Komatsu Avance Loader WA420-3 Shop Manual SEBM006204 -PDF
$33.95
Komatsu Avance Loader WA420-3 Shop Manual SEBM006204 -PDF DOWNLOAD
WA420-3
50001 and up
Description
Komatsu Avance Loader WA420-3 Shop Manual SEBM006204 -PDF DOWNLOAD
FILE DETAILS:
Komatsu Avance Loader WA420-3 Shop Manual SEBM006204 -PDF DOWNLOAD
Language : English
Pages :828
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Avance Loader WA420-3 Shop Manual SEBM006204 -PDF DOWNLOAD
WA420-3
50001 and up
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.
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
This section explains checks to be made before and after performing repairs, as well
as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling
or assembling each component, as well as precautions to be taken for these operations.
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu Avance Loader WA420-3 Shop Manual SEBM006204 -PDF DOWNLOAD
WA420-3
50001 and up
COVER 1
CONTENTS 2
01 GENERAL 25
GENERAL ASSEMBLY DRAWING 26
SPECIFICATIONS 28
WEIGHT TABLE 31
LIST OF LUBRICANT AND WATER 33
10 STRUCTURE AND FUNCTION 35
POWER TRAIN 36
POWER TRAIN SYSTEM 37
TORQUE CONVERTER, TRANSMISSION PIPING 39
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 40
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 41
TORQUE CONVERTER 42
TORQUE CONVERTER OIL FILTER 45
TRANSMISSION 46
TRANSMISSION CONTROL VALVE 56
TRANSMISSION SOLENOID VALVE 77
PILOT OIL FILTER 78
DRIVE SHAFT 79
AXLE 80
DIFFERENTIAL 82
FINAL DRIVE 86
AXLE MOUNT, CENTER HINGE PIN 87
STEERING PIPING 88
STEERING COLUMN 89
STEERING VALVE 90
ORBIT-ROLL VALVE104
STOP VALVE108
EMERGENCY STEERING PUMP109
DIVERTER VALVE110
BRAKE PIPING 113
BRAKE CIRCUIT DIAGRAM114
BRAKE VALVE116
CHARGE VALVE121
ACCUMULATOR (FOR BRAKE)127
SLACK ADJUSTER128
BRAKE131
PARKING BRAKE CONTROL133
PARKING BRAKE134
PARKING BRAKE SOLENOID VALVE135
PARKING BRAKE VALVE136
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE137
HYDRAULIC PIPING138
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM139
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM140
WORK EQUIPMENT LEVER LINKAGE142
HYDRAULIC TANK143
PPC VALVE145
PPC RELIEF VALVE150
ACCUMULATOR (FOR PPC VALVE)151
MAIN CONTROL VALVE152
WORK EQUIPMENT LINKAGE165
BUCKET167
BUCKET POSITIONED AND BOOM KICK-OUT168
CAB174
ROPS CAB176
AIR CONDITIONER177
ELECTRIC CIRCUIT DIAGRAM178
MACHINE MONITOR SYSTEM189
MAIN MONITOR 190
MAINTENANCE MONITOR195
WORK EQUIPMENT CONTROL SYSTEM198
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)205
SENSORS209
ENGINE STARTING CIRCUIT214
ENGINE STOP CIRCUIT215
PREHEATING CIRCUIT216
ELECTRIC TRANSMISSION CONTROL217
KICK-DOWN SWITCH220
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM221
TRANSMISSION CUT-OFF SWITCH226
TRANSMISSION CUT-OFF FUNCTION227
ELECTRIC PARKING BRAKE CONTROL229
20 TESTING AND ADJUSTING241
STANDARD VALUE TABLE FOR ENGINE242
STANDARD VALUE TABLE FOR CHASSIS243
STANDARD VALUE TABLE FOR ELECTRICAL PARTS246
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING251
ADJUSTING VALVE CLEARANCE252
MEASURING COMPRESSION PRESSURE253
TESTING AND ADJUSTING FUEL INJECTION TIMING254
MEASURING EXHAUST COLOR256
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)257
MEASURING BLOW-BY PRESSURE258
TESTING AND ADJUSTING FAN BELT TENSION259
MEASURING ENGINE SPEED260
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE261
MEASURING ENGINE OIL PRESSURE263
MEASURING EXHAUST GAS TEMPERATURE264
MEASURING ACCELERATOR PEDAL265
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER267
MEASURING STALL SPEED268
MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE270
METHOD OF OPERATING EMERGENCY MANUAL SPOOL272
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL274
TESTING AND ADJUSTING STEERING WHEEL275
TESTING AND ADJUSTING STEERING CONTROL278
MEASURING STEERING OIL PRESSURE279
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL281
MEASURING BRAKE PERFORMANCE282
TESTING BRAKE OIL PRESSURE283
TESTING FOR BRAKE DISC WEAR284
BLEEDING AIR FROM BRAKE SYSTEM285
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE286
MEASURING PARKING BRAKE PERFORMANCE287
METHOD FOR MANUAL RELEASE OF PARKING BRAKE288
TESTING WEAR OF PARKING BRAKE DISC289
MEASURING WORK EQUIPMENT CONTROL LEVER290
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE292
MEASURING WORK EQUIPMENT296
TESTING AND ADJUSTING BUCKET POSITIONER298
TESTING AND ADJUSTING BOOM KICK-OUT 299
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)301
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR302
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER303
TROUBLESHOOTING304
POINTS TO REMEMBER WHEN TROUBLESHOOTING305
SEQUENCE OF EVENTS IN TROUBLESHOOTING306
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE307
HANDLING CONNECTORS314
CHECKS BEFORE TROUBLESHOOTING315
METHOD OF USING TROUBLESHOOTING CHARTS316
CONNECTOR TYPES AND MOUNTING LOCATIONS324
CONNECTOR PIN ARRANGEMENT DIAGRAM325
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS328
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)335
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)336
S-2 ENGINE DOES NOT START337
(1) ENGINE DOES NOT TURN337
(2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)338
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)339
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)340
S-4 ENGINE STOPS DURING OPERATIONS341
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)342
S-6 ENGINE LACKS OUTPUT (NO POWER)343
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)344
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)345
S-9 OIL BECOMES CONTAMINATED QUICKLY346
S-10 FUEL CONSUMPTION IS EXCESSIVE347
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN348
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)349
S-13 OIL LEVEL RISES350
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)351
S-15 ABNORMAL NOISE IS MADE352
S-16 VIBRATION IS EXCESSIVE353
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)354
TROUBLE DATA DISPLAY356
M-1 MAIN MONITOR DOES NOT WORK359
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP360
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY361
M-4 ABNORMALITY IN SHIFT INDICATOR362
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F362
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R362
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F362
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R363
(e) DOES NOT DISPLAY 1ST,4TH363
(f) DOES NOT DISPLAY 3RD,4TH364
(g) DOES NOT DISPLAY 2ND,3RD364
(h) DOES NOT DISPLAY 1ST,2ND365
M-5 HIGH BEAM DOES NOT LIGHT UP366
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP367
(a) LH TURN SIGNAL DOES NOT LIGHT UP367
(b) RH TURN SIGNAL DOES NOT LIGHT UP367
M-7 ABNORMALITY IN PARKING DISPLAY368
(a) PARKING LAMP DOES NOT LIGHT UP368
(b) PARKING LAMP STAYS LIGHTED UP368
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS)369
(a) DOES NOT CARRY OUT PREHEATING369
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE370
(c) PREHEATING STAYS ON370
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION371
M-9 NIGHT LIGHTING DOES NOT LIGHT UP372
M-10 ABNORMALITY IN FRONT WORKING LAMP373
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP373
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP373
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP373
M-11 ABNORMALITY IN REAR WORKING LAMP374
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP374
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP374
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP374
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF376
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN376
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON376
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED377
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING378
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES378
(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 N378
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED379
(a) ACTUATED CONTINUOUSLY379
(b) NOT ACTUATED379
M-15 ABNORMALITY IN BUZZER380
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)380
(b) BUZZER ALWAYS SOUNDS380
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY381
M-17 ABNORMALITY IN FAILURE DISPLAY MODE382
(a) DOES NOT ENTER FAILURE DISPLAY MODE382
(b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE382
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY383
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP383
(b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP383
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY384
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP384
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP384
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM385
(a) FORCED GREASING CANNOT BE CARRIED OUT385
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)385
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)385
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)386
(e) MONITOR DISPLAY GOES OUT386
M-21 ABNORMALITY IN ECSS SYSTEM387
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED387
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK387
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED387
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)388
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)389
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK390
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS390
(b) SOME LAMPS DO NOT LIGHT UP391
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT391
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT392
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH393
(a) ENGINE OIL LEVEL DISPLAY FLASHES393
(b) ENGINE WATER LEVEL DISPLAY FLASHES394
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH395
(a) ENGINE OIL PRESSURE DISPLAY FLASHES395
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES396
(c) BRAKE OIL PRESSURE DISPLAY FLASHES397
(d) AIR CLEANER DISPLAY FLASHES398
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND399
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS400
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP401
(a) CHECK LAMP401
(b) CAUTION LAMP401
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP)LIGHTS UP402
(a) CHECK LAMP402
(b) CAUTION LAMP402
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)403
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP404
K-12 SERVICE METER DOES NOT WORK405
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED405
K-14 ABNORMALITY IN GAUGE ITEMS406
(a) ABNORMALITY IN FUEL GAUGE406
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE407
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE408
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)409
E-1 ENGINE DOES NOT START410
(a) STARTING MOTOR DOES NOT TURN410
(b) STARTING MOTOR TURNS414
E-2 ENGINE DOES NOT STOP416
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING416
E-4 PARKING BRAKE DOES NOT WORK417
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON417
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS417
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING418
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 420
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED420
E-8 TRANSMISSION DOES NOT WORK NORMALLY421
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)423
(b) PROBLEM IN H-L CIRCUIT423
(c) PROBLEM IN SPEED CIRCUIT424
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)424
(e) CONTACT IN H-L CIRCUIT425
(f) CONTACT IN SPEED CIRCUIT427
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)429
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)430
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)432
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL)434
(k) CONTACT IN FORWARD CIRCUIT436
(l) CONTACT IN REVERSE CIRCUIT438
(m) PROBLEM IN COMMON CIRCUIT FOE FORWARD AND REVERSE440
E-9 KICK-DOWN SWITCH DOES NOT WORK441
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION) (SELF-HOLDING FUNCTION))443
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED443
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R443
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH)444
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND446
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)447
POWER TRAIN448
T-1 MACHINE DOES NOT START448
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES450
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR452
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR453
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH454
STEERING SYSTEM455
T-6 STEERING DOES NOT TURN455
T-7 STEERING WHEEL IS HEAVY456
T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK457
T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING457
T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT457
BRAKE SYSTEM458
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR458
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG459
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS460
WORK EQUIPMENT461
T-14 BOOM DOES NOT RISE461
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER462
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT463
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)463
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM463
T-19 BOOM SHAKES DURING OPERATION463
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE464
T-21 BUCKET DOES NOT TILT BACK465
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER466
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION467
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER467
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET467
T-26 BUCKET SHAKES DURING LOADING OPERATION468
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT468
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY469
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)470
JUDGMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM471
D-1 ECSS DOES NOT WORK472
(a) ERROR CODE [d0] IS DISPLAYED473
(b) ERROR CODE [d1] IS DISPLAYED473
(c) ERROR CODE [d2] IS DISPLAYED474
(d) ERROR CODE [d3] IS DISPLAYED474
(e) ERROR CODE [d4] IS DISPLAYED475
(f) NO ABNORMALITY DISPLAY IS GIVEN475
D-2 ECSS CANNOT BE CANCELED479
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 km/h) (DEVIATES AROUND 5 km/h)480
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST480
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH481
D-6 CONTROLLER LED CODE IS NOT DISPLAYED482
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY482
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)483
OUTLINE485
1 FUNCTION485
2 WHEN CARRYING OUT TROUBLESHOOTING485
3 FAILURE COED TABLE485
4 TABLE OF TROUBLESHOOTING MODES AND CAUSES486
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM488
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF489
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM490
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM491
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID492
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID492
W-7 FAILURE CODE [48] ABNORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM493
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM495
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM496
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH497
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIOMETER SYSTEM498
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM498
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS500
W-14 SENSOR CANNOT BE ADJUSTED501
W-15 DOES NOT CARRY OUT AUTO-LEVELING502
(a) AUTO-LEVELER SWITCH SYSTEM502
(b) AUTO-LEVELER LED SYSTEM502
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM503
(d) ENGINE SPEED SIGNAL SYSTEM504
W-16 AUTO-LEVELER CANNOT BE SET505
(a) AUTO-LEVELER SET SWITCH SYSTEM505
(b) AUTO-LEVELER SET LED SYSTEM505
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP506
(a) REMOTE POSITIONED SWITCH SYSTEM506
(b) REMOTE POSITIONED LED SYSTEM506
W-18 REMOTE POSITIONED SET LEDS DO NOT FLASH507
(a) REMOTE POSITIONED SWITCH SYSTEM507
(b) REMOTE POSITIONED LED SYSTEM507
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONED IS AT RAISE AND AUTO MODE IS ON 508
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND509
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW510
W-22 BUCKET (LEVER) CONTROL511
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT511
(b) LEVER IS NOT HELD BY DETENT512
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR514
W-24 MAINTENANCE MONITOR CHECK515
30 DISASSEMBLY AND ASSEMBLY516
METHOD OF USING MANUAL518
PRECAUTIONS WHEN CARRYING OUT OPERATION519
SPECIAL TOOL LIST521
STARTING MOTOR523
REMOVAL AND INSTALLATION523
ALTERNATOR524
REMOVAL AND INSTALLATION524
ENGINE OIL COOLER525
REMOVAL AND INSTALLATION525
AFTERCOOLER CORE526
REMOVAL AND INSTALLATION526
FUEL INJECTION PUMP527
REMOVAL527
INSTALLATION528
WATER PUMP529
REMOVAL AND INSTALLATION529
TURBOCHARGER530
REMOVAL AND INSTALLATION530
NOZZLE HOLDER531
REMOVAL AND INSTALLATION531
THERMOSTAT532
REMOVAL AND INSTALLATION532
CYLINDER HEAD533
REMOVAL533
INSTALLATION539
RADIATOR541
REMOVAL541
INSTALLATION543
ENGINE544
REMOVAL544
INSTALLATION549
TORQUE CONVERTER CHARGING PUMP550
REMOVAL550
INSTALLATION550
TORQUE CONVERTER, TRANSMISSION551
REMOVAL551
INSTALLATION558
TORQUE CONVERTER560
DISASSEMBLY560
ASSEMBLY562
TRANSMISSION565
DISASSEMBLY565
ASSEMBLY570
TRANSMISSION CLUTCH PACK576
DISASSEMBLY576
ASSEMBLY585
PARKING BRAKE597
DISASSEMBLY597
ASSEMBLY599
TRANSMISSION CONTROL VALVE602
REMOVAL602
INSTALLATION604
DISASSEMBLY605
ASSEMBLY610
TRANSMISSION ACCUMULATOR VALVE616
DISASSEMBLY616
ASSEMBLY617
DRIVE SHAFT618
DISASSEMBLY618
ASSEMBLY620
FRONT AXLE622
REMOVAL622
INSTALLATION624
REAR AXLE625
REMOVAL625
INSTALLATION628
FRONT DIFFERENTIAL630
REMOVAL630
INSTALLATION633
REAR DIFFERENTIAL635
REMOVAL635
INSTALLATION638
DIFFERENTIAL640
DISASSEMBLY640
ASSEMBLY643
FINAL DRIVE651
DISASSEMBLY651
ASSEMBLY654
CENTER HINGE PIN658
REMOVAL658
INSTALLATION666
STEERING VALVE672
REMOVAL672
INSTALLATION673
DISASSEMBLY674
ASSEMBLY677
STEERING VALVE682
REMOVAL682
INSTALLATION683
STEERING DEMAND VALVE684
DISASSEMBLY684
ASSEMBLY688
STEERING,SWITCH PUMP 692
REMOVAL692
INSTALLATION695
STEERING CYLINDER696
REMOVAL696
INSTALLATION697
BRAKE VALVE698
REMOVAL698
INSTALLATION699
RIGHT BRAKE VALVE (TANDEM)700
DISASSEMBLY700
ASSEMBLY701
LEFT BRAKE VALVE (SINGLE)702
DISASSEMBLY702
ASSEMBLY703
SLACK ADJUSTER704
REMOVAL704
INSTALLATION705
DISASSEMBLY706
ASSEMBLY707
BRAKE708
DISASSEMBLY708
ASSEMBLY714
PARKING BRAKE DISC722
REMOVAL722
INSTALLATION724
ACCUMULATOR CHARGE VALVE725
REMOVAL AND INSTALLATION725
DISASSEMBLY726
ASSEMBLY728
HYDRAULIC TANK730
REMOVAL730
INSTALLATION732
WORK EQUIPMENT,PPC PUMP733
REMOVAL733
INSTALLATION736
PPC VALVE737
REMOVAL737
INSTALLATION738
DISASSEMBLY739
ASSEMBLY740
MAIN CONTROL VALVE741
REMOVAL741
INSTALLATION743
DISASSEMBLY744
ASSEMBLY746
BUCKET CYLINDER749
REMOVAL749
INSTALLATION750
BOOM CYLINDER751
REMOVAL751
INSTALLATION752
DISASSEMBLY753
ASSEMBLY756
WORK EQUIPMENT759
REMOVAL759
INSTALLATION762
COUNTERWEIGHT764
REMOVAL AND INSTALLATION764
FUEL TANK765
REMOVAL765
INSTALLATION766
CAB767
REMOVAL767
INSTALLATION768
MAIN MONITOR769
REMOVAL769
INSTALLATION770
MAINTENANCE MONITOR771
REMOVAL AND INSTALLATION771
AIR CONDITIONER UNIT772
REMOVAL772
INSTALLATION777
AIR CONDITIONER CONDENSER778
REMOVAL778
INSTALLATION779
DRY RECEIVER780
REMOVAL AND INSTALLATION780
AIR CONDITIONER CONDENSER COMPRESSOR781
REMOVAL781
INSTALLATION782
40 MAINTENANCE STANDARD783
ENGINE MOUNT, TRANSMISSION MOUNT784
TORQUE CONVERTER785
TRANSMISSION786
TRANSMISSION CONTROL VALVE793
DRIVE SHAFT797
DIFFERENTIAL798
FINAL DRIVE800
AXLE MOUNT801
STEERING COLUMN802
STEERING VALVE803
STEERING CYLINDER MOUNT804
SLACK ADJUSTER805
BRAKE VALVE (SINGLE)806
BRAKE809
PARKING BRAKE811
TORQUE CONVERTER,TRANSMISSION PUMP812
STEERING,SWITCH PUMP813
HYDRAULIC,PPC PUMP814
PPC VALVE815
CUT-OFF VALVE816
MAIN CONTROL VALVE817
HYDRAULIC CYLINDER821
CENTER HINGE PIN823
WORK EQUIPMENT LINKAGE825
BUCKET827
BUCKET POSITIONER AND BOOM KICK-OUT828
IMAGES PREVIEW OF THE MANUAL:
S.M 27/12/24
