Komatsu WA430-6 Install guide

WHEEL LOADER
SEN00823-16
WA430
-6
SERIAL NUMBERS
65001
and up

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WA430-6 1
SEN00832-16
WHEEL LOADER
1SHOP MANUAL
WA430-6
Machine model Serial number
WA430-6 65001 and up
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
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SEN00832-16 00 Index and foreword
2WA430-6
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00823-16
00 Index and foreword SEN00824-16
Index SEN00832-16 q
Foreword and general information SEN00833-04
01 Specification SEN00825-03
Specification and technical data SEN00834-03 q
10 Structure, function and maintenance standard SEN00826-05
Engine and cooling system SEN01363-01
Power train SEN01364-03
Steering system SEN01365-02
Brake system SEN01366-02
Undercarriage and frame SEN01367-02
Hydraulic system, Part 1 SEN01368-03
Hydraulic system, Part 2 SEN01369-01
Work equipment SEN01370-02 q
Cab and its attachments SEN01371-02
Electrical system, Part 1 SEN01372-03
Electrical system, Part 2 SEN01373-03 q
Electrical system, Part 3 SEN01374-04 q
20 Standard value table SEN00827-05
Standard service value table SEN01599-05 q
30 Testing and adjusting SEN00828-07
Testing and adjusting, Part 1 SEN01600-05
Testing and adjusting, Part 2 SEN01601-05
Testing and adjusting, Part 3 SEN01602-07
40 Troubleshooting SEN00829-06
Failure code table and fuse locations SEN01736-06
General information on troubleshooting SEN01737-03
Troubleshooting by failure code (Display of code), Part 1 SEN01738-04
Troubleshooting by failure code (Display of code), Part 2 SEN01739-05
Troubleshooting by failure code (Display of code), Part 3 SEN01740-05
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00 Index and foreword SEN00832-16
WA430-6 3
Troubleshooting by failure code (Display of code), Part 4 SEN01741-02
Troubleshooting by failure code (Display of code), Part 5 SEN01742-03
Troubleshooting by failure code (Display of code), Part 6 SEN01743-03
Troubleshooting by failure code (Display of code), Part 7 SEN01744-02
Troubleshooting by failure code (Display of code), Part 8 SEN01745-03
Troubleshooting by failure code (Display of code), Part 9 SEN01746-01
Troubleshooting by failure code (Display of code), Part 10 SEN01747-02
Troubleshooting of electrical system (E-mode) SEN01748-04
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01749-04
Troubleshooting of engine (S-mode) SEN01750-02
50 Disassembly and assembly SEN00830-05
General information on disassembly and assembly SEN02191-03 q
Engine and cooling system SEN02192-03
Power train, Part 1 SEN02193-04
Power train, Part 2 SEN02194-04 q
Steering system SEN02195-02 q
Brake system SEN02196-02
Undercarriage and frame SEN02197-03 q
Hydraulic system SEN02198-02
Work equipment SEN02199-04 q
Cab and its attachments SEN02200-02
Electrical system SEN02201-01
90 Diagrams and drawings SEN00831-04
Hydraulic diagrams and drawings SEN00835-02
Electrical diagrams and drawings SEN00836-03
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SEN00832-16 00 Index and foreword
4WA430-6
Table of contents 1
00 Index and foreword
Index SEN00832-16
Composition of shop manual................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00833-04
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard...................................................................... 9
Handling of electric equipment and hydraulic component....................................................... 11
Handling of connectors newly used for engines...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00834-03
Specification dimension drawing.............................................................................................. 3
Specifications........................................................................................................................... 4
Weight table............................................................................................................................. 8
Table of fuel, coolant and lubricants ........................................................................................ 10
10 Structure, function and maintenance standard
Engine and cooling system SEN01363-01
Engine mount and transmission mount ................................................................................... 2
Cooling system........................................................................................................................ 3
Cooling fan pump..................................................................................................................... 4
Cooling fan motor .................................................................................................................... 12
Power train SEN01364-03
Power train............................................................................................................................... 3
Power train system diagram .................................................................................................... 4
Drive shaft................................................................................................................................ 6
Power train piping diagram......................................................................................................7
Torque converter...................................................................................................................... 8
Transmission............................................................................................................................ 16
Flow control valve.................................................................................................................... 33
Transmission control valve ......................................................................................................36
ECMV ...................................................................................................................................... 40
Main relief valve and torque converter relief valve .................................................................. 46
Axle.......................................................................................................................................... 48
Differential................................................................................................................................ 50
Limited slip differential ............................................................................................................. 56
Final drive................................................................................................................................ 62
Steering system SEN01365-02
Steering piping diagram........................................................................................................... 3
Steering column....................................................................................................................... 4
Steering pump.......................................................................................................................... 5
Steering valve.......................................................................................................................... 17
Orbit-roll valve.......................................................................................................................... 32
Stop valve................................................................................................................................ 36
Steering relief valve ................................................................................................................. 37
Steering cylinder...................................................................................................................... 38
Emergency steering motor....................................................................................................... 40
Emergency steering pump....................................................................................................... 41
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00 Index and foreword SEN00832-16
WA430-6 5
Joystick steering lever linkage.................................................................................................42
Steering electric lever.............................................................................................................. 43
Joystick EPC valve.................................................................................................................. 44
Brake system SEN01366-02
Brake piping diagram............................................................................................................... 2
Charge valve ........................................................................................................................... 3
Brake valve.............................................................................................................................. 10
Accumulator (for brake)........................................................................................................... 15
Brake....................................................................................................................................... 16
Parking brake control............................................................................................................... 21
Parking brake .......................................................................................................................... 22
Parking brake solenoid valve................................................................................................... 24
Emergency parking brake release valve ................................................................................. 26
Undercarriage and frame SEN01367-02
Axle mount and center hinge pin............................................................................................. 2
Tires......................................................................................................................................... 6
Hydraulic system, Part 1 SEN01368-03
Hydraulic piping diagram......................................................................................................... 2
Work equipment control lever linkage ..................................................................................... 5
Hydraulic tank.......................................................................................................................... 8
Power train pump .................................................................................................................... 10
Work equipment pump ............................................................................................................ 11
Work equipment control valve ................................................................................................. 22
CLSS....................................................................................................................................... 36
Each function and operation of each valve.............................................................................. 40
Hydraulic system, Part 2 SEN01369-01
PPC valve................................................................................................................................ 2
Stabilizer valve......................................................................................................................... 10
Accumulator (for PPC circuit).................................................................................................. 16
Accumulator (for ECSS) ..........................................................................................................17
Work equipment PPC cut-off solenoid valve ........................................................................... 18
Work equipment SEN01370-02
Work equipment linkage..........................................................................................................2
Bucket...................................................................................................................................... 4
Bucket positioner and boom kick-out....................................................................................... 5
Work equipment cylinder.........................................................................................................11
Cab and its attachments SEN01371-02
Cab.......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 4
Electrical system, Part 1 SEN01372-03
Machine monitor system..........................................................................................................2
Machine monitor...................................................................................................................... 6
Electrical system, Part 2 SEN01373-03
Electrical system (Transmission controller system)................................................................. 2
Transmission controller............................................................................................................ 44
Electrical system (Work equipment controller system)............................................................ 46
Work equipment controller.......................................................................................................52
Electrical system, Part 3 SEN01374-04
Electric transmission control.................................................................................................... 2
Kickdown switch and hold switch ............................................................................................ 6
Multi-function knob .................................................................................................................. 7
Joystick steering knob............................................................................................................. 8
KOMTRAX system ..................................................................................................................10
Engine starting circuit .............................................................................................................. 12
Engine stopping circuit ............................................................................................................ 14
Preheating circuit..................................................................................................................... 15
Engine power mode selector circuit......................................................................................... 16
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SEN00832-16 00 Index and foreword
6WA430-6
Engine output derating function............................................................................................... 17
Automatic warm-up function.................................................................................................... 17
Parking brake circuit................................................................................................................ 18
Sensor ..................................................................................................................................... 20
20 Standard value table
Standard service value table SEN01599-05
Standard value table for engine............................................................................................... 2
Standard value table for chassis.............................................................................................. 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN01600-05
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Sketch of special tool............................................................................................................... 8
Testing exhaust gas color........................................................................................................ 11
Testing exhaust temperature ................................................................................................... 12
Adjusting valve clearance........................................................................................................ 14
Testing compression pressure................................................................................................. 16
Testing blow-by pressure......................................................................................................... 20
Testing engine oil pressure...................................................................................................... 21
Testing intake air (boost) pressure........................................................................................... 22
Handling fuel system equipment.............................................................................................. 23
Releasing residual pressure in fuel system............................................................................. 23
Testing fuel pressure................................................................................................................ 24
Testing fuel return and leak amount......................................................................................... 30
Bleeding air from fuel circuit .................................................................................................... 32
Testing leakage in fuel system................................................................................................. 33
Handling reduced cylinder mode operation............................................................................. 34
Handling no-injection cranking operation................................................................................. 34
Handling controller voltage circuit............................................................................................ 35
Check of muffler and muffler stack for looseness and damage............................................... 36
Check of muffler function......................................................................................................... 36
Check of installed condition of cylinder head and manifolds ................................................... 37
Check of engine piping for damage and looseness................................................................. 37
Checking and replacing alternator belt .................................................................................... 38
Checking and replacing auto-tensioner................................................................................... 40
Adjusting transmission speed sensor...................................................................................... 42
Adjusting directional lever length............................................................................................. 43
Adjusting gear shift lever length...............................................................................................43
Testing directional lever........................................................................................................... 44
Testing and adjusting power train oil pressure......................................................................... 45
Procedure for flushing torque converter and transmission hydraulic circuit ............................ 59
Method of moving machine when transmission valve is broken.............................................. 60
Checking axle final drive for oil leakage .................................................................................. 62
Checking drive shafts for looseness, play and damage .......................................................... 62
Testing and adjusting steering stop valve................................................................................ 63
Testing and adjusting steering wheel....................................................................................... 65
Testing and adjusting steering oil pressure.............................................................................. 67
Bleeding air from steering circuit ............................................................................................. 70
Testing and adjusting, Part 2 SEN01601-05
Testing hydraulic drive fan....................................................................................................... 3
Bleeding air from hydraulic drive fan circuit............................................................................. 5
Testing brake pedal.................................................................................................................. 7
Testing and adjusting brake pedal linkage............................................................................... 8
Testing brake performance...................................................................................................... 9
Testing and adjusting accumulator charge pressure ............................................................... 10
Testing wheel brake oil pressure ............................................................................................. 11
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00 Index and foreword SEN00832-16
WA430-6 7
Testing wear of wheel brake disc............................................................................................. 13
Bleeding air from wheel brake circuit....................................................................................... 14
Releasing residual pressure in brake accumulator circuit ....................................................... 15
Testing parking brake performance ......................................................................................... 16
Testing parking brake oil pressure........................................................................................... 17
Testing wear of parking brake disc .......................................................................................... 19
Method of releasing parking brake manually........................................................................... 20
Testing and adjusting work equipment control lever................................................................ 21
Testing and adjusting work equipment PPC oil pressure ........................................................ 22
Testing and adjusting work equipment oil pressure................................................................. 25
Bleeding air from work equipment circuit................................................................................. 29
Releasing residual pressure in work equipment circuit ........................................................... 30
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS
(Electronically Controlled Suspension System) accumulator............................. 31
Testing and adjusting bucket positioner................................................................................... 37
Testing and adjusting boom kick-out ....................................................................................... 39
Checking proximity switch operation pilot lamp....................................................................... 40
Procedure for testing diodes....................................................................................................41
Preparation work for troubleshooting for electrical system...................................................... 42
Starting KOMTRAX terminal operations.................................................................................. 47
Indicator lamps of KOMTRAX terminal.................................................................................... 52
Testing and adjusting, Part 3 SEN01602-07
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...... 2
Special functions of machine monitor (EMMS)........................................................................ 5
Pm-clinic inspection table........................................................................................................ 73
40 Troubleshooting
Failure code table and fuse locations SEN01736-06
Failure code table.................................................................................................................... 2
Fuse locations ......................................................................................................................... 13
General information on troubleshooting SEN01737-03
Points to remember when troubleshooting.............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Testing before troubleshooting ................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
Information contained in troubleshooting table........................................................................ 8
Connection table for connector pin numbers........................................................................... 10
T- branch box and T- branch adapter table ............................................................................. 46
Troubleshooting by failure code (Display of code), Part 1 SEN01738-04
Failure code [1500L0] (TORQFLOW transmission: Double meshing)...................................... 3
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) ..... 4
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF).... 6
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)..... 8
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF).... 10
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)... 12
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).. 14
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).. 16
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF). 18
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).. 20
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF). 22
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).. 24
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF). 26
Failure code [2F00MA] (Parking brake: Malfunction)................................................................ 28
Failure code [2G43ZG] (Accumulator: Low oil pressure).......................................................... 30
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)..................................... 32
Troubleshooting by failure code (Display of code), Part 2 SEN01739-05
Failure code [AA1ANX] (Air cleaner: Clogging)....................................................................... 4
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SEN00832-16 00 Index and foreword
8WA430-6
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............. 6
Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 8
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)................................. 10
Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 11
Failure code [B@BCNS] (Coolant: Overheating)..................................................................... 12
Failure code [B@BCZK] (Coolant: Low level).......................................................................... 14
Failure code [B@BEBF] (Water in fuel error) .......................................................................... 16
Failure code [b@CENS] (Torque converter oil: Overheating).................................................. 18
Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 20
Failure code [B@HANS] (Hydraulic oil: Overheating) ............................................................. 22
Failure code [CA111] (Abnormality in engine controller).......................................................... 24
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 25
Failure code [CA122] (Charge pressure sensor high error)..................................................... 26
Failure code [CA123] (Charge pressure sensor low error)...................................................... 28
Failure code [CA131] (Throttle sensor high error) ................................................................... 30
Failure code [CA132] (Throttle sensor low error)..................................................................... 32
Failure code [CA144] (Coolant sensor high error)................................................................... 34
Failure code [CA145] (Coolant sensor low error) .................................................................... 36
Failure code [CA153] (Charge temperature sensor high error)............................................... 38
Failure code [CA154] (Charge temperature sensor low error)................................................. 40
Failure code [CA155] (Derating of speed by abnormally high charge temperature)................ 42
Failure code [CA187] (Sensor power supply 2 low error)........................................................ 44
Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 46
Failure code [CA222] (Atmospheric sensor low error)............................................................. 48
Failure code [CA227] (Sensor power supply 2 high error)....................................................... 50
Failure code [CA234] (Engine overspeed)............................................................................... 51
Failure code [CA238] (Ne speed sensor power supply error).................................................. 52
Troubleshooting by failure code (Display of code), Part 3 SEN01740-05
Failure code [CA271] (IMV/PCV1 Short circuit)....................................................................... 3
Failure code [CA272] (IMV/PCV1 Disconnection)................................................................... 4
Failure code [CA281] High pressure pump error..................................................................... 6
Failure code [CA322] (Injector #1 open/short error)................................................................ 8
Failure code [CA323] (Injector #5 open/short error)................................................................ 10
Failure code [CA324] (Injector #3 open/short error)................................................................ 12
Failure code [CA325] (Injector #6 open/short error)................................................................ 14
Failure code [CA331] (Injector #2 open/short error)................................................................ 16
Failure code [CA332] (Injector #4 open/short error)................................................................ 18
Failure code [CA342] (Calibration code inconsistency)........................................................... 20
Failure code [CA351] (Injectors drive circuit error) .................................................................. 22
Failure code [CA352] (Sensor power supply 1 low error)........................................................ 24
Failure code [CA386] (Sensor power supply 1 high error)....................................................... 26
Failure code [CA428] (Abnormally high level in water sensor)................................................ 27
Failure code [CA429] (Abnormally low level in water sensor) ................................................. 28
Failure code [CA431] (Idle validation switch error).................................................................. 30
Failure code [CA432] (Idle validation action error) .................................................................. 32
Failure code [CA435] (Engine oil pressure switch error)......................................................... 34
Failure code [CA441] (Battery voltage low error)..................................................................... 35
Failure code [CA442] (Battery voltage high error) ................................................................... 38
Failure code [CA449] Common rail pressure high error 2....................................................... 40
Failure code [CA451] (Common rail pressure sensor high error)............................................ 44
Failure code [CA452] (Common rail pressure sensor low error) ............................................. 46
Failure code [CA488] (Derating of torque by abnormally high charge temperature) ............... 48
Failure code [CA553] (Common rail pressure high error 1)..................................................... 49
Failure code [CA559] (Supply pump pressure very low error)................................................. 50
Failure code [CA689] (Engine Ne speed sensor error)............................................................ 52
Failure code [CA731] (Engine Bkup speed sensor phase error)............................................. 54
Failure code [CA757] (All continuous data lost error).............................................................. 55
Failure code [CA778] (Engine Bkup speed sensor error)........................................................ 58
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