),Part4SEN05054-02

Failurecode[CA2185]Throttlesensorsupplyvoltagehigherror.................................................................4

Failurecode[CA2186]Throttlesensorpowersupplylowerror.....................................................................6

Failurecode[CA2249]Supplypumppressureverylowerror2....................................................................8

Failurecode[CA2271]EGRvalveliftsensorhigherror................................................................................10

Failurecode[CA2272]EGRvalveliftsensorlowerror.................................................................................12

Failurecode[CA2351]EGRvalvesolenoidoperationshortcircuit...............................................................14

Failurecode[CA2352]EGRvalvesolenoidoperationdisconnect................................................................16

Failurecode[CA2555]Intakeairheaterrelayopencircuiterror...................................................................18

Failurecode[CA2556]Intakeairheaterrelayshortcircuiterror...................................................................20

Failurecode[D191KA]AJSSneutralsafetyrelayopencircuit......................................................................22

Failurecode[D191KB]AJSSneutralsafetyrelayshortcircuit......................................................................24

Failurecode[D198KA]Transmissionoilpressurebypasssolenoid:Disconnection.....................................26

Failurecode[D198KB]Transmissionoilpressurebypasssolenoid:Shortcircuit.........................................27

Failurecode[D198KY]Transmissionoilpressurebypasssolenoid:Shortcircuitwithpowersupplyline.....28

Failurecode[D5ZHKA]TerminalCsignalopencircuit..................................................................................30

Failurecode[D5ZHKB]TerminalCsignalshortcircuit..................................................................................32

Failurecode[D5ZHKZ]TerminalCsignalopenorshortcircuit.....................................................................34

Failurecode[D5ZHL6]TerminalCsignaldisagreeswithrunandstopofengine.........................................36

Failurecode[DA80L4]Auto-greasingcontrollerdisagreeswithON/OFFsignal...........................................38

Failurecode[DAF3KK]Machinemonitor:Sourcevoltagelow(input)...........................................................40

Failurecode[DAF5KP]Machinemonitor:Outputvoltagelow......................................................................42

Failurecode[DAFRKR]CANcommunicationwithmachinemonitor:Communicationerror(Abnormalityintargetcomponentsystem)...........................................................................................................................44

Failurecode[DAQ0KK]Transmissioncontroller:Sourcevoltagelow...........................................................45

Failurecode[DAQ0KT]Transmissioncontroller:Defectincontroller...........................................................48

Failurecode[DAQ2KK]Transmissioncontrollerloadpowersupplyline:Sourcevoltagelow(Input)...........50

Failurecode[DAQ9KQ]Transmissioncontrollermodelselection:Modelselectionsignaldisagreement.....53

Failurecode[DAQRKR]CANcommunicationwithtransmissioncontroller:Communicationerror(Abnormality intargetcomponentsystem)...................................................................................................................54

Failurecode[DAQRMA]Transmissioncontroller(Optionsetting):Malfunction............................................59 305Troubleshootingbyfailurecode(Displayofcode),Part5SEN05055-02

Failurecode[DB2RKR]CANcommunicationfromenginecontroller:Communicationerror(Abnormalityintargetcomponentsystem)...........................................................................................................................4

Failurecode[DB90KK]Workequipmentcontroller:Sourcevoltagelow(input)............................................7

Failurecode[DB90KT]Workequipmentcontroller:Defectincontroller.......................................................10

Failurecode[DB92KK]Workequipmentcontrollerloadpowersupplyline:Sourcevoltagelow(input).......11

Failurecode[DB95KX]Workequipmentcontrollerpowersupplyoutput:Outofrange................................14

Failurecode[DB99KQ]Workequipmentcontrollermodelselection:Modelselectionsignaldisagreement.16

Failurecode[DB9RKR]CANcommunicationwithworkequipmentcontroller:Communicationerror(Abnormalityintargetcomponentsystem)...............................................................................................................17

Failurecode[DB9RMA]Workequipmentcontroller(Optionsetting):Malfunction........................................18

Failurecode[DB9RMC]CANcommunicationwithtransmissioncontroller:Malfunction..............................19

Failurecode[DBB0KK]orchangeofVHMS_LEDdisplayfrom"n9"to"01"(VHMScontroller:Sourcevoltage low(input))..............................................................................................................................................20

Failurecode[DBB0KQ]orchangeofVHMS_LEDdisplayfrom"nF"to"11"(VHMScontroller:Disagreementof modelselectionsignals)..........................................................................................................................22

Failurecode[DBB3KK]orchangeofVHMS_LEDdisplayfrom"n9"to"05"(VHMScontrollerbatterypower supply:Sourcevoltagelow(input)).........................................................................................................24

Failurecode[DBB5KP]orchangeofVHMS_LEDdisplayfrom"n9"to"04"(VHMScontroller5Vpowersupply output:Outputvoltagelow).....................................................................................................................26

Failurecode[DBB6KP]orchangeofVHMS_LEDdisplayfrom"n9"to"02"(VHMScontroller24Vpowersupply output:Outputvoltagelow).....................................................................................................................28

Failurecode[DBB7KP]orchangeofVHMS_LEDdisplayfrom"n9"to"03"(VHMScontroller12Vpowersupply output:Outputvoltagelow).....................................................................................................................30

Failurecode[DBBQKR]orchangeofVHMS_LEDdisplayfrom"n8"to"02"(CANcommunicationofVHMS controller:Communicationerror(Abnormalityintargetcomponentsystem)).........................................32

Failurecode[DD15LD]tswitch(Panelswitch1):Switchiskeptpressedforlongtime.............................34

Failurecode[DD16LD]Uswitch(Panelswitch2):Switchiskeptpressedforlongtime.............................36

Failurecode[DD17LD]<switch(Panelswitch3):Switchiskeptpressedforlongtime..............................38

Failurecode[DD18LD]>switch(Panelswitch4):Switchiskeptpressedforlongtime..............................40

306Troubleshootingbyfailurecode(Displayofcode),Part6SEN05056-03

Failurecode[DDA7L4]RPMsetON/OFFswitch:ON-OFFsignalsdisagree...............................................4

Failurecode[DDA8KB]RPMsetidle-up/downselectorswitch(idle-up):Shortcircuit.................................6

Failurecode[DDA9KB]RPMsetidle-up/downselectorswitch(idle-down):Shortcircuit............................9

Failurecode[DDB6L4]Parkingbrakeswitch(Neutralizer):ON/OFFsignalsdisagree................................12

Failurecode[DDD1LD]Pitchoperationswitch:Switchiskeptpressedforlongtime..................................16

Failurecode[DDDBKA]Tractionadjustmentdial:Disconnection.................................................................18

Failurecode[DDDBKB]Tractionadjustmentdial:Shortcircuit....................................................................20

Failurecode[DDE5MA]Emergencysteeringdriveswitch:Malfunction.......................................................22

Failurecode[DDK4KA]AJSSFNRswitch:Disconnection...........................................................................24

Failurecode[DDK4KB]AJSSFNRswitch:Shortcircuit...............................................................................26

Failurecode[DDK5L4]AJSSshift-up/downswitch:ON/OFFsignalsdisagree............................................28

Failurecode[DDK6KA]FNRleverswitch:Disconnection............................................................................31

Failurecode[DDK6KB]FNRleverswitch:Shortcircuit................................................................................34

Failurecode[DDP5KA]Lockdetectionpressureswitchofsteeringlocklever:Disconnection....................36

Failurecode[DDT0L4]Shiftmodeselectorswitch:ON/OFFsignalsdisagree.............................................38

Failurecode[DDW9LD]Kick-downswitch:Switchiskeptpressedforlongtime.........................................40

Failurecode[DDWLLD]Holdswitch:Switchiskeptpressedforlongtime..................................................42

Failurecode[DF10KA]Transmissionshiftleverswitch:Disconnection........................................................44

Failurecode[DF10KB]Transmissionshiftleverswitch:Shortcircuit...........................................................48

Failurecode[DGE5KX](orVHMS_LEDdisplay:“n4”o“01”)

(Atmospherictemperaturesensor:Outofinputsignalrange)................................................................50

Failurecode[DGF1KA]Transmissionoiltemperaturesensor:Disconnection.............................................52

Failurecode[DGF1KB]Transmissionoiltemperaturesensor:Shortcircuit.................................................54 307Troubleshootingbyfailurecode(Displayofcode),Part7SEN05057-01

Failurecode[DGH2KX]Hydraulicoiltemperaturesensor:Outofinputsignalrange...................................4

Failurecode[DGR2KA]Rearbrakeoiltemperaturesensor:Disconnection................................................6

Failurecode[DGR2KX]Rearbrakeoiltemperaturesensor:Outofinputsignalrange................................8

Failurecode[DGT1KA]Torqueconverteroiltemperaturesensor:Disconnection........................................10

Failurecode[DGT1KB]Torqueconverteroiltemperaturesensor:Shortcircuit...........................................12

Failurecode[DGT1KX]Torqueconverteroiltemperaturesensor:Outofinputsignalrange)......................14

Failurecode[DGT4KA](orVHMS_LEDdisplay:"n3""12")Exhaustgastemperaturesensor(F):Disconnection..........................................................................................................................................................16

Failurecode[DGT4KB](orVHMS_LEDdisplay:"n3""11")Exhaustgastemperaturesensor(F):Shortcircuit...........................................................................................................................................................19

Failurecode[DGT5KA](orVHMS_LEDdisplay:"n3""22")Exhaustgastemperaturesensor(R):Disconnection.....................................................................................................................................................22

Failurecode[DGT5KB](orVHMS_LEDdisplay:"n3""21")Exhaustgastemperaturesensor(R):Shortcircuit...........................................................................................................................................................25

Failurecode[DH21KA]Workequipmentpumpoilpressuresensor:Disconnection....................................28

Failurecode[DH21KB]Workequipmentpumpoilpressuresensor:Shortcircuit........................................30

Failurecode[DHE5KB](orVHMS_LEDdisplay:“n3”“32”)Blow-bypressuresensor:Shortcircuit........32

Failurecode[DHE5KY](orVHMS_LEDdisplay:“n3”“31”)Blow-bypressuresensor:Shortcircuitwith powersupplyline.....................................................................................................................................34

Failurecode[DHT2L6]Transmissionfiltercloggingsensor:Signaldisagreeswithoperatingstateofengine36

Failurecode[DHT8KX](orVHMS_LEDdisplay:“n5”“33”)Steeringoilpressuresensor:Outofinputsignal range.......................................................................................................................................................38

Failurecode[DHTBKA]Modulationclutchoilpressuresensor:Disconnection............................................42

Failurecode[DHTBKB]Modulationclutchoilpressuresensor:Shortcircuit................................................44

Failurecode[DHU2KX](orVHMS_LEDdisplay:“n7”“11”)Frontbrakeoilpressuresensor(F):Outofinput signalrange.............................................................................................................................................46

Failurecode[DHU3KX](orVHMS_LEDdisplay:“n7”“12”)Rearbrakeoilpressuresensor(R):Outofinput signalrange.............................................................................................................................................48

Failurecode[DK30KA]AJSSleveranglesensor:Disconnection.................................................................50

Failurecode[DK30KY]AJSSleveranglesensor:Shortcircuitwithpowersupplyline................................52

308Troubleshootingbyfailurecode(Displayofcode),Part8SEN05058-01

Failurecode[DK59KA]LiftEPCleverpotentiometer(Main):Disconnection................................................3

Failurecode[DK59KY]LiftEPCleverpotentiometer(Main):Shortcircuitwithpowersupplyline................6

Failurecode[DK59L8]LiftEPCleverpotentiometer(Main):Analogsignalsdisagree.................................8

Failurecode[DK5AKA]LiftEPCleverpotentiometer(Sub):Disconnection.................................................11

Failurecode[DK5AKY]LiftEPCleverpotentiometer(Sub):Shortcircuitwithpowersupplyline.................14

Failurecode[DK5BKA]Tilt&pitchEPCleverpotentiometer(Main):Disconnection....................................16

Failurecode[DK5BKY]Tilt&pitchEPCleverpotentiometer(Main):Shortcircuitwithpowersupplyline...20

Failurecode[DK5BL8]Tilt&pitchEPCleverpotentiometer(Main):Analogsignalsdisagree.....................22

Failurecode[DK5CKA]Tilt&pitchEPCleverpotentiometer(Sub):Disconnection.....................................25

Failurecode[DK5CKY]Tilt&pitchEPCleverpotentiometer(Sub):Shortcircuitwithpowersupplyline.....28

Failurecode[DKD0KA]Frameanglesensor:Disconnection........................................................................30

Failurecode[DKD0KY]Frameanglesensor:Shortcircuitwithpowersupplyline.......................................32

Failurecode[DKD0KZ]AJSSleverandframeanglesensor:Disconnectionorshortcircuit........................34

Failurecode[DLFAKA]Modulationclutchoutputshaftspeedsensor:Disconnection..................................38

Failurecode[DLFALC]Modulationclutchoutputshaftspeedsensor:Speedsignalsdisagree....................40

Failurecode[DLT3KA]Transmissionoutputshaftspeedsensor(2):Disconnection....................................42

Failurecode[DLT3LC]Transmissionoutputshaftspeedsensor(2):Speedsignalsdisagree.....................44

Failurecode[DLT4KB]Transmissionoutputshaftspeedsensor(1):Shortcircuit.......................................46

Failurecode[DLT4KX]Transmissionoutputshaftspeedsensor(1):Outofinputsignalrange...................48

Failurecode[DV00KB]Alarmbuzzer:Shortcircuit.......................................................................................50

Failurecode[DW4PKA]BladeraiseEPCsolenoid:Disconnection..............................................................52

Failurecode[DW4PKB]BladeraiseEPCsolenoid:Shortcircuit..................................................................54

Failurecode[DW4PKY]BladeraiseEPCsolenoid:Shortcircuitwithpowersupplyline..............................55

Failurecode[DW4QKA]BladelowerEPCsolenoid:Disconnection.............................................................56

Failurecode[DW4QKB]BladelowerEPCsolenoid:Shortcircuit.................................................................57

Failurecode[DW4QKY]BladelowerEPCsolenoid:Shortcircuitwithpowersupplyline............................58

Failurecode[DW4RKA]Tilt&pitchEPCsolenoid:Disconnection...............................................................59

Failurecode[DW4RKB]Tilt&pitchEPCsolenoid:Shortcircuit...................................................................60

Failurecode[DW4RKY]Tilt&pitchEPCsolenoid:Shortcircuitwithpowersupplyline...............................61

Failurecode[DW4SKA]Tilt&pitchEPCsolenoid:Disconnection................................................................62

Failurecode[DW4SKB]Tilt&pitchEPCsolenoid:Shortcircuit...................................................................63

Failurecode[DW4SKY]Tilt&pitchEPCsolenoid:Shortcircuitwithpowersupplyline...............................64

Failurecode[DW7BKA]Fanreversesolenoid:Disconnection.....................................................................66

Failurecode[DW7BKB]Fanreversesolenoid:Shortcircuit.........................................................................68

Failurecode[DW7BKY]Fanreversesolenoid:Shortcircuitwithpowersupplyline.....................................70

309Troubleshootingbyfailurecode(Displayofcode),Part9SEN05059-01

Failurecode[DWM1KA]Workequipmentneutrallocksolenoid:Disconnection..........................................4

Failurecode[DWM1KB]Workequipmentneutrallocksolenoid:Shortcircuit..............................................6

Failurecode[DWM1KY]Workequipmentneutrallocksolenoid:Shortcircuitwithpowersupplyline..........8

Failurecode[DWN7KA]Bladefloatmagnetdetentsolenoid:Disconnection...............................................10

Failurecode[DWN7KB]Bladefloatmagnetdetentsolenoid:Shortcircuit...................................................12

Failurecode[DWN7KY]Bladefloatmagnetdetentsolenoid:Shortcircuitwithpowersupplyline...............14

Failurecode[DWNFKA]Modulationclutchcut-offreleasesolenoid:Disconnection....................................16

Failurecode[DWNFKB]Modulationclutchcut-offreleasesolenoid:Shortcircuit........................................18

Failurecode[DWNFKY]Modulationclutchcut-offreleasesolenoid:Shortcircuitwithpowersourceline....20

Failurecode[DX16KA]FanpumpEPCsolenoid:Disconnection.................................................................22

Failurecode[DX16KB]FanpumpEPCsolenoid:Shortcircuit.....................................................................23

Failurecode[DX16KY]FanpumpEPCsolenoid:Shortcircuitwithpowersupplyline................................24

Failurecode[DXA1KA]PumpPC-EPCsolenoid:Disconnection.................................................................25

Failurecode[DXA1KB]PumpPC-EPCsolenoid:Shortcircuit.....................................................................26

Failurecode[DXF0KA]AJSSEPCsolenoid:Disconnection........................................................................27

Failurecode[DXF0KB]AJSSEPCsolenoid:Shortcircuit............................................................................28

Failurecode[DXH1KA]LockupECMVsolenoid:Disconnection..................................................................30

Failurecode[DXH1KB]LockupECMVsolenoid:Shortcircuit......................................................................32

Failurecode[DXH1KY]LockupECMVsolenoid:Shortcircuitwithpowersupplyline.................................34

Failurecode[DXH4KA]1stclutchECMVsolenoid:Disconnection..............................................................36

Failurecode[DXH4KB]1stclutchECMVsolenoid:Shortcircuit..................................................................38

Failurecode[DXH4KY]1stclutchECMVsolenoid:Shortcircuitwithpowersupplyline..............................40

310Troubleshootingbyfailurecode(Displayofcode),Part10SEN05060-01

Failurecode[DXH5KA]2ndclutchECMVsolenoid:Disconnection.............................................................4

Failurecode[DXH5KB]2ndclutchECMVsolenoid:Shortcircuit.................................................................6

Failurecode[DXH5KY]2ndclutchECMVsolenoid:Shortcircuitwithpowersupplyline.............................8

Failurecode[DXH6KA]3rdclutchECMVsolenoid:Disconnection..............................................................10

Failurecode[DXH6KB]3rdclutchECMVsolenoid:Shortcircuit..................................................................12

Failurecode[DXH6KY]3rdclutchECMVsolenoid:Shortcircuitwithpowersupplyline.............................14

Failurecode[DXH7KA]RclutchECMVsolenoid:Disconnection.................................................................16

Failurecode[DXH7KB]RclutchECMVsolenoid:Shortcircuit....................................................................18

Failurecode[DXH7KY]RclutchECMVsolenoid:Shortcircuitwithpowersupplyline................................20

Failurecode[DXH8KA]FclutchECMVsolenoid:Disconnection.................................................................22

Failurecode[DXH8KB]FclutchECMVsolenoid:Shortcircuit.....................................................................24

Failurecode[DXH8KY]FclutchECMVsolenoid:Shortcircuitwithpowersupplyline................................26

Failurecode[DXHHKA]4thclutchECMVsolenoid:Disconnection..............................................................28

Failurecode[DXHHKB]4thclutchECMVsolenoid:Shortcircuit.................................................................30

Failurecode[DXHHKY]4thclutchECMVsolenoid:Shortcircuitwithpowersupplyline.............................32

Failurecode[DXHJKA]RHpitchREAREPCsolenoid:Disconnection........................................................34

Failurecode[DXHJKB]RHpitchREAREPCsolenoid:Shortcircuit............................................................35

Failurecode[DXHJKY]RHpitchREAREPCsolenoid:Shortcircuitwithpowersupplyline.......................36

Failurecode[DXHKKA]RHpitchFORWARDEPCsolenoid:Disconnection...............................................37

Failurecode[DXHKKB]RHpitchFORWARDEPCsolenoid:Shortcircuit...................................................38

Failurecode[DXHKKY]RHpitchFORWARDEPCsolenoid:Shortcircuitwithpowersupplyline..............39

Failurecode[DXHPKA]Modulationclutchsolenoid:Disconnection.............................................................40

Failurecode[DXHPKB]Modulationclutchsolenoid:Shortcircuit................................................................42

Failurecode[DXHPKY]Modulationclutchsolenoid:Shortcircuitwithpowersourceline............................44

Failurecode[DXHPMA]Modulationclutchsolenoid:Malfunction................................................................46

Failurecode[F@BBZL](orVHMS_LEDdisplay:“n3”“38”)Blow-bypressure:Higherror......................48

Failurecode[F@BYNR](orVHMS_LEDdisplay:“n3”o“62”)

(Exhaustgastemperature(F):Abnormalheat).......................................................................................50

Failurecode[F@BYNS](orVHMS_LEDdisplay:“n3”“61”)Exhaustgastemperature(F):Overheat.....52

Failurecode[F@BZNR](orVHMS_LEDdisplay:“n3”o“72”)

(Exhaustgastemperature(R):abnormalheat).......................................................................................54

Failurecode[F@BZNS](orVHMS_LEDdisplay“n3”“71”)Exhaustgastemperature(R):Overheat.....56 400Troubleshootingofelectricalsystem(E-mode)SEN05061-01 Beforecarryingouttroubleshootingofelectricalsystem...............................................................................2 Informationintroubleshootingtable..............................................................................................................5

E-1Enginedoesnotstart..............................................................................................................................6

E-2Wiperdoesnotoperate..........................................................................................................................16

E-3Windshieldwasherdoesnotoperate.....................................................................................................24

E-4Headlamp,clearancelamp,taillamp,andlicenselampdonotlightuporgooff...................................30

E-5Workinglampdoesnotlightuporgooff................................................................................................46

E-6Steplampdoesnotlightuporgooff......................................................................................................54

E-7Turnsignallampandhazardlampdonotlightuporgooff....................................................................56

E-8Brakelampdoesnotlightoritkeepslightingup....................................................................................66

E-9Backuplampdoesnotlightoritkeepslightingup..................................................................................70

E-10Backupbuzzerdoesnotsoundoritkeepssounding...........................................................................74

E-11Horndoesnotsoundoritkeepssounding............................................................................................78

E-12Alarmbuzzerdoesnotsoundoritkeepssounding..............................................................................82

E-13Airconditionerdoesnotoperateorstop...............................................................................................84

E-14Electricprimingpumpdoesnotoperateordoesnotstopautomatically...............................................86

E-15WhenstartingswitchisturnedtoONposition,machinemonitordisplaysnothing...............................88

500Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN05062-01

Methodofusingtroubleshootingchart..........................................................................................................4

Tableoffailuremodesandcauses................................................................................................................6

H-1Machinedoesnotstart...........................................................................................................................10

H-2Torqueconverterlockupisnotswitched(enginestalls).........................................................................12

H-3Torqueconverterlockupisnotturnedon................................................................................................13

H-4Travelspeedisslow,thrustingforceisweak,uphilltravelingpowerisweak,andgearisnotshifted....14

H-5Shocksarelargeatthetimesofstartingandshiftinggear.....................................................................16

H-6Timelagislargeatthetimesofstartingandshiftinggear......................................................................18

H-7Torqueconverteroiltemperatureishigh................................................................................................20

H-8Steeringdoesnotturn[machinewithsteeringwheel]............................................................................21

H-9Steeringdoesnotturn[machinewithAJSS]...........................................................................................22

H-10Turning,responseofsteeringispoor[machinewithsteeringwheel]...................................................23

H-11Turning,responseofAJSSispoor[machinewithAJSS].....................................................................24

H-12Steeringisheavy[machinewithsteeringwheel]..................................................................................25

H-13Whenmachineturns,itshakesormakeslargeshocks[machinewithsteeringwheel].......................26

H-14Whenmachineturns,itshakesormakeslargeshocks[machinewithAJSS]......................................27

H-15Wheelbrakedoesnotworkordoesnotworkwell...............................................................................28

H-16Wheelbrakeisnotreleasedoritdrags................................................................................................29

H-17Parkingbrakedoesnotworkordoesnotworkwell.............................................................................30

H-18Parkingbrakeisnotreleasedoritdrags(includingemergencyreleasesystem).................................31

H-19Bladedoesnotrise...............................................................................................................................32

H-20Bladespeedisloworrisingforceofliftisinsufficient...........................................................................33

H-21Whenrising,bladecomestomoveslowlyatspecificheight................................................................34

H-22Liftcylindercannotholddownblade(Bladefloats)...............................................................................34

H-23Hydraulicdriftsofbladeoccuroften......................................................................................................34

H-24Bladewobblesduringoperation...........................................................................................................34

H-25Bladedoesnottiltandpitch..................................................................................................................35

H-26Bladespeedislowortiltandpitchforceisinsufficient.........................................................................36

H-27Bladecomestooperateslowlyinthemidstoftiltandpitch.................................................................37

H-28Tilt&pitchcylindercannotholddownblade.........................................................................................37

H-29Hydraulicdriftsofbladeoccuroften......................................................................................................37

H-30Bladewobblesduringtravelwhenloaded(Workequipmentvalveissetto“HOLD”)...........................37

H-31Duringoperationofmachine,enginespeedlowersremarkablyorenginestalls..................................38

H-32Largeshocksaremadewhenworkequipmentstartsandstops..........................................................38

H-33Whenworkequipmentcircuitisrelievedsingly,otherworkequipmentmoves....................................38

H-34Fanspeedisabnormal(Fansoundandvibrationareabnormallylargeorengineoverheats).............39

600Troubleshootingofengine(S-mode)SEN05063-00 Methodofusingtroubleshootingchart..........................................................................................................2

S-1Enginedoesnotstarteasily....................................................................................................................6

S-2Enginedoesnotstart..............................................................................................................................8

S-3Enginedoesnotpickupsmoothly..........................................................................................................12

S-4Enginestopsduringoperation................................................................................................................13

S-5Enginedoesnotrotatesmoothly(Huntingoccurs).................................................................................14

S-6Enginelacksoutput(orlackspower)......................................................................................................15

S-7Exhaustsmokeisblack(Incompletecombustion)..................................................................................16

S-8Oilisconsumedmuch(orexhaustgascolorisblue).............................................................................18

S-9Engineoilbecomescontaminatedquickly..............................................................................................19

S-10Fuelconsumptionisexcessive.............................................................................................................20

S-11Coolantcontainsoil(blowsbackorreduces).......................................................................................21 S-12Oilpressuredrops................................................................................................................................22 S-13Oillevelrises(Water,fuelinoil)...........................................................................................................24

S-14Coolanttemperaturerisestoohigh(Overheating)...............................................................................26

50Disassemblyandassembly

201Engineandcoolingsystem,Part1SEN05142-02 Removalandinstallationofengineassembly...............................................................................................2

Removalandinstallationofcylinderheadassembly....................................................................................8

Removalandinstallationoffuelinjectorassembly.......................................................................................24

Removalandinstallationofenginefrontseal...............................................................................................28

Removalandinstallationofenginerearseal................................................................................................31

301Powertrain,Part1SEN05144-01

Removalandinstallationofparkingbrakeassembly....................................................................................2

Removalandinstallationoftorqueconverterandtransmissionassembly...................................................4

302Powertrain,Part2SEN05145-02

Disassemblyandassemblyoftorqueconverterassembly...........................................................................2

Disassemblyandassemblyoftransmissionassembly.................................................................................29

Disassemblyandassemblyoftransferassembly.........................................................................................56

Disassemblyandassemblyofparkingbrakeassembly................................................................................72

303Powertrain,Part3SEN05146-01

Removalandinstallationoffrontaxleassembly...........................................................................................2

Removalandinstallationofrearaxleassembly............................................................................................4

Removalandinstallationofcentersupportassembly...................................................................................6

Disassemblyandassemblyofcentersupportassembly..............................................................................8

Disassemblyandassemblyofdifferentialassembly.....................................................................................12

304Powertrain,Part4SEN05147-00

Removalandinstallationoffinaldrivecarrierassembly...............................................................................2

Disassemblyandassemblyoffinaldrivecarrierassembly...........................................................................4

Removalandinstallationoffrontfinaldrivebrakeassembly........................................................................5

Disassemblyandassemblyoffinaldriveassembly......................................................................................7

400BrakesystemSEN05148-01

Disassemblyandassemblyofbrakeassembly............................................................................................2

Removalandinstallationofbrakevalveassembly.......................................................................................10

Disassemblyandassemblyofaccumulatorandchargevalveassembly.....................................................11

Disassemblyandassemblyofslackadjustorassembly...............................................................................14

500UndercarriageandframeSEN05149-01

Removalandinstallationofcenterhingepin.................................................................................................2

Removalandinstallationofcounterweightassembly....................................................................................9

600HydraulicsystemSEN05150-01

Removalandinstallationofhydraulictankassembly....................................................................................2

Removalandinstallationofhydraulicpumpassembly..................................................................................4

Removalandinstallationofcontrolvalveassembly......................................................................................8

Disassemblyandassemblyofcontrolvalveassembly..................................................................................10

Removalandinstallationofsteeringvalveassembly....................................................................................15

Disassemblyandassemblyofhydrauliccylinderassembly..........................................................................16

700WorkequipmentSEN05151-00

Removalandinstallationofworkequipmentassembly.................................................................................2

800CabanditsattachmentsSEN05152-02

Removalandinstallationofoperator'scabassembly....................................................................................2

Removalandinstallationofoperator'scabglass(stuckglass).....................................................................6

Removalandinstallationoffloorframeassembly.........................................................................................14

Disassemblyandassemblyofoperator’sseatassembly..............................................................................17

Removalandinstallationofairconditionerunitassembly.............................................................................50

RemovalandinstallationofAJSSleverswitchassembly.............................................................................53

900ElectricalsystemSEN05153-00

Removalandinstallationofenginecontrollerassembly................................................................................2

Removalandinstallationoftransmissioncontrollerassembly......................................................................4

Removalandinstallationofloadercontrollerassembly................................................................................4

RemovalandinstallationofVHMScontrollerassembly................................................................................5

Removalandinstallationofmachinemonitorassembly................................................................................6

90Diagramsanddrawings

100HydraulicdiagramsanddrawingsSEN05004-01

Powertrainhydrauliccircuitdiagram.............................................................................................................2

Brakehydrauliccircuitdiagram.....................................................................................................................3

200ElectricaldiagramsanddrawingsSEN05005-03

Airconditionerelectricalcircuitdiagram........................................................................................................3

Electricalcircuitdiagram(1/10).....................................................................................................................5

Electricalcircuitdiagram(2/10).....................................................................................................................7

Electricalcircuitdiagram(3/10).....................................................................................................................9

Electricalcircuitdiagram(4/10).....................................................................................................................11

Electricalcircuitdiagram(5/10).....................................................................................................................13

Electricalcircuitdiagram(6/10).....................................................................................................................15

Electricalcircuitdiagram(7/10).....................................................................................................................17

Electricalcircuitdiagram(8/10).....................................................................................................................19

Electricalcircuitdiagram(9/10).....................................................................................................................21

Electricalcircuitdiagram(10/10)...................................................................................................................23

Connectorlistandstereogram......................................................................................................................25