Komatsu Avance Loader WA320-3 Shop Manual SEBM006006 – PDF DOWNLOAD

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Komatsu Avance Loader WA320-3 Shop Manual SEBM006006 – PDF DOWNLOAD

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Komatsu Avance Loader WA320-3 Shop Manual SEBM006006 – PDF DOWNLOAD

Language : English
Pages :845
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Avance Loader WA320-3 Shop Manual SEBM006006 – PDF DOWNLOAD

FOREWORD GENERAL

• This shop manual has been prepared as an aid to improve the quality of repairs by g1vmg the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

TABLE OF CONTENTS:

Komatsu Avance Loader WA320-3 Shop Manual SEBM006006 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 24
GENERAL ASSEMBLY DRAWING 25
SPECIFICATIONS 27
WEIGHT TABLE 30
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
POWER TRAIN 35
POWER TRAIN SYSTEM 36
TORQUE CONVERTER, TRANSMISSION PIPING 38
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 39
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 40
TORQUE CONVERTER 41
TORQUE CONVERTER OIL FILTER 43
TRANSMISSION 44
TRANSMISSION CONTROL VALVE 54
DRIVE SHAFT 76
AXLE 77
DIFFERENTIAL 81
FINAL DRIVE 87
AXLE MOUNT, CENTER HINGE PIN 89
STEERING PIPING 91
STEERING COLUMN 92
PRIORITY VALVE 93
STEERING VALVE (ORBIT-ROLL) 98
CUSHION VALVE106
2-WAY RESTRICTOR VALVE107
BRAKE PIPING108
BRAKE HYDRAULIC CIRCUIT DIAGRAM109
BRAKE VALVE111
ACCUMULATOR CHARGE VALVE116
ACCUMULATOR (FOR BRAKE)122
BRAKE124
PARKING BRAKE CONTROL129
PARKING BRAKE130
PARKING BRAKE SOLENOID VALVE131
PARKING BRAKE VALVE132
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE133
HYDRAULIC PIPING134
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM135
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM136
WORK EQUIPMENT LEVER LINKAGE140
HYDRAULIC TANK141
PPC VALVE143
PPC RELIEF VALVE148
ACCUMULATOR (FOR PPC VALVE)149
MAIN CONTROL VALVE150
WORK EQUIPMENT LINKAGE165
BUCKET167
BUCKET POSITIONER AND BOOM KICK-OUT168
CAB174
ROPS CAB176
AIR CONDITIONER177
ELECTRIC CIRCUIT DIAGRAM 178
MACHINE MONITOR SYSTEM193
MAIN MONITOR194
MAINTENANCE MONITOR199
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM202
WORK EQUIPMENT CONTROL SYSTEM210
ECSS(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)217
SENSORS221
ENGINE STARTING CIRCUIT225
ENGINE STOP CIRCUIT226
PREHEATING CIRCUIT227
ELECTRIC TRANSMISSION CONTROL228
KICK-DOWN, HOLD SWITCH231
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM232
TRANSMISSION CUT-OFF SWITCH241
TRANSMISSION CUT-OFF FUNCTION242
ELECTRIC PARKING BRAKE CONTROL 246
20 TESTING AND ADJUSTING 259
STANDARD VALUE TABLE FOR ENGINE260
STANDARD VALUE TABLE FOR CHASSIS261
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM265
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING269
ADJUSTING VALVE CLEARANCE270
MEASURING COMPRESSION PRESSURE271
MEASURING BLOW-BY PRESSURE272
TESTING AND ADJUSTING FUEL INJECTION TIMING273
MEASURING EXHAUST COLOR275
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)276
MEASURING EXHAUST GAS TEMPERATURE277
MEASURING ENGINE OIL PRESSURE278
MEASURING ENGINE SPEED279
TESTING AND ADJUSTING FAN BELT TENSION280
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE281
MEASURING ACCELERATOR PEDAL283
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER285
MEASURING STALL SPEED286
MEASURING TORQUE CONVERTER, TRANSMISSION,PARKING BRAKE OIL PRESSURE288
METHOD OF OPERATING EMERGENCY MANUAL SPOOL290
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL 292
TESTING AND ADJUSTING STEERING WHEEL 293
MEASURING STEERING OIL PRESSURE295
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 297
MEASURING BRAKE PERFORMANCE298
TESTING BRAKE OIL PRESSURE299
TESTING FOR BRAKE DISC WEAR300
BLEEDING AIR FROM BRAKE SYSTEM301
MEASURING PARKING BRAKE PERFORMANCE302
MANUAL RELEASE METHOD FOR PARKING BRAKE303
TESTING WEAR OF PARKING BRAKE DISC304
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE305
MEASURING WORK EQUIPMENT CONTROL LEVER306
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE308
MEASURING PPC VALVE PRESSURE310
MEASURING WORK EQUIPMENT 312
TESTING AND ADJUSTING BUCKET POSITIONER314
TESTING AND ADJUSTING BOOM KICK-OUT315
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)317
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER318
TROUBLESHOOTING319
POINTS TO REMEMBER WHEN TROUBLESHOOTING320
SEQUENCE OF EVENTS IN TROUBLESHOOTING321
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE322
HANDLING CONNECTORS329
CHECKS BEFORE TROUBLESHOOTING330
METHOD OF USING TROUBLESHOOTING CHARTS331
CONNECTOR TYPES AND MOUNTING LOCATIONS339
CONNECTOR PIN ARRANGEMENT DIAGRAM340
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS345
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)352
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)353
S-2 ENGINE DOES NOT START 354
(1) ENGINE DOES NOT TURN354
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)355
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)356
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)357
S-4 ENGINE STOPS DURING OPERATIONS358
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)359
S-6 ENGINE LACKS OUTPUT (NO POWER)360
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)361
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)362
S-9 OIL BECOMES CONTAMINATED QUICKLY363
S-10 FUEL CONSUMPTION IS EXCESSIVE364
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN365
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)366
S-13 OIL LEVEL RISES367
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)368
S-15 ABNORMAL NOISE IS MADE369
S-16 VIBRATION IS EXCESSIVE370
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)371
TROUBLE DATA DISPLAY373
M-1 MAIN MONITOR DOES NOT WORK375
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP376
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY377
M-4 ABNORMALITY IN SHIFT INDICATOR378
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F378
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R378
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F378
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R 379
(e) DOES NOT DISPLAY 1ST, 4TH379
(f) DOES NOT DISPLAY 3RD, 4TH379
(g) DOES NOT DISPLAY 2ND, 3RD380
(h) DOES NOT DISPLAY 1ST, 2ND380
M-5 HIGH BEAM DOES NOT LIGHT UP381
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP382
(a) LH TURN SIGNAL DOES NOT LIGHT UP382
(b) RH TURN SIGNAL DOES NOT LIGHT UP382
M-7 ABNORMALITY IN PARKING DISPLAY383
(a) PARKING LAMP DOES NOT LIGHT UP383
(b) PARKING LAMP STAYS LIGHTED UP383
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS)384
(a) DOES NOT CARRY OUT PREHEATING 384
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE385
(c) PREHEATING STAYS ON 385
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION386
M-9 NIGHT LIGHTING DOES NOT LIGHT UP387
M-10 ABNORMALITY IN FRONT WORKING LAMP388
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP388
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP388
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP388
M-11 ABNORMALITY IN REAR WORKING LAMP389
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP389
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP389
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP389
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF391
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 391
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON 391
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED392
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 393
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES393
(b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N393
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED 394
(a) ACTUATED CONTINUOUSLY394
(b) NOT ACTUATED394
M-15 ABNORMALITY IN BUZZER 395
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)395
(b) BUZZER ALWAYS SOUNDS395
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY396
M-17 ABNORMALITY IN FAILURE DISPLAY MODE397
(a) DOES NOT ENTER FAILURE DISPLAY MODE 397
(b) TIMES FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 397
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY398
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP398
(b) EMERGENCY STEERING NORMAL DISPLAY LIGHTED UP398
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY399
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP399
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP399
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM400
(a) FORCED GREASING CANNOT BE CARRIED OUT400
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)400
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)400
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)401
(e) MONITOR DISPLAY GOES OUT 401
M-21 ABNORMALITY IN ECSS SYSTEM402
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED402
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK402
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED402
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)403
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)404
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK405
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS405
(b) SOME LAMPS DO NOT LIGHT UP406
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT406
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT407
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH408
(a) ENGINE OIL LEVEL DISPLAY FLASHES408
(b) ENGINE WATER LEVEL DISPLAY FLASHES 409
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH410
(a) ENGINE OIL PRESSURE DISPLAY FLASHES410
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES411
(c) BRAKE OIL PRESSURE DISPLAY FLASHES412
(d) AIR CLEANER DISPLAY FLASHES413
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND414
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS415
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP416
(a) CHECK LAMP416
(b) CAUTION LAMP416
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP417
(a) CHECK LAMP417
(b) CAUTION LAMP417
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)418
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP419
K-12 SERVICE METER DOES NOT WORK420
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED420
K-14 ABNORMALITY IN GAUGE ITEMS 421
(a) ABNORMALITY IN FUEL GAUGE421
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE422
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE423
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)424
E-1 ENGINE DOES NOT START 425
(a) STARTING MOTOR DOES NOT TURN 425
(b) STARTING MOTOR TURNS429
E-2 ENGINE DOES NOT STOP431
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 431
E-4 PARKING BRAKE DOES NOT WORK 432
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (PARKING)432
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE)432
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 433
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 435
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (WITHOUT AUTO-SIFT TRANSMISSION)435
E-8 TRANSMISSION DOES NOT WORK NORMALLY (WITHOUT AUTO-SIFT TRANSMISSION)436
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)438
(b) PROBLEM IN H-L CIRCUIT438
(c) PROBLEM IN SPEED CIRCUIT 439
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)439
(e) CONTACT IN H-L CIRCUIT440
(f) CONTACT IN SPEED CIRCUIT442
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)444
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)445
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)447
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL)449
(k) CONTACT IN FORWARD CIRCUIT451
(l) CONTACT IN REVERSE CIRCUIT 453
(m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE455
E-9 KICK-DOWN SWITCH DOES NOT WORK (WITHOUT AUTO-SIFT TRANSMISSION) (THE REGULAR F1 TO F4 SHIFTS NORMALLY)456
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION (SELF-HOLDING FUNCTION))(WITHOUT AUTO-SIFT TRANSMISSION)458
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED (WITHOUT AUTO-SIFT TRANSMISSION)458
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R 458
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH)459
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND (WITHOUT AUTO-SIFT TRANSMISSION)461
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)(T MODE)462
POWER TRAIN 463
T-1 MACHINE DOES NOT START463
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 465
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR467
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR468
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH469
STEERING SYSTEM470
T-6 STEERING WHEEL DOES NOT TURN 470
T-7 STEERING IS HEAVY471
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK472
BRAKE SYSTEM473
T-9 BRAKE DO NOT WORK OR BRAKING EFFECT IS POOR473
T-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG474
T-11 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS475
WORK EQUIPMENT 476
T-12 BOOM DOES NOT RISE476
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER477
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 478
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)478
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM478
T-17 BOOM SHAKES DURING OPERATION478
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE479
T-19 BUCKET DOES NOT TILT BACK480
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER481
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 482
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 482
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET482
T-24 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)483
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT483
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 484
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE)485
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM)486
D-1 ECSS DOES NOT WORK487
(a) ERROR CODE [d0] IS DISPLAYED 488
(b) ERROR CODE [d1] IS DISPLAYED 488
(c) ERROR CODE [d2] IS DISPLAYED 489
(d) ERROR CODE [d3] IS DISPLAYED 489
(e) ERROR CODE [d4] IS DISPLAYED 490
(f) NO ABNORMALITY DISPLAY IS GIVEN490
D-2 ECSS CANNOT BE CANCELED494
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 KM/H)(DEVIATES AROUND 5 KM/H)495
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST 495
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH496
D-6 CONTROLLER LED CODE IS NOT DISPLAYED 497
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY497
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)498
OUTLINE500
1 FUNCTION500
2 WHEN CARRYING OUT TROUBLESHOOTING 500
3 FAILURE CODE TABLE500
4 TABEL OF TROUBLESHOOTING MODES AND CAUSES501
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM503
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF504
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM505
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM506
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID 507
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID507
W-7 FAILURE CODE [48] ANMORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM508
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM510
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM511
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH512
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIONMETER SYSTEM513
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM513
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS515
W-14 SENSOR CANNOT BE ADJUSTED516
W-15 DOES NOT CARRY OUT AUTO-LEVELING517
(a) AUTO-LEVELER SWITCH SYSTEM517
(b) AUTO-LEVELER LED SYSTEM517
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM518
(d) ENGINE SPEED SIGNAL SYSTEM519
W-16 AUTO-LEVELER CANNOT BE SET 520
(a) AUTO-LEVELER SET SWITCH SYSTEM520
(b) AUTO-LEVELER SET LED SYSTEM520
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP521
(a) REMOTE POSITIONER SWITCH SYSTEM521
(b) REMOTE POSITIONER LED SYSTEM521
W-18 REMOTE POSITIONER SET LEDS DO NOT FLASH522
(a) REMOTE POSITIONER SWITCH SYSTEM522
(b) REMOTE POSITIONER LED SYSTEM522
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONER IS AT RAISE AND AUTO MODE IS ON 523
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND524
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW525
W-22 BUCKET (LEVER) CONTROL 526
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT 526
(b) LEVER IS NOT HELD BY DETENT 527
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR529
W-24 MAINTENANCE MONITOR CHECK530
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (WITH AUTO-SIFT TRANSMISSION)(A MODE)531
OUTLINE532
1 FUNCTION532
2 WHEN CARRYING OUT TROUBLESHOOTING532
3 FAILURE CODE TABLE532
4 ACTION CODE TABLE533
5 TABLE OF TROUBLESHOOTING MODES AND CAUSES534
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLER SYSTEM535
A-1 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM537
A-2 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM537
A-3 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM538
A-4 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM539
A-5 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM540
A-6 TROUBLESHOOTING CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM541
A-7 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM542
A-8 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL543
A-9 HOLD SWITCH SYSTEM544
A-10 KICK-DOWN SWITCH SYSTEM544
A-11 TRANSMISSION CUT-OFF SIGNAL SYSTEM545
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM546
A-13 BUZZER SIGNAL SYSTEM547
A-14 NETWORK SIGNAL SYSTEM548
A-15 CONTROLLER POWER SOURCE SYSTEM549
30 DISASSEMBLY AND ASSEMBLY550
METHOD OF USING MANUAL 552
PRECAUTIONS WHEN CARRYING OUT OPERATION 553
SPECIAL TOOL LIST555
SKETCHES OF SPECIAL TOOLS557
STARTING MOTOR558
REMOVAL AND INSTALLATION558
ALTERNATOR559
REMOVAL AND INSTALLATION559
ENGINE OIL COOLER560
REMOVAL AND INSTALLATION560
FUEL INJECTION PUMP561
REMOVAL561
INSTALLATION562
WATER PUMP563
REMOVAL AND INSTALLATION563
TURBOCHARGER565
REMOVAL AND INSTALLATION565
NOZZLE HOLDER 566
REMOVAL AND INSTALLATION566
THERMOSTAT567
REMOVAL AND INSTALLATION567
CYLINDER HEAD568
REMOVAL 568
INSTALLATION573
RADIATOR575
REMOVAL575
INSTALLATION580
ENGINE581
REMOVAL581
INSTALLATION585
TORQUE CONVERTER CHARGING PUMP586
REMOVAL AND INSTALLATION586
TORQUE CONVERTER, TRANSMISSION 587
REMOVAL587
INSTALLATION600
TORQUE CONVERTER603
DISASSEMBLY603
ASSEMBLY605
TRANSMISSION607
DISASSEMBLY607
ASSEMBLY617
TRANSMISSION CLUTCH PACK631
DISASSEMBLY631
ASSEMBLY637
TRANSMISSION CONTROL VALVE649
REMOVAL649
INSTALLATION651
DISASSEMBLY652
ASSEMBLY654
TRANSMISSION ACCUMULATOR VALVE657
DISASSEMBLY657
ASSEMBLY658
TRANSMISSION MODULATING VALVE659
DISASSEMBLY659
ASSEMBLY660
DRIVE SHAFT661
DISASSEMBLY661
ASSEMBLY663
FRONT AXLE665
REMOVAL665
INSTALLATION667
REAR AXLE 668
REMOVAL668
INSTALLATION672
DIFFERENTIAL673
DISASSEMBLY673
ASSEMBLY678
AXLE HOUSING 688
DISASSEMBLY688
ASSEMBLY694
CENTER HINGE PIN 703
REMOVAL703
INSTALLATION708
PRIORITY VALVE712
REMOVAL712
INSTALLATION713
STEERING VALVE714
REMOVAL714
INSTALLATION715
DISASSEMBLY716
ASSEMBLY719
STEERING CYLINDER724
REMOVAL724
INSTALLATION725
RIGHT BRAKE VALVE (TANDEM)726
DISASSEMBLY726
ASSEMBLY727
LEFT BRAKE VALVE (SINGLE)728
DISASSEMBLY728
ASSEMBLY729
PARKING BRAKE DISC730
REMOVAL730
INSTALLATION732
ACCUMULATOR CHARGE VALVE733
REMOVAL733
INSTALLATION733
DISASSEMBLY734
ASSEMBLY736
HYDRAULIC TANK738
REMOVAL738
INSTALLATION739
HYDRAULIC FILTER740
REMOVAL AND INSTALLATION740
HYDRAULIC, STEERING PUMP741
REMOVAL741
INSTALLATION747
MAIN CONTROL VALVE748
REMOVAL748
INSTALLATION749
DISASSEMBLY750
ASSEMBLY752
PPC VALVE755
REMOVAL755
INSTALLATION756
DISASSEMBLY757
ASSEMBLY758
BUCKET CYLINDER759
REMOVAL759
INSTALLATION760
BOOM CYLINDER761
REMOVAL761
INSTALLATION762
HYDRAULIC CYLINDER763
DISASSEMBLY763
ASSEMBLY766
WORK EQUIPMENT 769
REMOVAL769
INSTALLATION772
COUNTERWEIGHT774
REMOVAL AND INSTALLATION774
FUEL TANK775
REMOVAL775
INSTALLATION777
CAB 778
REMOVAL778
INSTALLATION779
MAIN MONITOR780
REMOVAL780
INSTALLATION781
MAINTENANCE MONITOR782
REMOVAL AND INSTALLATION782
AIR CONDITIONER UNIT783
REMOVAL783
INSTALLATION788
AIR CONDITIONER CONDENSER789
REMOVAL789
INSTALLATION790
DRY RECEIVER 791
REMOVAL AND INSTALLATION791
AIR CONDITIONER COMPRESSOR792
REMOVAL792
INSTALLATION793
40 MAINTENANCE STANDARD794
ENGINE MOUNT, TRANSMISSION MOUNT795
TORQUE CONVERTER CHARGING PUMP796
TORQUE CONVERTER797
TRANSMISSION798
TRANSMISSION CONTROL VALVE806
MODULATION VALVE ASSEMBLY810
ACCUMULATOR VALVE811
DRIVE SHAFT812
DIFFERENTIAL813
FINAL DRIVE819
AXLE MOUNT823
CENTER HINGE PIN824
STEERING COLUMN826
PRIORITY VALVE827
STEERING CYLINDER MOUNT828
BRAKE 829
BRAKE VALVE831
PARKING BRAKE834
HYDRAULIC PUMP 835
MAIN CONTROL VALVE836
PPC VALVE840
HYDRAULIC CYLINDER841
WORK EQUIPMENT LINKAGE842
BUCKET844
BUCKET POSITIONER AND BOOM KICK-OUT845

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24