Komatsu WA500-6 Wheel Loader Service Manual
1,865 pages · Publication SEN00236-19
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- Models
- WA500-6
- Serial coverage
- 55001 and up
- Manual type
- Service Manual
- Pages
- 1,865
- Publication
- SEN00236-19
- Condition
- Brand new
What's inside
From the manual's own table of contents: 268 sections, 545 entries. See sample pages (PDF, 771 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Cooling system
Engine mount and transmission mount
Joint
Cooling fan pump
Cooling fan motor
Power train
Power train system diagram
Drive shaft
Power train piping diagram
Show all 268 sections
Torque converter
Torque converter regulator valve
Transmission
Transfer
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Lubrication relief valve
Torque converter oil cooler
Torque converter oil filter
Center support
Axle
Differential
Limited slip differential
Final drive
Steering piping diagram
Steering column
Steering control valve48 topics
- Steering valve
- Stop valve
- Joystick steering lever linkage (if equipped)
- Steering cylinder
- Emergency steering piping diagram (if equipped)
- Diverter valve
- Brake piping diagram
- Brake valve
- Slack adjuster
- Accumulator charge valve
- PPC relief valve
- Accumulator (for brake)
- Brake
- Parking brake control
- Parking brake
- Parking brake solenoid valve
- Emergency parking brake release valve
- Axle mount
- Center hinge pin
- Hydraulic piping diagram
- Work equipment control lever linkage
- Hydraulic tank
- Steering pump
- Work equipment hydraulic pump
- Control valve
- CLSS
- Each function and operation of each valve
- Accumulator (for PPC circuit)
- Work equipment electric lever
- Work equipment linkage
- Bucket
- Bucket positioner and boom kick-out
- Work equipment lubrication
- Work equipment cylinder
- ROPS cab
- Air conditioner
- Machine monitor system
- Machine monitor
- Work equipment control system
- Transmission controller system
- Electric transmission control
- Engine starting circuit
- Engine stopping circuit
- Preheating circuit
- Parking brake circuit
- Backup and stop lamp circuits
- Small lamp and head lamp circuits
- Working lamp circuit
Horn circuit
Wiper and window washer circuits
Sensor
KOMTRAX system
Standard service value table for engine
Standard service value table for chassis
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring exhaust gas color
Measuring exhaust temperature
Adjusting valve clearance
Testing compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Testing fuel pressure
Testing return rate and leakage
Bleeding air from fuel circuit
Testing leakage in fuel system
Handling reduced cylinder mode operation
Handling no injection cranking operation
Handling controller voltage circuit
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting transmission speed sensor
Measuring directional lever (Steering wheel specification)
Testing and adjusting power train oil pressure
Flushing procedure for torque converter and transmission hydraulic circuit
Method of moving machine when transmission valve is broken
Testing and adjusting steering stop valve
Testing and adjusting steering wheel
Testing steering oil pressure
Bleeding air from steering cylinder circuit
Testing hydraulic drive fan
Bleeding air from hydraulic drive fan circuit
Measuring brake pedal
Measuring brake performance1 topic
- with nitrogen gas
Testing and adjusting accumulator charge pressure
Testing wheel brake oil pressure
Measuring wear of wheel brake disc
Bleeding air from brake circuit
Releasing residual pressure in brake accumulator circuit
Testing parking brake performance
Measuring parking brake oil pressure
Testing wear of parking brake disc
Method of releasing parking brake manually44 topics
- Measuring and adjusting work equipment control lever
- Testing and adjusting work equipment PPC oil pressure
- Measuring work equipment oil pressure
- Bleeding air from work equipment circuit
- Releasing residual pressure in work equipment circuit
- floor specification)
- Testing and adjusting bucket positioner
- Testing and adjusting lift arm position detecting lever
- Checking proximity switch operation indication lamp
- Procedure for testing diodes
- Preparations for work on troubleshooting of electrical system
- How to start KOMTRAX terminal operations (if equipped)
- Indicator lamps of KOMTRAX terminal (if equipped)
- and additional installation for each sensor and controller
- Special functions of machine monitor (EMMS)
- Pm clinic inspection table
- Points to remember when performing troubleshooting
- How to proceed in troubleshooting
- Testing before troubleshooting
- Classification and procedures of troubleshooting
- Information in troubleshooting table
- Troubleshooting method for disconnecting wiring harness of pressure sensor system
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Failure codes list
- Before carrying out troubleshooting for electrical system
- Information contained in troubleshooting table
- Failure code [1500L0] (TORQFLOW transmission : Double meshing)
- Failure code [15B0NX] (Transmission filter: Clogged)
- Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
- Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
- Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
- Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
- Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)
- Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)
- Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)
- Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)
- Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)
- Failure code [2F00MA] (Parking brake: Malfunction)
- Failure code [2G42ZG] (Front accumulator: Low oil pressure)
- Failure code [2G43ZG] Rear accumulator: Low oil pressure
- Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree
- Failure code [AA1ANX] Air cleaner: Clogging
- Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine
Failure code [AB00MA] Alternator: Malfunction
Failure code [B@BAZG] Low engine oil pressure
Failure code [B@BAZK] Engine oil: Low level
Failure code [B@BCNS] Coolant: Overheating
Failure code [B@BCZK] Coolant: Low level
Failure code [b@CENS] Torque converter oil: Overheating
Failure code [B@GAZK] Battery electrolyte: Low level
Failure code [B@HANS] Hydraulic oil: Overheating
Failure code [CA111] Abnormality in engine controller
Failure code [CA115] Engine Ne or Bkup speed sensor error
Failure code [CA122] Charge (boost) pressure sensor high error
Failure code [CA123] Charge (boost) pressure sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA135] Engine oil pressure sensor high error
Failure code [CA141] Engine oil pressure sensor low error
Failure code [CA144] Coolant temperature sensor high error
Failure code [CA145] Coolant temperature sensor low error
Failure code [CA153] Charge (boost) temperature sensor high error
Failure code [CA154] Charge (boost) temperature sensor low error
Failure code [CA187] Sensor power supply 2 low error
Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA227] Sensor power supply 2 high error
Failure code [CA234] Engine overspeed
Failure code [CA238] Ne speed sensor power supply error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] PCV1 Short circuit
Failure code [CA272] PCV1 Disconnection
Failure code [CA273] PCV2 Short circuit
Failure code [CA274] PCV2 Disconnection
Failure code [CA322] Injector #1 open/short error
Failure code [CA323] Injector #5 open/short error
Failure code [CA324] Injector #3 open/short error
Failure code [CA325] Injector #6 open/short error
Failure code [CA331] Injector #2 open/short error
Failure code [CA332] Injector #4 open/short error
Failure code [CA342] Calibration code inconsistency
Failure code [CA351] Injectors drive circuit error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sensor power supply 1 high error
Failure code [CA431] Idle validation switch error
Failure code [CA432] Idle validation action error
Failure code [CA441] Battery voltage low error
Failure code [CA442] Battery voltage high error
Failure code [CA449] Common rail pressure high error 2
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Common rail pressure high error 1
Failure code [CA554] Common rail pressure sensor in range error
Failure code [CA559] Supply pump pressure very low error 1
Failure code [CA689] Engine Ne speed sensor error
Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA757] All continuous data lost error
Failure code [CA778] Engine Bkup speed sensor error47 topics
- Failure code [CA1228] EGR valve servo error 1
- Failure code [CA1625] EGR valve servo error 2
- Failure code [CA1626] Bypass valve solenoid current high error
- Failure code [CA1627] Bypass valve solenoid current low error
- Failure code [CA1628] Bypass Valve Servo Error 1
- Failure code [CA1629] Bypass Valve Servo Error 2
- Failure code [CA1631] Bypass valve lift sensor high error
- Failure code [CA1632] Bypass valve lift sensor low error
- Failure code [CA1633] KOMNET datalink timeout error
- Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor
- Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor
- Failure code [CA2185] Throttle sensor supply voltage high error
- Failure code [CA2186] Throttle sensor power supply low error
- Failure code [CA2249] Supply pump pressure very low error 2
- Failure code [CA2271] EGR valve lift sensor high error
- Failure code [CA2272] EGR valve lift sensor low error
- Failure code [CA2351] EGR valve solenoid operation short circuit
- Failure code [CA2352] EGR valve solenoid operation disconnect
- Failure code [CA2555] Intake air heater relay open circuit error
- Failure code [CA2556] Intake air heater relay short circuit error
- Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit
- Failure code [D191KA] Joystick steering neutral safety relay: Disconnection
- Failure code [D191KB] Joystick steering neutral safety relay: Short circuit
- Failure code [D192KA] ECSS solenoid: Disconnection
- Failure code [D192KB] ECSS solenoid: Short circuit
- Failure code [D192KY] ECSS solenoid: Short circuit with power supply line
- Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection
- Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit
- Failure code [D5ZHKA] Terminal C signal: Disconnection
- Failure code [D5ZHKB] Terminal C signal: Short circuit
- Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit
- Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree
- Failure code [DAF3KK] Machine monitor: Low source voltage (input)
- Failure code [DAF5KP] Machine monitor: Low output voltage
- mality in target component system)
- Failure code [DAQ0KK] Transmission controller: Low source voltage
- Failure code [DAQ0KT] Transmission controller: Abnormality in controller
- Low source voltage (input)
- Disagreement of model selection signals
- Communication error (Abnormality in target component system)
- Failure code [DAQRMA] Transmission controller option setting: Malfunction
- mality in target component system)
- Failure code [DB90KK] Work equipment controller: Low source voltage (input)
- Failure code [DB90KT] Work equipment controller: Abnormality in controller
- (input)
- tion signals
- (Abnormality in target component system)
Failure code [DB9RMA] Work equipment controller option setting: Malfunction
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time1 topic
- long time
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time1 topic
- Switch is kept pressed for long time
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree1 topic
- Switch is kept pressed for long time)
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
Failure code [DDK3KA] (Right FNR switch: Disconnection)
Failure code [DDK3KB] (Right FNR switch: Short circuit)
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)
Failure code [DDK6KA] (FNR lever switch: Disconnection)
Failure code [DDK6KB] (FNR lever switch: Short circuit)
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
Failure code [DF10KA] (Transmission shift lever switch: Disconnection)
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)43 topics
- Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range)
- Signal disagrees with operating and stopped states of engine)
- Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
- Short circuit with power supply line)
- Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
- Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)
- Short circuit with power supply line)
- Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)
- Short circuit with power supply line)
- Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)
- Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)
- Short circuit with power supply line)
- Disconnection)
- Short circuit with power supply line)
- Analog signals disagree)
- Disconnection)
- Short circuit with power supply line)
- Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)
- Short circuit with power supply line)
- Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
- Short circuit with power supply line)
- Analog signals disagree)
- Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)
- Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)
- Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
- Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)
- Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)
- Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)
- Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)
- Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range)
- Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
- Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)
- Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)
- Failure code [DV00KB] (Alarm buzzer: Short circuit)
- Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)
- Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)
- Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)
- Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)
- Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)
- Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)
- Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)
- Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)
- Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)1 topic
- Short circuit with power supply line)
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1 topic
- Shorted with the power source)
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)49 topics
- Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)
- Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)
- power supply line)
- Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
- Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
- power supply line)
- Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
- Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
- power supply line)
- Before carrying out troubleshooting of electrical system
- Engine does not start
- Wiper does not operate
- Windshield washer does not operate
- Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
- Working lamp does not light up or go off
- Turn signal lamp and hazard lamp do not light up or go off
- Brake lamp does not light or it keeps lighting up
- Backup lamp does not light or it keeps lighting up
- Backup buzzer does not sound or it keeps sounding
- Horn does not sound or it keeps sounding
- Alarm buzzer does not sound or it keeps sounding
- Air conditioner does not operate or stop
- KOMTRAX system does not work properly
- Method of using troubleshooting chart
- Table of failure modes and causes
- Machine does not start
- [Machine with lockup clutch (if equipped)]
- Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)]
- and gear is not shifted
- Shocks are large at the times of starting and shifting gear
- Time lag is large at the times of starting and shifting gear
- Torque converter oil temperature is high
- Steering does not turn
- Steering does not turn [Machine with joystick steering (if equipped)]
- Steering response is low
- Turning response of steering is poor [machine with joystick steering (if equipped)]
- Steering is heavy
- When machine turns, it shakes or makes large shocks
- [machine with joystick steering (if equipped)]
- Wheel brake does not work or does not work well
- Wheel brake is not released or it drags
- Parking brake does not work or does not work well
- Parking brake is not released or it drags (including emergency release system)
- Lift arm does not rise
- Lift arm speed is low or rising force of lift arm is insufficient
- When rising, lift arm comes to move slowly at specific height
- Lift arm cylinder cannot hold down bucket (Bucket floats)
- Hydraulic drifts of lift arm occur often
- Lift arm wobbles during operation
Bucket does not tilt back
Bucket speed is low or tilting back force is insufficient
Bucket comes to operate slowly in the midst of tilting-back
Bucket cylinder cannot hold down the bucket
Hydraulic drifts of bucket occur often
Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)
During operation of machine, engine speed lowers remarkably or engine stalls
Large shocks are made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment moves
ECSS does not operate, and pitching and bouncing occur
Engine does not start easily
Engine does not start
Engine does not pick up smoothly
Engine stops during operation
Engine does not rotate smoothly (Engine hunts.)
Engine lacks output (or lacks power)
Exhaust smoke is black (Incomplete combustion)
Oil is consumed much (or exhaust gas color is blue)
Engine oil becomes contaminated quickly
Fuel consumption is excessive
Coolant contains oil (blows back or reduces)
Oil pressure drops
Oil level rises (Water, fuel in oil)
Coolant temperature rises too high (Overheating)
Abnormal noise is made
Vibration is excessive
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of air aftercooler
Removal and installation of cooling fan and fan motor assembly
Removal and installation of radiator guard and cooling fan motor assembly
Removal and installation of fuel tank assembly
Removal and installation of hood
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of torque converter and transmission assembly
Disconnection and connection of power train unit
Disassembly and assembly of input transfer assembly
Disassembly and assembly of torque converter assembly (Lockup specification)
Disassembly and assembly of torque converter assembly (Lockup-less specification)40 topics
- Disassembly and assembly of transmission assembly
- Disassembly and assembly of transfer and parking brake assembly
- Removal and installation of front axle assembly
- Removal and installation of rear axle assembly
- Removal and installation of front differential assembly
- Disassembly and assembly of differential assembly (LSD specification)
- Disassembly and assembly of differential assembly (LSD-less specification)
- Disassembly and assembly of final drive assembly (Front and rear)
- Removal and installation of brake assembly (Front and rear)
- Disassembly and assembly of brake assembly (Front and rear)
- Disassembly and assembly of slack adjuster assembly
- Disassembly and assembly of brake accumulator charge valve assembly
- Removal and installation of center hinge pin
- Removal and installation of hydraulic tank assembly
- Removal and installation of cooling pump assembly
- Removal and installation of fan pump assembly
- Removal and installation of work equipment pump assembly
- Removal and installation of steering, torque converter charge and EPC pump assembly
- Removal and installation of work equipment valve assembly
- Disassembly and assembly of work equipment control valve assembly
- Disassembly and assembly of steering cylinder assembly
- Disassembly and assembly of lift arm and/bucket cylinder assembly
- Removal and installation of steering valve assembly
- Removal and installation of work equipment assembly
- Removal and installation of large counterweight assembly
- Removal and installation of small counterweight assembly
- Removal and installation of operator's cab glass (Stuck glass)
- Disassembly and assembly of operator’s seat assembly
- Removal and installation of engine controller assembly
- Removal and installation of transmission controller assembly
- Removal and installation of work equipment controller assembly
- Removal and installation of KOMTRAX terminal assembly
- Removal and installation of air conditioner unit assembly
- Automatic greasing circuit diagram
- Power train hydraulic circuit diagram
- Brake hydraulic circuit diagram
- Work equipment hydraulic circuit diagram
- Air conditioner electrical circuit diagram
- Electrical circuit diagram
- Connector arrangement diagram
Inside this manual
Real pages from this service manual (1,865 pages). Open the sample pages (PDF, 770 KB)
- Specifications, page 329: 10 Structure, function and maintenance standard
- Troubleshooting, page 1,001: Troubleshooting by failure code (Display of code), Part 4
- Diagram, page 1,281: 40 Troubleshooting
- Foldout diagram, page 1,857: Electrical circuit diagram (2/7)
Other manuals for this machine
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This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,865 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).