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WD600-6R | SN: 60001 and up | Komatsu | Heavy Equipment Manual PDF

Page 1


WHEELDOZER

WD600-6R

MachinemodelSerialnumber

WD600-6R60001andup

00Indexandforeword

00Indexandforeword

00Indexandforeword

Tableofcontents.........................................................................................................................................00-2

Forewordandgeneralinformation...........................................................................................................00-14

Safetynotice...........................................................................................................................................00-14

Howtoreadtheshopmanual...............................................................................................................00-19

Explanationoftermsformaintenancestandard..................................................................................00-21

Handlingofelectricequipmentandhydrauliccomponent..................................................................00-23

Handlingofconnectorsnewlyusedforengines..................................................................................00-32

Howtoreadelectricwirecode..............................................................................................................00-35

Precautionswhencarryingoutoperation.............................................................................................00-38

Methodofdisassemblingandconnectingpush-pulltypecoupler......................................................00-41

Standardtighteningtorquetable...........................................................................................................00-44

Conversiontable....................................................................................................................................00-48

01Specification

Specificationandtechnicaldata.................................................................................................................01-3

Specificationdimensiondrawing.............................................................................................................01-3

Specifications...........................................................................................................................................01-4

Weighttable..............................................................................................................................................01-7

Tableoffuel,coolantandlubricants.......................................................................................................01-9

10Structure,functionandmaintenancestandard

Engineandcoolingsystem.........................................................................................................................10-4

Enginemountandtransmissionmount..................................................................................................10-4

Damper.....................................................................................................................................................10-6

Coolingsystem.........................................................................................................................................10-8

Coolingfanpump...................................................................................................................................10-12

Coolingfanmotor...................................................................................................................................10-20

Powertrain.................................................................................................................................................10-26

Powertrain.............................................................................................................................................10-26

Powertrainsystemdiagram..................................................................................................................10-27

Torqueconverterandtransmissionpipingdiagram.............................................................................10-28

Torqueconverter....................................................................................................................................10-30

Modulationclutch...................................................................................................................................10-39

Torqueconverterregulatorvalve..........................................................................................................10-40

Transmission..........................................................................................................................................10-42 Transfer...................................................................................................................................................10-62

Transmissioncontrolvalve....................................................................................................................10-64

ECMV......................................................................................................................................................10-66

Mainreliefvalveandtorqueconverterreliefvalve..............................................................................10-73

Lubricationreliefvalve...........................................................................................................................10-75

Torqueconverteroilcooler....................................................................................................................10-76

Torqueconverteroilfilter.......................................................................................................................10-77

Driveshaft...............................................................................................................................................10-79

Centersupport........................................................................................................................................10-82

Axle.........................................................................................................................................................10-84 Differential...............................................................................................................................................10-88

Limitedslipdifferential...........................................................................................................................10-97 Finaldrive.............................................................................................................................................10-102

Steeringsystem.......................................................................................................................................10-106

Steeringpipingdiagram.......................................................................................................................10-106

Steeringcolumn...................................................................................................................................10-108

Joysticksteeringleverlinkage............................................................................................................10-109

JoystickEPCvalve..............................................................................................................................10-110

Lockvalve..............................................................................................................................................10-111

Steeringvalve.......................................................................................................................................10-112

Rotaryvalve..........................................................................................................................................10-115

Steeringcontrolvalve...........................................................................................................................10-118

Two-wayrestrictorvalve......................................................................................................................10-134

Stopvalve.............................................................................................................................................10-135

Steeringpump.......................................................................................................................................10-136

Steeringcylinder...................................................................................................................................10-150

Emergencysteeringpipingdiagram...................................................................................................10-151

Divertervalve........................................................................................................................................10-152

Emergencysteeringpump...................................................................................................................10-160

Brakesystem...........................................................................................................................................10-162

Brakepipingdiagram...........................................................................................................................10-162

Brake.....................................................................................................................................................10-164

Brakevalve...........................................................................................................................................10-168

Accumulatorchargevalve...................................................................................................................10-176

EPCreliefvalve....................................................................................................................................10-182

Accumulator(forbrake).......................................................................................................................10-184

Slackadjuster.......................................................................................................................................10-186

Parkingbrake........................................................................................................................................10-190

Parkingbrakesolenoidvalve...............................................................................................................10-192 Emergencyparkingbrakereleasevalve.............................................................................................10-194

Brakecoolingpump.............................................................................................................................10-195

Undercarriageandframe........................................................................................................................10-196

Axlemount............................................................................................................................................10-196

Centerhingepin...................................................................................................................................10-201

Hydraulicsystem.....................................................................................................................................10-204

Hydraulicpipingdiagram.....................................................................................................................10-204

Workequipmentcontrolleverlinkage.................................................................................................10-206

Hydraulictank.......................................................................................................................................10-208

Workequipmentpump.........................................................................................................................10-210

Controlvalve.........................................................................................................................................10-230

CLSS.....................................................................................................................................................10-244

Functionsandoperationbyvalve.......................................................................................................10-248

Accumulator(forPPCcircuit)..............................................................................................................10-258

Triplepump...........................................................................................................................................10-259

Workequipment.......................................................................................................................................10-260

Workequipmentlinkage......................................................................................................................10-260

Cuttingedgeandendbit......................................................................................................................10-263

Workequipmentlubrication.................................................................................................................10-265

Hydrauliccylinder.................................................................................................................................10-268

Cabanditsattachments..........................................................................................................................10-270

ROPScab.............................................................................................................................................10-270

Airconditioner.......................................................................................................................................10-272

Electricalsystem......................................................................................................................................10-276

Machinemonitorsystem......................................................................................................................10-276

Machinemonitor...................................................................................................................................10-282

Workequipmentcontrolsystem..........................................................................................................10-330 Transmissioncontrollersystem...........................................................................................................10-356

Electrictransmissioncontrol................................................................................................................10-388

Enginestarting/stoppingcircuit...........................................................................................................10-390 Parkingbrakecircuit.............................................................................................................................10-393 Sensor...................................................................................................................................................10-397

VHMScontrollerrelated.......................................................................................................................10-418

VHMScontrollerandwirelessLANsystem...............................................................................10-419-1

Standardservicevaluetableforchassis................................................................................................20-4

30Testingandadjusting

Precautionsbeforework...................................................................................................................30-3-1

Relatedinformationontestingandadjusting............................................................................................30-4

Toolsfortesting,adjusting,andtroubleshooting...................................................................................30-4

Engineandcoolingsystem.........................................................................................................................30-9

Measuringenginespeed.........................................................................................................................30-9

Measuringexhaustgascolor................................................................................................................30-11

Measuringexhausttemperature...........................................................................................................30-12

Adjustingvalveclearance......................................................................................................................30-14

Testingcompressionpressures............................................................................................................30-16

Measuringblowbypressure..................................................................................................................30-19

Measuringengineoilpressure..............................................................................................................30-20

Measuringintakeair(boost)pressure..................................................................................................30-21

Handlingfuelsystemequipment...........................................................................................................30-22

Releasingresidualpressureinfuelsystem.........................................................................................30-22

Testingfuelpressures............................................................................................................................30-23

Testingreturnrateandleakage............................................................................................................30-24

Bleedingairfromfuelcircuit..................................................................................................................30-27

Testingleakageinfuelsystem..............................................................................................................30-29

Handlingreducedcylindermodeoperation.........................................................................................30-30

Handlingno-injectioncrankingoperation.............................................................................................30-30

Handlingcontrollervoltagecircuit.........................................................................................................30-31

Replacingandadjustingalternatorandairconditionercompressorbelttension..............................30-32

Powertrain.................................................................................................................................................30-33

Adjustingmodulationclutchspeedsensorandspeedsensor............................................................30-33

Measuringdirectionalleverandgearshiftlever(Steeringwheelspecification)................................30-35

Testingandadjustingpowertrainoilpressure.....................................................................................30-36

Flushingprocedurefortorqueconverterandtransmissionhydrauliccircuit.....................................30-50

Methodofmovingmachinewhentransmissionvalveisbroken........................................................30-52

Movingmethodofmachinedisabledbyshort-to-powerfailureinworkequipmentpotentiometer..30-54

Steeringsystem.........................................................................................................................................30-56

Adjustingsteeringstopvalve................................................................................................................30-56

MeasuringoperatingeffortofAJSSlever(AJSSspecification).........................................................30-57

TestingandadjustingAJSSleveranglesensorandframeanglesensor(AJSSspecification).......30-58

Testingandadjustingsteeringstopperbolt(AJSSspecification).......................................................30-60

Testingandadjustingsteeringwheel(Steeringwheelspecification).................................................30-62

Testingsteeringoilpressure.................................................................................................................30-64

Bleedingairfromsteeringcylindercircuit............................................................................................30-68

Testinghydraulicdrivefan.....................................................................................................................30-69

Bleedingairfromhydraulicdrivefancircuit.........................................................................................30-72

Brakesystem.............................................................................................................................................30-74

Measuringbrakepedal..........................................................................................................................30-74

Measuringbrakeperformance..............................................................................................................30-75

Testingandadjustingaccumulatorchargepressure...........................................................................30-76

Testingofaccumulatornitrogengaspressureandprocedureforchargingbrake accumulatorwithnitrogengas...........................................................................................................30-77-1

Testingwheelbrakeoilpressure..........................................................................................................30-78

Measuringwearofwheelbrakedisc....................................................................................................30-80

Bleedingairfromwheelbrakecircuit....................................................................................................30-81

Releasingresidualpressureinbrakeaccumulatorcircuit..................................................................30-82

Testingparkingbrakeperformance......................................................................................................30-83

Measuringparkingbrakeoilpressure..................................................................................................30-84

Testingwearofparkingbrakedisc.......................................................................................................30-87

Methodofreleasingparkingbrakemanually.......................................................................................30-88

Hydraulicsystem.......................................................................................................................................30-89

Measuringandadjustingworkequipmentcontrollever......................................................................30-89

Measuringworkequipmentoilpressure...............................................................................................30-90

Releasingresidualpressureinworkequipmentcircuit................................................................30-94-1

Bleedingairfromworkequipmentcircuit..............................................................................................30-95

Cabanditsattachments............................................................................................................................30-96

Movingmachineforremovingoperatorcab.........................................................................................30-96

Electricalsystem........................................................................................................................................30-98

Preparationsforworkontroubleshootingofelectricsystem...............................................................30-98

Procedurefortestingdiodes................................................................................................................30-102

Machinemonitor-basedadjustmentatreplacement,disassemblyandassembly,andadditional installationforeachsensorandcontroller............................................................................................30-103

Specialfunctionsofmachinemonitor(EMMS)..................................................................................30-107

VHMScontrollerinitialsettingprocedure(ORBCOMMinstallationspecification).........................30-176

VHMScontrollerinitialsettingprocedure(IRIDIUMinstallationspecification)............................30-197-1

PrecautionsforreplacingVHMScontroller....................................................................................30-198

InitializationofVHMSwirelessLANmodemanddownloadingofdata......................................30-203-1

Pm-clinic...................................................................................................................................................30-204

Pm-clinicinspectiontable....................................................................................................................30-204

40Troubleshooting

Precautionsbeforework..................................................................................................................40-8-1

Relatedinformationontroubleshooting.....................................................................................................40-9

Pointstorememberwhenperformingtroubleshooting..........................................................................40-9

Howtoproceedintroubleshooting.......................................................................................................40-11

Testingbeforetroubleshooting..............................................................................................................40-13

Classificationandproceduresoftroubleshooting................................................................................40-14

Failurecodeslist.....................................................................................................................................40-18

Informationintroubleshootingtable......................................................................................................40-30

Troubleshootingmethodfordisconnectingwiringharnessofpressuresensorsystem....................40-32

Connectiontableforconnectorpinnumbers........................................................................................40-35

T-branchboxandT-branchadaptertable..........................................................................................40-71

Fuselocations.........................................................................................................................................40-74

Troubleshootingbyfailurecode(Displayofcode)..................................................................................40-77

Failurecode[1500L0]TORQFLOWtransmission:Doublemeshing..................................................40-77

Failurecode[15B0NX]TransmissionOilFilterClogging....................................................................40-78

Failurecode[15SAL1]ECMVFclutch:WhencommandcurrentisOFF,fillsignalisON................40-80

Failurecode[15SALH]ECMVFclutch:WhencommandcurrentisON,fillsignalisOFF..............40-82

Failurecode[15SBL1]ECMVRclutch:WhencommandcurrentisOFF,fillsignalisON...............40-84

Failurecode[15SBLH]ECMVRclutch:WhencommandcurrentisON,fillsignalisOFF..............40-86

Failurecode[15SEL1]ECMV(1):WhencommandcurrentisOFF,fillsignalisON........................40-88

Failurecode[15SELH]ECMV(1):WhencommandcurrentisON,fillsignalisOFF.......................40-90

Failurecode[15SFL1]ECMV(2):WhencommandcurrentisOFF,fillsignalisON........................40-92

Failurecode[15SFLH]ECMV(2):WhencommandcurrentisON,fillsignalisOFF.......................40-94

Failurecode[15SGL1]ECMV(3):WhencommandcurrentisOFF,fillsignalisON........................40-96

Failurecode[15SGLH]ECMV(3):WhencommandcurrentisON,fillsignalisOFF.......................40-98

Failurecode[15SHL1]ECMV(4):WhencommandcurrentisOFF,fillsignalisON......................40-100

Failurecode[15SHLH]ECMV(4):WhencommandcurrentisON,fillsignalisOFF.....................40-102

Failurecode[15W0NT]Transmissionmodulationclutch:Overheating...........................................40-104

Failurecode[2F00MA]Parkingbrake:Malfunction...........................................................................40-105

Failurecode[2G42ZG]FrontAccumulatorOilPressureLow...........................................................40-108

Failurecode[2G43ZG]RearAccumulatorOilPressureLow...........................................................40-110

Failurecode[A000N1](orVHMS_LEDdisplay:“n2”“01”)Engine:Overrun..............................40-113

Failurecode[AA1ANX]AirCleanerClogging....................................................................................40-114

Failurecode[AB00L6]Alternator:Signaldisagreeswithrunandstopofengine...........................40-116

Failurecode[AB00MA]Alternator:Malfunction.................................................................................40-118

Failurecode[B@BAZG]Engineoilpressure:Lowerror...................................................................40-120

Failurecode[B@BAZK]EngOilLevelLow.......................................................................................40-121

Failurecode[B@BCNS]Enginecoolanttemperature:Overheating................................................40-122

Failurecode[B@BCZK]Enginecoolantlevellow.............................................................................40-124

Failurecode[B@C7NS]Brakeoiloverheating.................................................................................40-126 Failurecode[b@CENS]Torqueconverteroiloverheating...............................................................40-127 Failurecode[B@CENS]Torqueconverteroiloverheating...............................................................40-128 Failurecode[B@GAZK]LowBatteryFluidLevel.............................................................................40-129 Failurecode[B@HANS]HydOilOverheat........................................................................................40-130 Failurecode[CA111]Abnormalityinenginecontroller.....................................................................40-132 Failurecode[CA115]EngineNeorBkupspeedsensorerror..........................................................40-135 Failurecode[CA122]Charge(boost)pressuresensorhigherror...................................................40-136 Failurecode[CA123]Charge(boost)pressuresensorlowerror.....................................................40-138 Failurecode[CA131]Throttlesensorhigherror...............................................................................40-140 Failurecode[CA132]Throttlesensorlowerror.................................................................................40-143 Failurecode[CA135]Engineoilpressuresensorhigherror............................................................40-146 Failurecode[CA141]Engineoilpressuresensorlowerror.............................................................40-148 Failurecode[CA144]Coolanttemperaturesensorhigherror..........................................................40-150 Failurecode[CA145]Coolanttemperaturesensorlowerror...........................................................40-152 Failurecode[CA153]Charge(boost)temperaturesensorhigherror..............................................40-154 Failurecode[CA154]Charge(boost)temperaturesensorlowerror...............................................40-156 Failurecode[CA187]Sensorpowersupply2lowerror....................................................................40-158

Failurecode[CA212]Engineoiltemperaturesensorhigherror......................................................40-160 Failurecode[CA213]Engineoiltemperaturesensorlowerror........................................................40-162

Failurecode[CA221]Atmosphericpressuresensorhigherror.......................................................40-164 Failurecode[CA222]Atmosphericpressuresensorlowerror.........................................................40-166

Failurecode[CA227]Sensorpowersupply2higherror..................................................................40-168 Failurecode[CA234]Engineoverspeed...........................................................................................40-169 Failurecode[CA238]Nespeedsensorpowersupplyerror.............................................................40-170 Failurecode[CA263]Fueltemperaturesensorhigherror...............................................................40-172 Failurecode[CA265]Fueltemperaturesensorlowerror.................................................................40-174

Failurecode[CA271]PCV1Shortcircuit...........................................................................................40-176 Failurecode[CA272]PCV1Disconnection.......................................................................................40-177 Failurecode[CA273]PCV2Shortcircuit...........................................................................................40-178 Failurecode[CA274]PCV2Disconnection.......................................................................................40-179 Failurecode[CA322]Injector#1open/shorterror............................................................................40-180 Failurecode[CA323]Injector#5open/shorterror............................................................................40-182 Failurecode[CA324]Injector#3open/shorterror............................................................................40-184 Failurecode[CA325]Injector#6open/shorterror............................................................................40-186 Failurecode[CA331]Injector#2open/shorterror............................................................................40-188 Failurecode[CA332]Injector#4open/shorterror............................................................................40-190 Failurecode[CA342]Calibrationcodeinconsistency.......................................................................40-192 Failurecode[CA351]Injectorsdrivecircuiterror..............................................................................40-193 Failurecode[CA352]Sensorpowersupply1lowerror....................................................................40-194 Failurecode[CA386]Sensorpowersupply1higherror..................................................................40-196 Failurecode[CA431]Idlevalidationswitcherror..............................................................................40-197 Failurecode[CA432]Idlevalidationactionerror...............................................................................40-200 Failurecode[CA441]Batteryvoltagelowerror.................................................................................40-203 Failurecode[CA442]Batteryvoltagehigherror...............................................................................40-204 Failurecode[CA449]Commonrailpressurehigherror2................................................................40-205 Failurecode[CA451]Commonrailpressuresensorhigherror.......................................................40-206 Failurecode[CA452]Commonrailpressuresensorlowerror........................................................40-208 Failurecode[CA553]Commonrailpressurehigherror1................................................................40-210 Failurecode[CA554]Commonrailpressuresensorinrangeerror................................................40-211 Failurecode[CA559]Supplypumppressureverylowerror1.........................................................40-212 Failurecode[CA689]EngineNespeedsensorerror.......................................................................40-216 Failurecode[CA731]EngineBkupspeedsensorphaseerror........................................................40-218 Failurecode[CA757]Allcontinuousdatalosterror..........................................................................40-219 Failurecode[CA778]EngineBkupspeedsensorerror....................................................................40-220 Failurecode[CA1633]KOMNETdatalinktimeouterror...................................................................40-222 Failurecode[CA2185]Throttlesensorsupplyvoltagehigherror....................................................40-224 Failurecode[CA2186]Throttlesensorpowersupplylowerror.......................................................40-226

Failurecode[CA2249]Supplypumppressureverylowerror2.......................................................40-228

Failurecode[CA2555]Intakeairheaterrelayopencircuiterror......................................................40-230

Failurecode[CA2556]Intakeairheaterrelayshortcircuiterror......................................................40-232

Failurecode[D191KA]AJSSneutralsafetyrelayopencircuit.........................................................40-234

Failurecode[D191KB]AJSSneutralsafetyrelayshortcircuit.........................................................40-236

Failurecode[D198KA]Transmissionoilpressurebypasssolenoid:Disconnection.......................40-238

Failurecode[D198KB]Transmissionoilpressurebypasssolenoid:Shortcircuit...........................40-239

Failurecode[D198KY]Transmissionoilpressurebypasssolenoid:Shortcircuitwithpowersupplyline ...............................................................................................................................................................40-240

Failurecode[D5ZHKA]TerminalCsignalopencircuit......................................................................40-242

Failurecode[D5ZHKB]TerminalCsignalshortcircuit......................................................................40-244

Failurecode[D5ZHKZ]TerminalCsignalopenorshortcircuit........................................................40-246

Failurecode[D5ZHL6]TerminalCsignaldisagreeswithrunandstopofengine...........................40-248

Failurecode[DA80L4]Auto-greasingcontrollerdisagreeswithON/OFFsignal............................40-250

Failurecode[DAF3KK]Machinemonitor:Sourcevoltagelow(input).............................................40-252

Failurecode[DAF5KP]Machinemonitor:Outputvoltagelow..........................................................40-254

Failurecode[DAFRKR]CANcommunicationwithmachinemonitor:Communicationerror(Abnormality intargetcomponentsystem)...............................................................................................................40-256

Failurecode[DAQ0KK]Transmissioncontroller:Sourcevoltagelow.............................................40-257

Failurecode[DAQ0KT]Transmissioncontroller:Defectincontroller..............................................40-260

Failurecode[DAQ2KK]Transmissioncontrollerloadpowersupplyline:Sourcevoltagelow(Input) ...............................................................................................................................................................40-262

Failurecode[DAQ9KQ]Transmissioncontrollermodelselection:Modelselectionsignaldisagreement ...............................................................................................................................................................40-265

Failurecode[DAQRKR]CANcommunicationwithtransmissioncontroller:Communicationerror (Abnormalityintargetcomponentsystem).........................................................................................40-266

Failurecode[DAQRMA]Transmissioncontroller(Optionsetting):Malfunction..............................40-271

Failurecode[DB2RKR]CANcommunicationfromenginecontroller:Communicationerror(Abnormalityintargetcomponentsystem)..........................................................................................................40-272

Failurecode[DB90KK]Workequipmentcontroller:Sourcevoltagelow(input).............................40-275

Failurecode[DB90KT]Workequipmentcontroller:Defectincontroller..........................................40-278

Failurecode[DB92KK]Workequipmentcontrollerloadpowersupplyline:Sourcevoltagelow(input) ...............................................................................................................................................................40-279

Failurecode[DB95KX]Workequipmentcontrollerpowersupplyoutput:Outofrange.................40-282

Failurecode[DB99KQ]Workequipmentcontrollermodelselection:Modelselectionsignaldisagreement.......................................................................................................................................................40-284

Failurecode[DB9RKR]CANcommunicationwithworkequipmentcontroller:Communicationerror (Abnormalityintargetcomponentsystem).........................................................................................40-285

Failurecode[DB9RMA]Workequipmentcontroller(Optionsetting):Malfunction..........................40-286

Failurecode[DB9RMC]CANcommunicationwithtransmissioncontroller:Malfunction...............40-287

Failurecode[DBB0KK]orchangeofVHMS_LEDdisplayfrom"n9"to"01"(VHMScontroller:Source voltagelow(input))...............................................................................................................................40-288

Failurecode[DBB0KQ]orchangeofVHMS_LEDdisplayfrom"nF"to"11"(VHMScontroller:Disagreementofmodelselectionsignals)...............................................................................................40-290

Failurecode[DBB3KK]orchangeofVHMS_LEDdisplayfrom"n9"to"05"(VHMScontrollerbattery powersupply:Sourcevoltagelow(input))..........................................................................................40-292

Failurecode[DBB5KP]orchangeofVHMS_LEDdisplayfrom"n9"to"04"(VHMScontroller5Vpower supplyoutput:Outputvoltagelow)......................................................................................................40-294

Failurecode[DBB6KP]orchangeofVHMS_LEDdisplayfrom"n9"to"02"(VHMScontroller24V powersupplyoutput:Outputvoltagelow)..........................................................................................40-296

Failurecode[DBB7KP]orchangeofVHMS_LEDdisplayfrom"n9"to"03"(VHMScontroller12V powersupplyoutput:Outputvoltagelow)..........................................................................................40-298

Failurecode[DBBQKR]orchangeofVHMS_LEDdisplayfrom"n8"to"02"(CANcommunicationof VHMScontroller:Communicationerror(Abnormalityintargetcomponentsystem))......................40-300

Failurecode[DD15LD]tswitch(Panelswitch1):Switchiskeptpressedforlongtime...............40-302

Failurecode[DD16LD]Uswitch(Panelswitch2):Switchiskeptpressedforlongtime..............40-304

Failurecode[DD17LD]<switch(Panelswitch3):Switchiskeptpressedforlongtime................40-306

Failurecode[DD18LD]>switch(Panelswitch4):Switchiskeptpressedforlongtime................40-308

Failurecode[DDA7L4]RPMsetON/OFFswitch:ON-OFFsignalsdisagree.................................40-310 Failurecode[DDA8KB]RPMsetidle-up/downselectorswitch(idle-up):Shortcircuit..................40-312 Failurecode[DDA9KB]RPMsetidle-up/downselectorswitch(idle-down):Shortcircuit..............40-315 Failurecode[DDB6L4]Parkingbrakeswitch(Neutralizer):ON/OFFsignalsdisagree..................40-318 Failurecode[DDD1LD]Pitchoperationswitch:Switchiskeptpressedforlongtime....................40-322 Failurecode[DDDBKA]Tractionadjustmentdial:Disconnection....................................................40-324 Failurecode[DDDBKB]Tractionadjustmentdial:Shortcircuit........................................................40-326 Failurecode[DDE5MA]Emergencysteeringdriveswitch:Malfunction..........................................40-328 Failurecode[DDK4KA]AJSSFNRswitch:Disconnection...............................................................40-330 Failurecode[DDK4KB]AJSSFNRswitch:Shortcircuit..................................................................40-332 Failurecode[DDK5L4]AJSSshift-up/downswitch:ON/OFFsignalsdisagree..............................40-334 Failurecode[DDK6KA]FNRleverswitch:Disconnection................................................................40-337 Failurecode[DDK6KB]FNRleverswitch:Shortcircuit....................................................................40-340 Failurecode[DDP5KA]Lockdetectionpressureswitchofsteeringlocklever:Disconnection.....40-342 Failurecode[DDT0L4]Shiftmodeselectorswitch:ON/OFFsignalsdisagree...............................40-344 Failurecode[DDW9LD]Kick-downswitch:Switchiskeptpressedforlongtime...........................40-346 Failurecode[DDWLLD]Holdswitch:Switchiskeptpressedforlongtime....................................40-348 Failurecode[DF10KA]Transmissionshiftleverswitch:Disconnection..........................................40-350 Failurecode[DF10KB]Transmissionshiftleverswitch:Shortcircuit..............................................40-354 Failurecode[DGE5KX](orVHMS_LEDdisplay:“n4”“01”)Atmospherictemperaturesensor:Outof inputsignalrange.................................................................................................................................40-356 Failurecode[DGF1KA]Transmissionoiltemperaturesensor:Disconnection...............................40-358 Failurecode[DGF1KB]Transmissionoiltemperaturesensor:Shortcircuit...................................40-360 Failurecode[DGH2KX]Hydraulicoiltemperaturesensor:Outofinputsignalrange....................40-362 Failurecode[DGR2KA]Rearbrakeoiltemperaturesensor:Disconnection...................................40-364 Failurecode[DGR2KX]Rearbrakeoiltemperaturesensor:Outofinputsignalrange.................40-366 Failurecode[DGT1KA]Torqueconverteroiltemperaturesensor:Disconnection.........................40-368 Failurecode[DGT1KB]Torqueconverteroiltemperaturesensor:Shortcircuit.............................40-370 Failurecode[DGT1KX]Torqueconverteroiltemperaturesensor:Outofinputsignalrange).......40-372 Failurecode[DGT4KA](orVHMS_LEDdisplay:"n3""12")Exhaustgastemperaturesensor(F): Disconnection.......................................................................................................................................40-374

Failurecode[DGT4KB](orVHMS_LEDdisplay:"n3""11")Exhaustgastemperaturesensor(F): Shortcircuit...........................................................................................................................................40-377 Failurecode[DGT5KA](orVHMS_LEDdisplay:"n3""22")Exhaustgastemperaturesensor(R): Disconnection.......................................................................................................................................40-380 Failurecode[DGT5KB](orVHMS_LEDdisplay:"n3""21")Exhaustgastemperaturesensor(R): Shortcircuit...........................................................................................................................................40-383

Failurecode[DH21KA]Workequipmentpumpoilpressuresensor:Disconnection......................40-386

Failurecode[DH21KB]Workequipmentpumpoilpressuresensor:Shortcircuit..........................40-388

Failurecode[DHE5KB](orVHMS_LEDdisplay:“n3”“32”)Blow-bypressuresensor:Shortcircuit ...............................................................................................................................................................40-390

Failurecode[DHE5KY](orVHMS_LEDdisplay:“n3”“31”)Blow-bypressuresensor:Shortcircuit withpowersupplyline..........................................................................................................................40-392

Failurecode[DHT2L6]Transmissionfiltercloggingsensor:Signaldisagreeswithoperatingstateof engine...................................................................................................................................................40-394

Failurecode[DHT8KX](orVHMS_LEDdisplay:“n5”“33”)Steeringoilpressuresensor:Outofinput signalrange..........................................................................................................................................40-396

Failurecode[DHTBKA]Modulationclutchoilpressuresensor:Disconnection..............................40-400

Failurecode[DHTBKB]Modulationclutchoilpressuresensor:Shortcircuit..................................40-402

Failurecode[DHU2KX](orVHMS_LEDdisplay:“n7”“11”)Frontbrakeoilpressuresensor(F):Out ofinputsignalrange............................................................................................................................40-404

Failurecode[DHU3KX](orVHMS_LEDdisplay:“n7”“12”)Rearbrakeoilpressuresensor(R):Out ofinputsignalrange............................................................................................................................40-406

Failurecode[DK30KA]AJSSleveranglesensor:Disconnection....................................................40-408

Failurecode[DK30KY]AJSSleveranglesensor:Shortcircuitwithpowersupplyline.................40-410

Failurecode[DK59KA]LiftEPCleverpotentiometer(Main):Disconnection..................................40-412

Failurecode[DK59KY]LiftEPCleverpotentiometer(Main):Shortcircuitwithpowersupplyline40-416

Failurecode[DK59L8]LiftEPCleverpotentiometer(Main):Analogsignalsdisagree..................40-418

Failurecode[DK5AKA]LiftEPCleverpotentiometer(Sub):Disconnection...................................40-421

Failurecode[DK5AKY]LiftEPCleverpotentiometer(Sub):Shortcircuitwithpowersupplyline.40-424

Failurecode[DK5BKA]Tilt&pitchEPCleverpotentiometer(Main):Disconnection.....................40-426

Failurecode[DK5BKY]Tilt&pitchEPCleverpotentiometer(Main):Shortcircuitwithpowersupplyline ...............................................................................................................................................................40-430

Failurecode[DK5BL8]Tilt&pitchEPCleverpotentiometer(Main):Analogsignalsdisagree......40-432

Failurecode[DK5CKA]Tilt&pitchEPCleverpotentiometer(Sub):Disconnection.......................40-435

Failurecode[DK5CKY]Tilt&pitchEPCleverpotentiometer(Sub):Shortcircuitwithpowersupplyline ...............................................................................................................................................................40-438

Failurecode[DKD0KA]Frameanglesensor:Disconnection...........................................................40-440

Failurecode[DKD0KY]Frameanglesensor:Shortcircuitwithpowersupplyline.........................40-442

Failurecode[DKD0KZ]AJSSleverandframeanglesensor:Disconnectionorshortcircuit.........40-444

Failurecode[DLFAKA]Modulationclutchoutputshaftspeedsensor:Disconnection...................40-448

Failurecode[DLFALC]Modulationclutchoutputshaftspeedsensor:Speedsignalsdisagree....40-450

Failurecode[DLT3KA]Transmissionoutputshaftspeedsensor(2):Disconnection.....................40-452

Failurecode[DLT3LC]Transmissionoutputshaftspeedsensor(2):Speedsignalsdisagree......40-454

Failurecode[DLT4KB]Transmissionoutputshaftspeedsensor(1):Shortcircuit.........................40-456

Failurecode[DLT4KX]Transmissionoutputshaftspeedsensor(1):Outofinputsignalrange....40-458

Failurecode[DV00KB]Alarmbuzzer:Shortcircuit...........................................................................40-460

Failurecode[DW4PKA]BladeraiseEPCsolenoid:Disconnection.................................................40-462

Failurecode[DW4PKB]BladeraiseEPCsolenoid:Shortcircuit.....................................................40-464

Failurecode[DW4PKY]BladeraiseEPCsolenoid:Shortcircuitwithpowersupplyline...............40-465

Failurecode[DW4QKA]BladelowerEPCsolenoid:Disconnection................................................40-466

Failurecode[DW4QKB]BladelowerEPCsolenoid:Shortcircuit....................................................40-467

Failurecode[DW4QKY]BladelowerEPCsolenoid:Shortcircuitwithpowersupplyline..............40-468

Failurecode[DW4RKA]Tilt&pitchEPCsolenoid:Disconnection..................................................40-469

Failurecode[DW4RKB]Tilt&pitchEPCsolenoid:Shortcircuit......................................................40-470 Failurecode[DW4RKY]Tilt&pitchEPCsolenoid:Shortcircuitwithpowersupplyline................40-471 Failurecode[DW4SKA]Tilt&pitchEPCsolenoid:Disconnection..................................................40-472 Failurecode[DW4SKB]Tilt&pitchEPCsolenoid:Shortcircuit......................................................40-473

Failurecode[DW4SKY]Tilt&pitchEPCsolenoid:Shortcircuitwithpowersupplyline................40-474

Failurecode[DW7BKA]Fanreversesolenoid:Disconnection.........................................................40-476

Failurecode[DW7BKB]Fanreversesolenoid:Shortcircuit............................................................40-478

Failurecode[DW7BKY]Fanreversesolenoid:Shortcircuitwithpowersupplyline......................40-480

Failurecode[DWM1KA]Workequipmentneutrallocksolenoid:Disconnection............................40-482

Failurecode[DWM1KB]Workequipmentneutrallocksolenoid:Shortcircuit................................40-484

Failurecode[DWM1KY]Workequipmentneutrallocksolenoid:Shortcircuitwithpowersupplyline ...............................................................................................................................................................40-486

Failurecode[DWN7KA]Bladefloatmagnetdetentsolenoid:Disconnection.................................40-488

Failurecode[DWN7KB]Bladefloatmagnetdetentsolenoid:Shortcircuit.....................................40-490

Failurecode[DWN7KY]Bladefloatmagnetdetentsolenoid:Shortcircuitwithpowersupplyline ...............................................................................................................................................................40-492

Failurecode[DWNFKA]Modulationclutchcut-offreleasesolenoid:Disconnection......................40-494

Failurecode[DWNFKB]Modulationclutchcut-offreleasesolenoid:Shortcircuit..........................40-496

Failurecode[DWNFKY]Modulationclutchcut-offreleasesolenoid:Shortcircuitwithpowersourceline ...............................................................................................................................................................40-498

Failurecode[DX16KA]FanpumpEPCsolenoid:Disconnection....................................................40-500

Failurecode[DX16KB]FanpumpEPCsolenoid:Shortcircuit........................................................40-501

Failurecode[DX16KY]FanpumpEPCsolenoid:Shortcircuitwithpowersupplyline..................40-502

Failurecode[DXA1KA]PumpPC-EPCsolenoid:Disconnection.....................................................40-503

Failurecode[DXA1KB]PumpPC-EPCsolenoid:Shortcircuit........................................................40-504

Failurecode[DXF0KA]AJSSEPCsolenoid:Disconnection............................................................40-505

Failurecode[DXF0KB]AJSSEPCsolenoid:Shortcircuit................................................................40-506

Failurecode[DXH1KA]LockupECMVsolenoid:Disconnection......................................................40-508

Failurecode[DXH1KB]LockupECMVsolenoid:Shortcircuit.........................................................40-510

Failurecode[DXH1KY]LockupECMVsolenoid:Shortcircuitwithpowersupplyline...................40-512

Failurecode[DXH4KA]1stclutchECMVsolenoid:Disconnection..................................................40-514

Failurecode[DXH4KB]1stclutchECMVsolenoid:Shortcircuit......................................................40-516

Failurecode[DXH4KY]1stclutchECMVsolenoid:Shortcircuitwithpowersupplyline...............40-518 Failurecode[DXH5KA]2ndclutchECMVsolenoid:Disconnection................................................40-520 Failurecode[DXH5KB]2ndclutchECMVsolenoid:Shortcircuit....................................................40-522 Failurecode[DXH5KY]2ndclutchECMVsolenoid:Shortcircuitwithpowersupplyline..............40-524 Failurecode[DXH6KA]3rdclutchECMVsolenoid:Disconnection.................................................40-526 Failurecode[DXH6KB]3rdclutchECMVsolenoid:Shortcircuit.....................................................40-528 Failurecode[DXH6KY]3rdclutchECMVsolenoid:Shortcircuitwithpowersupplyline...............40-530 Failurecode[DXH7KA]RclutchECMVsolenoid:Disconnection....................................................40-532 Failurecode[DXH7KB]RclutchECMVsolenoid:Shortcircuit.......................................................40-534 Failurecode[DXH7KY]RclutchECMVsolenoid:Shortcircuitwithpowersupplyline.................40-536 Failurecode[DXH8KA]FclutchECMVsolenoid:Disconnection....................................................40-538 Failurecode[DXH8KB]FclutchECMVsolenoid:Shortcircuit........................................................40-540 Failurecode[DXH8KY]FclutchECMVsolenoid:Shortcircuitwithpowersupplyline..................40-542 Failurecode[DXHHKA]4thclutchECMVsolenoid:Disconnection................................................40-544 Failurecode[DXHHKB]4thclutchECMVsolenoid:Shortcircuit....................................................40-546 Failurecode[DXHHKY]4thclutchECMVsolenoid:Shortcircuitwithpowersupplyline..............40-548 Failurecode[DXHJKA]RHpitchREAREPCsolenoid:Disconnection...........................................40-550 Failurecode[DXHJKB]RHpitchREAREPCsolenoid:Shortcircuit..............................................40-551 Failurecode[DXHJKY]RHpitchREAREPCsolenoid:Shortcircuitwithpowersupplyline........40-552 Failurecode[DXHKKA]RHpitchFORWARDEPCsolenoid:Disconnection.................................40-553 Failurecode[DXHKKB]RHpitchFORWARDEPCsolenoid:Shortcircuit.....................................40-554 Failurecode[DXHKKY]RHpitchFORWARDEPCsolenoid:Shortcircuitwithpowersupplyline ...............................................................................................................................................................40-555 Failurecode[DXHPKA]Modulationclutchsolenoid:Disconnection...............................................40-556 Failurecode[DXHPKB]Modulationclutchsolenoid:Shortcircuit...................................................40-558 Failurecode[DXHPKY]Modulationclutchsolenoid:Shortcircuitwithpowersourceline.............40-560 Failurecode[DXHPMA]Modulationclutchsolenoid:Malfunction...................................................40-562 Failurecode[F@BBZL](orVHMS_LEDdisplay:“n3”“38”)Blow-bypressure:Higherror.......40-564 Failurecode[F@BYNR](orVHMS_LEDdisplay:“n3”“62”)Exhaustgastemperature(F):Abnormal heat.......................................................................................................................................................40-566

Failurecode[F@BYNS](orVHMS_LEDdisplay:“n3”“61”)Exhaustgastemperature(F):Overheat ...............................................................................................................................................................40-568 Failurecode[F@BZNR](orVHMS_LEDdisplay:“n3”“72”)Exhaustgastemperature(R):abnormal heat.......................................................................................................................................................40-570

Failurecode[F@BZNS](orVHMS_LEDdisplay“n3”“71”)Exhaustgastemperature(R):Overheat ...............................................................................................................................................................40-572

Troubleshootingofelectricalsystem(E-mode).....................................................................................40-574

E-1Enginedoesnotstart....................................................................................................................40-574

E-2Wiperdoesnotoperate................................................................................................................40-584

E-3Windshieldwasherdoesnotoperate..........................................................................................40-592

E-4Headlamp,clearancelamp,taillamp,andlicenselampdonotlightuporgooff....................40-598

E-5Workinglampdoesnotlightuporgooff.....................................................................................40-614

E-6Steplampdoesnotlightuporgooff...........................................................................................40-622

E-7Turnsignallampandhazardlampdonotlightuporgooff.......................................................40-624

E-8Brakelampdoesnotlightoritkeepslightingup........................................................................40-634

E-9Backuplampdoesnotlightoritkeepslightingup.....................................................................40-638

E-10Backupbuzzerdoesnotsoundoritkeepssounding...............................................................40-642

E-11Horndoesnotsoundoritkeepssounding................................................................................40-646

E-12Alarmbuzzerdoesnotsoundoritkeepssounding.................................................................40-650

E-13Airconditionerdoesnotoperateorstop...................................................................................40-652

E-14Electricprimingpumpdoesnotoperateordoesnotstopautomatically................................40-654

E-15WhenstartingswitchisturnedtoONposition,machinemonitordisplaysnothing................40-656

Troubleshootingofhydraulicandmechanicalsystem(H-mode).........................................................40-660

Methodofusingtroubleshootingchart...............................................................................................40-660

Tableoffailuremodesandcauses.....................................................................................................40-662

H-1Machinedoesnotstart.................................................................................................................40-666

H-2Torqueconverterlockupisnotswitched(enginestalls).............................................................40-668

H-3Torqueconverterlockupisnotturnedon....................................................................................40-669

H-4Travelspeedisslow,thrustingforceisweak,uphilltravelingpowerisweak,andgearisnotshifted ...............................................................................................................................................................40-670

H-5Shocksarelargeatthetimesofstartingandshiftinggear........................................................40-672

H-6Timelagislargeatthetimesofstartingandshiftinggear.........................................................40-674

H-7Torqueconverteroiltemperatureishigh.....................................................................................40-676

H-8Steeringdoesnotturn[machinewithsteeringwheel]................................................................40-677

H-9Steeringdoesnotturn[machinewithAJSS]...............................................................................40-678

H-10Turning,responseofsteeringispoor[machinewithsteeringwheel].....................................40-679

H-11Turning,responseofAJSSispoor[machinewithAJSS].........................................................40-680

H-12Steeringisheavy[machinewithsteeringwheel]......................................................................40-681

H-13Whenmachineturns,itshakesormakeslargeshocks[machinewithsteeringwheel]........40-682

H-14Whenmachineturns,itshakesormakeslargeshocks[machinewithAJSS].......................40-683

H-15Wheelbrakedoesnotworkordoesnotworkwell...................................................................40-684

H-16Wheelbrakeisnotreleasedoritdrags.....................................................................................40-685

H-17Parkingbrakedoesnotworkordoesnotworkwell.................................................................40-686

H-18Parkingbrakeisnotreleasedoritdrags(includingemergencyreleasesystem)..................40-687

H-19Bladedoesnotrise.....................................................................................................................40-688

H-20Bladespeedisloworrisingforceofliftisinsufficient..............................................................40-689

H-21Whenrising,bladecomestomoveslowlyatspecificheight...................................................40-690

H-22Liftcylindercannotholddownblade(Bladefloats)..................................................................40-690

H-23Hydraulicdriftsofbladeoccuroften...........................................................................................40-690

H-24Bladewobblesduringoperation.................................................................................................40-690

H-25Bladedoesnottiltandpitch.......................................................................................................40-691

H-26Bladespeedislowortiltandpitchforceisinsufficient............................................................40-692

H-27Bladecomestooperateslowlyinthemidstoftiltandpitch....................................................40-693

H-28Tilt&pitchcylindercannotholddownblade.............................................................................40-693

H-29Hydraulicdriftsofbladeoccuroften...........................................................................................40-693

H-30Bladewobblesduringtravelwhenloaded(Workequipmentvalveissetto“HOLD”)...........40-693

H-31Duringoperationofmachine,enginespeedlowersremarkablyorenginestalls...................40-694

H-32Largeshocksaremadewhenworkequipmentstartsandstops.............................................40-694

H-33Whenworkequipmentcircuitisrelievedsingly,otherworkequipmentmoves......................40-694

H-34Fanspeedisabnormal(Fansoundandvibrationareabnormallylargeorengineoverheats) ...............................................................................................................................................................40-695

Troubleshootingofengine(S-mode)......................................................................................................40-697

Methodofusingtroubleshootingchart................................................................................................40-697

S-1Enginedoesnotstarteasily..........................................................................................................40-700

S-2Enginedoesnotstart....................................................................................................................40-701

S-3Enginedoesnotpickupsmoothly...............................................................................................40-704

S-4Enginestopsduringoperation......................................................................................................40-705

S-5Enginedoesnotrotatesmoothly(Huntingoccurs).....................................................................40-706

S-6Enginelacksoutput(orlackspower)...........................................................................................40-707

S-7Exhaustsmokeisblack(Incompletecombustion)......................................................................40-708

S-8Oilisconsumedmuch(orexhaustgascolorisblue).................................................................40-709

S-9Engineoilbecomescontaminatedquickly...................................................................................40-710

S-10Fuelconsumptionisexcessive...................................................................................................40-711

S-11Coolantcontainsoil(blowsbackorreduces)............................................................................40-712

S-12Oilpressuredrops.......................................................................................................................40-713

S-13Oillevelrises(Water,fuelinoil).................................................................................................40-714

S-14Coolanttemperaturerisestoohigh(Overheating)....................................................................40-715

S-15Abnormalnoiseismade.............................................................................................................40-716

S-16Vibrationisexcessive..................................................................................................................40-717

S-17Aircannotbebledfromfuelcircuit.............................................................................................40-718

50Disassemblyandassembly

Precautionsbeforework...................................................................................................................50-3-1

Generalinformationondisassemblyandassembly.................................................................................50-4

Howtoreadthismanual..........................................................................................................................50-4

Coatingmaterialslist................................................................................................................................50-6

Specialtoolslist........................................................................................................................................50-9

Sketchesofspecialtools.......................................................................................................................50-13

Engineandcoolingsystem.......................................................................................................................50-21

Removalandinstallationofengineassembly......................................................................................50-21

Removalandinstallationofradiatorassembly....................................................................................50-24

Removalandinstallationofairaftercooler...........................................................................................50-29

Removalandinstallationofcoolingfanandfanmotorassembly......................................................50-30

Removalandinstallationofdamperassembly....................................................................................50-32

Disassemblyandassemblyofdamperassembly................................................................................50-34

Removalandinstallationoffueltankassembly...................................................................................50-38

Removalandinstallationofenginehoodassembly............................................................................50-40

Removalandinstallationofbulkheadassembly..................................................................................50-42

Removalandinstallationoffuelsupplypumpassembly....................................................................50-46

Removalandinstallationofcylinderheadassembly...........................................................................50-52

Removalandinstallationoffuelinjectorassembly..............................................................................50-67

Removalandinstallationofenginefrontseal......................................................................................50-71

Removalandinstallationofenginerearseal.......................................................................................50-74

Powertrain.................................................................................................................................................50-78

Removalandinstallationofparkingbrakeassembly..........................................................................50-78

Removalandinstallationoftorqueconverterandtransmissionassembly........................................50-80

Disassemblyandassemblyoftorqueconverterassembly.................................................................50-85

Disassemblyandassemblyoftransmissionassembly.....................................................................50-112

Disassemblyandassemblyoftransferassembly..............................................................................50-139

Disassemblyandassemblyofparkingbrakeassembly...................................................................50-154 Removalandinstallationoffrontaxleassembly...............................................................................50-161 Removalandinstallationofrearaxleassembly................................................................................50-163 Removalandinstallationofcentersupportassembly.......................................................................50-165 Disassemblyandassemblyofcentersupportassembly..................................................................50-167

Disassemblyandassemblyofdifferentialassembly.........................................................................50-171

Removalandinstallationoffinaldrivecarrierassembly...................................................................50-185 Disassemblyandassemblyoffinaldrivecarrierassembly..............................................................50-187

Removalandinstallationoffrontfinaldrivebrakeassembly............................................................50-188

Disassemblyandassemblyoffinaldriveassembly..........................................................................50-190

Brakesystem...........................................................................................................................................50-193

Disassemblyandassemblyofbrakeassembly.................................................................................50-193 Removalandinstallationofbrakevalveassembly............................................................................50-201 Disassemblyandassemblyofaccumulatorandchargevalveassembly........................................50-202 Disassemblyandassemblyofslackadjustorassembly...................................................................50-205 Undercarriageandframe........................................................................................................................50-207 Removalandinstallationofcenterhingepin.....................................................................................50-207 Removalandinstallationofcounterweightassembly.......................................................................50-214 Hydraulicsystem.....................................................................................................................................50-215 Removalandinstallationofhydraulictankassembly........................................................................50-215 Removalandinstallationofhydraulicpumpassembly.....................................................................50-217 Removalandinstallationofcontrolvalveassembly..........................................................................50-221 Disassemblyandassemblyofcontrolvalveassembly.....................................................................50-223 Removalandinstallationofsteeringvalveassembly........................................................................50-228 Disassemblyandassemblyofhydrauliccylinderassembly.............................................................50-229

Workequipment......................................................................................................................................50-234 Removalandinstallationofworkequipmentassembly....................................................................50-234 Cabanditsattachments.........................................................................................................................50-238 Removalandinstallationofoperator'scabassembly.......................................................................50-238 Removalandinstallationofoperator'scabglass(stuckglass)........................................................50-242 Removalandinstallationoffloorframeassembly.............................................................................50-250 Disassemblyandassemblyofoperator’sseatassembly.................................................................50-253 Removalandinstallationofairconditionerunitassembly................................................................50-286 RemovalandinstallationofAJSSleverswitchassembly..............................................................50-288-1

Electricalsystem......................................................................................................................................50-289

Removalandinstallationofenginecontrollerassembly...................................................................50-289

Removalandinstallationoftransmissioncontrollerassembly..........................................................50-291

Removalandinstallationofloadercontrollerassembly....................................................................50-291

RemovalandinstallationofVHMScontrollerassembly....................................................................50-292

Removalandinstallationofmachinemonitorassembly...................................................................50-293

90Diagramsanddrawings

Hydraulicdiagramsanddrawings..............................................................................................................90-3

Symbolsusedinhydrauliccircuitdiagrams...........................................................................................90-3

Powertrainhydrauliccircuitdiagram......................................................................................................90-5

Brakehydrauliccircuitdiagram...............................................................................................................90-6

Workequipmenthydrauliccircuitdiagram.............................................................................................90-9

Electricaldiagramsanddrawings.............................................................................................................90-11

Symbolsusedinelectriccircuitdiagrams.............................................................................................90-11

Airconditionerelectricalcircuitdiagram..............................................................................................90-15

Electricalcircuitdiagram...........................................................................................................................90-17

KOMTRAXelectricalcircuitdiagram(GPRStype).............................................................................90-37

Connectorlistandlayout......................................................................................................................90-39 Index.........................................................................................................................................................1

00Indexandforeword

Forewordandgeneralinformation1

Safetynotice1

Importantsafetynotice

Properserviceandrepairareextremelyimportantforsafemachineoperation.Theserviceandrepair techniquesrecommendedbyKomatsuanddescribedinthismanualarebotheffectiveandsafe. SomeofthesetechniquesrequiretheuseoftoolsspeciallydesignedbyKomatsuforthespecific purpose.

Topreventinjurytoworkers,thesymbolkisusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwith thesituation.

1.Generalprecautions

kMistakesinoperationareextremely dangerous.ReadtheOperationand MaintenanceManualcarefullybefore operatingthemachine.Inaddition, readthismanualandunderstandits contentsbeforestartingthework.

1)Beforecarryingoutanygreasingor repairs,readallthesafetylabelsstuckto themachine.Forthelocationsofthe safetylabelsanddetailedexplanationof precautions,seetheOperationandMaintenanceManual.

2)Decideaplaceintherepairworkshopto keeptoolsandremovedparts.Always keepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareaclean andmakesurethatthereisnodirt,water, oroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhile working.

3)Whencarryingoutanyoperation,always wearsafetyshoesandhelmet.Donot wearlooseworkclothes,orclotheswith buttonsmissing.

qAlwayswearsafetyglasseswhenhittingpartswithahammer.

qAlwayswearsafetyglasseswhen grindingpartswithagrinder,etc.

4)Whencarryingoutanyoperationwith2or moreworkers,alwaysagreeontheoperatingprocedurebeforestarting.Always informyourfellowworkersbeforestarting anystepoftheoperation.Beforestarting work,hangUNDERREPAIRwarning signsintheoperator'scompartment.

5)Onlytheapprovedpersonnelcandothe workinaclosedenvironmentorinaprohibitedarea.

6)Onlyqualifiedworkersmustcarryoutwork andoperationwhichrequirelicenseor qualification.

7)Keepalltoolsingoodcondition,learnthe correctwaytousethem,andusethe properonesofthem.Beforestartingwork, thoroughlycheckthetools,machine,forklift,servicecar,etc.

8)Ifweldingrepairsareneeded,always haveatrainedandexperiencedwelder carryoutthework.Whencarryingout weldingwork,alwayswearwelding gloves,apron,shieldinggoggles,capand otherclothessuitedforweldingwork.

9)Beforestartingwork,warmupyourbody thoroughlytostartworkundergoodcondition.

10)Avoidcontinuingworkforlonghoursand takerestsatproperintervalstokeepyour bodyingoodcondition.Takerestsin specifiedsafeplaces.

11)Whenyouworkinhighplaces,useaplatform.

12)Beforeyoustartthework,usethepersonal fall-arrestequipmenttopreventfalling. Thereisadangerofpersonalaccidentthat youfallbyslipping.

13)Alwaysdotheworkcorrectly.Ifyoufind theunsafebehaviorofco-worker,give him/heranoticeandstopit.

14)Becausethereisadangerthatyouare caught,beverycarefulwhentheworkis doneindangerousareassuchas:when yougointherangewheretheliftedload possiblyfalls,orwhenyoustanddirectlyin frontoftire,orwhenyouareneartheslidingparts.

15)Whenyouhandlechemicalmaterials (suchasnitrogengas),seetheMSDS (safetydatasheet)andlocalguidelines, andgettheimportantinformation(suchas asafehandlingmethod).Also,puton applicableprotectiveequipment(suchas protectivegoggles,gloves,andmasks).

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