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KOMATSU AVANCE LOADER WA600-3 SERVICE REPAIR MANUAL (SN:50001 & UP) – PDF DOWNLOAD
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- KOMATSU AVANCE LOADER WA600-3 SERVICE REPAIR MANUAL (SN:50001 & UP)
- PUBLICATION NUMBER:SEBM013219
- SERIAL NUMBER:WA600-3 50001 and up
WA600-3D (TBG SPEC.) 50001 and up
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Description
KOMATSU AVANCE LOADER WA600-3 SERVICE REPAIR MANUAL (SN:50001 & UP)
KOMATSU AVANCE LOADER WA600-3 SERVICE REPAIR MANUAL (SN:50001 & UP) – PDF DOWNLOAD:
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KOMATSU AVANCE LOADER WA600-3 SERVICE REPAIR MANUAL (SN:50001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving 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.
- STRUCTURE AND FUNCTION
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
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” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA600-3 SERVICE REPAIR MANUAL (SN:50001 & UP)
COVER...................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................... 2 01 GENERAL................................................................................................................................................................. 29 GENERAL ASSEMBLY DRAWING............................................................................................................................................... 30 SPECIFICATIONS......................................................................................................................................................... 35 WEIGHT TABLE........................................................................................................................................................... 41 LIST OF LUBRICANT AND COOLANT.......................................................................................................................................... 44 10 STRUCTURE AND FUNCTION.................................................................................................................................................. 46 POWER TRAIN............................................................................................................................................................ 47 POWER TRAIN SYSTEM..................................................................................................................................................... 48 RADIATOR,HYDRAULIC OIL COOLER.......................................................................................................................................... 52 RADIATOR, HYDRAULIC OIL COOLER (WITH SUCTION FAN)...................................................................................................................... 55 TORQUE CONVERTER AND TRANSMISSION PIPING............................................................................................................................... 57 HYDRAULIC CIRCUIT FOR POWER TRAIN...................................................................................................................................... 59 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.............................................................................................................................. 61 TORQUE CONVERTER....................................................................................................................................................... 65 TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)............................................................................................................. 71 TRANSMISSION........................................................................................................................................................... 73 TRANSMISSION CONTROL VALVE............................................................................................................................................. 82 TORQUE CONVERTER OIL COOLER............................................................................................................................................ 102 TORQUE CONVERTER OIL FILTER............................................................................................................................................ 103 TRANSFER............................................................................................................................................................... 105 DRIVE SHAFT............................................................................................................................................................ 106 CENTER SUPPORT......................................................................................................................................................... 107 AXLE................................................................................................................................................................... 108 DIFFERENTIAL........................................................................................................................................................... 110 LIMITED SLIP DIFFERENTIAL(OP).......................................................................................................................................... 113 FINAL DRIVE............................................................................................................................................................ 117 AXLE MOUNT............................................................................................................................................................. 120 CENTER HINGE PIN....................................................................................................................................................... 122 STEERING PIPING........................................................................................................................................................ 123 STEERING COLUMN........................................................................................................................................................ 126 STEERING UNIT (ORBIT-ROLL VAVLE)....................................................................................................................................... 127 STEERING VALVE......................................................................................................................................................... 130 TWO-WAY RESTRICTION VALVE.............................................................................................................................................. 141 STOP VALVE............................................................................................................................................................. 142 EMERGENCY STEERING PIPING.............................................................................................................................................. 143 DIVERTER VALVE (FOR EMERGENCY STEERING)................................................................................................................................ 144 BRAKE PIPING........................................................................................................................................................... 147 BRAKE CIRCUIT DIAGRAM.................................................................................................................................................. 151 BRAKE VALVE............................................................................................................................................................ 155 CHARGE VALVE........................................................................................................................................................... 162 ACCUMULATOR (FOR BRAKE)................................................................................................................................................ 166 SLACK ADJUSTER......................................................................................................................................................... 167 BRAKE.................................................................................................................................................................. 171 PARKING BRAKE.......................................................................................................................................................... 174 SPRING CYLINDER........................................................................................................................................................ 176 PARKING BRAKE SOLENOID VALVE........................................................................................................................................... 177 HYDRAULIC PIPING....................................................................................................................................................... 178 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................... 182 WORK EQUIPMENT LEVER LINKAGE........................................................................................................................................... 188 HYDRAULIC TANK......................................................................................................................................................... 189 ACCUMULATOR (FOR PPC VALVE)............................................................................................................................................ 191 PPC VALVE.............................................................................................................................................................. 192 PPC RELIEF VALVE....................................................................................................................................................... 196 CUT-OFF VALVE.......................................................................................................................................................... 197 MAIN CONTROL VALVE..................................................................................................................................................... 199 AUTO GREASE SYSTEM..................................................................................................................................................... 213 LUBRICATION OF WORK EQUIPMENT.......................................................................................................................................... 225 WORK EQUIPMENT LINKAGE................................................................................................................................................. 227 BUCKET................................................................................................................................................................. 229 BUCKET POSITIONER AND BOOM KICK-OUT.................................................................................................................................... 230 OPERATION OF PROXIMITY SWITCH.......................................................................................................................................... 233 ROPS CANOPY............................................................................................................................................................ 237 CAB.................................................................................................................................................................... 238 CAR HEATER............................................................................................................................................................. 239 AIR CONDITIONER........................................................................................................................................................ 241 ELECTRIC CIRCUIT DIAGRAM............................................................................................................................................... 245 MACHINE MONITOR SYSTEM................................................................................................................................................. 250 MAIN MONITOR........................................................................................................................................................... 252 MANITENANCE MONITOR.................................................................................................................................................... 256 MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL...................................................................................................................... 258 ENGINE STARTING CIRCUIT................................................................................................................................................ 274 ENGINE STOP CIRCUIT.................................................................................................................................................... 277 AUTO PRIMING SYSTEM (APS) (SERIAL NO.:50001-52000)..................................................................................................................... 279 PRE-HEATING CIRCUIT (SERIAL NO.:52001 AND UP).......................................................................................................................... 283 ELECTRIC TRANSMISSION CONTROL.......................................................................................................................................... 284 KICK-DOWN,HOLD SWITCH.................................................................................................................................................. 287 KICK-DOWN ELECTRICAL CIRCUIT........................................................................................................................................... 288 ELECTRIC PARKING BRAKE CONTROL......................................................................................................................................... 294 E.C.S.S.(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM).................................................................................................................. 303 20 TESTING AND ADJUSTING................................................................................................................................................... 317 STANDARD VALUE TABLE FOR ENGINE........................................................................................................................................ 318 STANDARD VALUE TABLE FOR CHASSIS....................................................................................................................................... 320 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.............................................................................................................................. 330 TESTING AND ADJUSTING.................................................................................................................................................. 343 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING......................................................................................................... 344 MEASURING ENGINE SPEED............................................................................................................................................. 347 MEASURING EXHAUST GAS COLOR........................................................................................................................................ 351 ADJUSTING VALVE CLEARANCE.......................................................................................................................................... 352 TESTING AND ADJUSTING INJECTOR LIFT (SERIAL NO.:52001 AND UP)...................................................................................................... 354 MEASURING COMPRESSION PRESSURE..................................................................................................................................... 356 MEASURING BLOW-BY PRESSURE......................................................................................................................................... 359 MEASURING ENGINE OIL PRESSURE...................................................................................................................................... 360 TESTING AND ADJUSTING FUEL INJECTON TIMING (SERIAL NO.:50001-52000)................................................................................................ 361 REPLACING FAN BELT ADJUSTING AUTO-TENSIONER........................................................................................................................ 363 TESTING AND ADJUSTING ALTERNATOR BELT TENSION...................................................................................................................... 364 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................................................. 365 HANDLING EQUIPMENT IN FUEL CIRCUIT (SERIAL NO.:52001 AND UP)....................................................................................................... 366 MEASURING FUEL PUMP OUTPUT PORT PRESSURE (SERIAL NO.:52001 AND UP)................................................................................................. 366 BLEEDING AIR FROM FUEL CIRCUIT (SERIAL NO.:52001 AND UP)........................................................................................................... 367 MEASURING EXHAUST TEMPERATURE...................................................................................................................................... 369 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)..................................................................................................................... 372 ADJUSTING SPEED SENSOR............................................................................................................................................. 373 ADJUSTIN FUEL CONTROL CABLE (SERIAL NO.:50001-52000)............................................................................................................... 374 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.:50001-52000).............................................................................................. 375 TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE................................................................................................... 377 PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT............................................................................................. 386 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS......................................................................................................... 387 TESTING AND ADJUSTING STEERING OIL PRESSURE........................................................................................................................ 391 TESTING AND ADJUSTING STEERING STOP VALVE.......................................................................................................................... 393 TESTING BRAKE OIL PRESSURE......................................................................................................................................... 394 MEASURING WEAR OF BRAKE DISC....................................................................................................................................... 395 MEASURING BRAKE PERFORMANCE........................................................................................................................................ 396 TESTING AND ADJUSTING PARKING BRAKE................................................................................................................................ 397 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE............................................................................................... 399 TESTING AND ADJUSTING PPC OIL PRESSURE............................................................................................................................. 400 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................................................................ 402 ADJUSTING WORK EQUIPMENT LEVER LINKAGE............................................................................................................................. 404 TESTING AND ADJUSTING OF BUCKET POSITIONER......................................................................................................................... 406 TESTING AND ADJUSTING OF BOOM KICK-OUT............................................................................................................................. 407 TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP...................................................................................................................... 408 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)........................................................................................................................ 409 BLEEDING AIR....................................................................................................................................................... 410 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................................................................................................................. 411 TROUBLESHOOTING........................................................................................................................................................ 414 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................................ 415 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................................................................. 416 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................................... 417 CHECKS BEFORE TROUBLESHOOTING...................................................................................................................................... 425 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................................................................. 426 CONNECTOR ARRANGEMENT DIAGRAM...................................................................................................................................... 429 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................................................................... 441 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................. 462 METHOD OF USING MATRIX TROUBLESHOOTING TABLES...................................................................................................................... 464 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).......................................................................................................................... 466 METHOD OF USING TROUBLESHOOTING CHART.......................................................................................................................... 467 S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)................................................................................................... 471 S-2 ENGINE DOES NOT START...................................................................................................................................... 473 (1) ENGINE DOES NOT TURN................................................................................................................................... 473 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)............................................................................... 474 (3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)......................................................................... 475 S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)....................................................................................................... 476 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................................. 477 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................................. 478 S-6 ENGINE LACKS OUTPUT........................................................................................................................................ 479 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................................................. 480 S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................................... 481 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................... 482 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................................. 483 S-11 OIL IS COOLING, OR COOLANT SPURTS BACK,OR COOLANT LEVEL GOES DOWN......................................................................................... 484 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................................................................ 485 S-13 OIL LEVEL RISES........................................................................................................................................... 486 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).......................................................................................................... 487 S-15 ABNORMAL NOISE IS MADE.................................................................................................................................... 488 S-16 VIBRATION IS EXCESSIVE.................................................................................................................................... 489 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE).............................................................................................................. 490 METHOD OF ERROR CODE DISPLAY................................................................................................................................... 492 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED............................................................................... 494 SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM.................................................................................................................... 502 EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)....................................................................................................... 504 EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR).................................................................................................... 504 EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)....................................................................... 505 EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)............................................................................................ 506 EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)........................................................................... 508 EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)............................................................................ 509 EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)............................................................................. 510 EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL).............................................................................. 511 EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)............................................................................................ 512 EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)................................................................................ 513 EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)................................................................................. 514 EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)................................................................................... 515 EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL).................................................................................... 516 EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIHG LEVEL).................................................................................. 517 EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)................................................................................... 518 EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))............................................................................................... 519 EA-17 ERROR CODE [144] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM HIGH LEVEL)........................................................................... 520 EA-18 ERROR CODE [145] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM LOW LEVEL)............................................................................ 521 EA-19 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)................................................................................................. 521 EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)........................................................................ 522 EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMERATURE SENSOR SYSTEM LOW LEVEL).......................................................................... 522 EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL).......................................................................... 523 EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)................................................................................. 524 EA-24 ERROR CODE [234] (OVERSPEED)............................................................................................................................. 526 EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)..................................................................................... 527 EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE).................................................................................................... 528 EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)..................................................................................................... 528 EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL).............................................................................. 529 EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)............................................................................... 529 EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)...................................................................................... 530 EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)..................................................................................................... 531 EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)...................................................................................... 531 EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN).................................................................................................. 532 EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)....................................................................................... 533 EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))............................................................................................... 534 EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)............................................................................ 535 EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)...................................................................................... 537 EA-38 ERROR CODE [432] (IDLE VALIDATION PROCESS ERROR)......................................................................................................... 539 EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL).............................................................................................. 541 EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)............................................................................................. 541 EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)............................................................................ 542 EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)............................................................................. 543 EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)...................................................................................... 544 EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)........................................................................................... 545 EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)............................................................................................. 545 EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)..................................................................................................... 545 EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM).......................................................................................... 546 EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLE VALIDATION SWITCH SYSTEM)........................................................................................ 546 EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)..................................................................................... 547 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).................................................................................................................... 549 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR.................................................................................................................... 551 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN................................................................................................................... 555 M-1 MAIN MONITOR DOES NOT WORK................................................................................................................................. 556 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP.............................................................. 557 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY................................................................................................................. 558 M-4 ABNORMALITY IN SHIFT INDICATOR............................................................................................................................. 559 a) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT F.......................................................................................................... 559 b) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT R.......................................................................................................... 559 c) DOES NOT DISPLAY N EVEN WHEN DIRCETIONAL LEVER IS AT N.................................................................................................. 559 d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST............................................................................................ 560 e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND............................................................................................ 560 f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD............................................................................................ 560 g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH............................................................................................ 560 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP........................................................................................................................ 562 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...................................................................................................................... 563 a) L.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................................................................... 563 b) R.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................................................................... 563 M-7 ABNORMALITY IN PARKING LAMP DISPLAY........................................................................................................................ 564 a) PARKING LAMP DISPLAY DOES NOT LIGHT UP.................................................................................................................. 564 b) PARKING LAMP DISPLAY STAYS LIGHTED UP................................................................................................................... 564 M-8 ABNORMALITY IN PREHEATING DISPLAY.......................................................................................................................... 565 a) PREHEATIGN DISPLAY DOES NOT LIGHT UP.................................................................................................................... 565 b) PREHEATIGN DISPLAY STAYS LIGHTED UP..................................................................................................................... 565 M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP................................................................................................................ 567 M-10 ABNORMALITY IN FRONT WORKING LAMP......................................................................................................................... 568 a) NEITHER MONITOR DISPLAY NOR FRONT WORKIGN LAMP LIGHT UP................................................................................................. 568 b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP........................................................................................... 568 c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP............................................................................................ 568 M-11 ABNORMALITY IN REAR WORKIGN LAMP.......................................................................................................................... 570 a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.................................................................................................. 570 b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP........................................................................................... 570 c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP............................................................................................ 570 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF....................................................................................................................... 572 a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE................................................ 572 b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED...................................................................... 572 c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED.......................................................................... 573 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN............................................................................................................. 574 a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AN N................................. 574 b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRCETIONAL LEVER IS AT POSITION OTHER THAN N.......... 574 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED................................... 575 a) ACTUATED CONTINUOUSLY................................................................................................................................... 575 b) NOT ACTUATED............................................................................................................................................ 575 M-15 ABNORMALITY IN BUZZER..................................................................................................................................... 576 a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON................................................................. 576 b) BUZZER ALWAYS SOUNDS.................................................................................................................................... 576 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY..................................................................................................... 577 M-17 ABNORMALITY IN FAILURE DISPLAY MODE....................................................................................................................... 578 a) FAILURE DISPLAY MODE DOES NOT WORK...................................................................................................................... 578 b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE........................................................................... 578 M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY................................................................................................................. 579 a) EMERGENCY STEERING DISPLAY DOES NOT FLASH............................................................................................................... 579 b) EMERGENCY STEERING DISPLAY STAYS FLASHED................................................................................................................ 579 M-19 ABNORMALITY IN AUTO-GREASING SYSTEM....................................................................................................................... 580 a) FORCED GREASING CANNOT BE CARRIED OUT .................................................................................................................. 580 b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)........................................................................................................... 580 c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES REPIDLY (2 TIMES/SEC)............................................................................... 580 d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)............................................................................................................. 581 e) MONITOR DISPLAY GOES OUT ............................................................................................................................... 581 M-20 ABNORMALITY IN ECSS SYSTEM................................................................................................................................ 582 a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED.......................................................................................................... 582 b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK............................................................................................... 582 M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)......................................................................................... 585 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)............................................................................................................. 586 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR............................................................................................................. 587 K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SCONDS,MAINTENANCE MONITOR DOES NOT WORK.......................... 591 a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP................................................................................................................ 591 b) SOME LAMPS DO NOT LIGHT UP.............................................................................................................................. 591 K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SCONDS.......................................... 592 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTIGN SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT.............................. 593 K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES......................................................................... 594 a) ENGINE OIL LEVEL DISPLAY FLASHES........................................................................................................................ 594 b) ENGINE COOLANT LEVEL DISPLAY FLASHES.................................................................................................................... 595 K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES....................................................................... 596 a) ENGINE OIL PRESSURE DISPLAY FLASHES..................................................................................................................... 596 b) BATTERY CHARGE DISPLAY FLASHES.......................................................................................................................... 598 c) BRAKE OIL PRESSURE DISPLAY FLASHES...................................................................................................................... 599 d) AIR CLEANER CLOGGED DISPLAY FLASHES..................................................................................................................... 600 K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND......................................................................................... 601 K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS..................................................................................................... 602 K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH............................................................. 603 a) CHECK LAMP.............................................................................................................................................. 603 b) CAUTION LAMP............................................................................................................................................ 603 K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP.......................................................... 604 a) CHECK LAMP.............................................................................................................................................. 604 b) CAUTION LAMP............................................................................................................................................ 604 K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON............................................................................ 605 K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF.......................................................................................... 606 K-12 SERVICE METER DOES NOT WORK............................................................................................................................... 607 K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED...................................................................................................... 607 K-14 ABNORMALITY IN GAUGES..................................................................................................................................... 608 a) ABNORMALITY IN FUEL GAUGE............................................................................................................................... 608 b) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE......................................................................................................... 609 c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE................................................................................................... 610 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...................................................................................................................... 611 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM......................................................................... 613 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE.................................................................................................. 615 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN................................................................................................................... 616 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER............................................................................................. 617 E-1 ENGINE DOES NOT START ..................................................................................................................................... 618 a) STARTING MOTOR DOES NOT TURN............................................................................................................................ 618 b) STARTING MOTOR TURNS.................................................................................................................................... 623 E-2 ENGINE DOES NOT STOP (SERIAL NO.:50001-52000).............................................................................................................. 631 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (SERIAL NO.:50001-52000)............................................................................................ 631 E-4A ABNORMALITY IN APS SYSTEM (SERIAL NO.:50001-52000)........................................................................................................ 633 a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP.................................... 635 b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL.... 636 c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL................. 637 d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL..................................................................................................... 638 e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL..................................................................................................... 638 f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL..................................................................................................... 639 g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL..................................................................................................... 639 h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL..................................................................................................... 640 i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL..................................................................................................... 640 j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP................................................................................................. 641 E-4B PREHEATING FAULT (SERIAL NO.:52001 AND UP)................................................................................................................ 642 E-5 PARKING BRAKE DOES NOT HAVE EFFECT......................................................................................................................... 643 a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON...................................................................................... 643 b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS...................................................... 643 E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING......................................................................................................... 644 E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON................................................................................................ 646 E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY..................................................... 646 E-9 TRANSMISSION DOES NOT WORK PROPELY......................................................................................................................... 648 a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT................................................... 649 b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT........................................................................................................ 652 c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT........................................................................................................ 654 d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRCETIONAL SOLENOID CIRCUIT......................................................................................... 656 e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT................................................................................................................... 661 f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT............................................................................................... 664 E-10 KICK-DOWN SWITCH DOES NOT WORK............................................................................................................................ 669 E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON............................................................................................. 672 E-12 KICK-DOWN ALWAYS WORKS.................................................................................................................................... 673 E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND................................................................................................. 675 E-14 BOOM KICK-OUT DOES NOT WORK............................................................................................................................... 677 E-15 DEFECTIVE BUCKET POSITIONER............................................................................................................................... 680 E-16 POWER WINDOW DOES NOT WORK................................................................................................................................ 683 a) POWER WINDOW DOES NOT RISE.............................................................................................................................. 683 b) POWER WINDOW DOES NOT LOWER............................................................................................................................. 684 E-17 ABNORMALITY IN FRONT WORKING LAMP......................................................................................................................... 686 E-18 ABNORMALITY IN REAR WORKING LAMP.......................................................................................................................... 686 E-19 ABNORMALITY IN TRANSMISSION CUT-OFF....................................................................................................................... 686 E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................................................................. 686 E-21 ABNORMALITY IN BUZZER..................................................................................................................................... 686 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)........................................................................................................ 687 POWER TRAIN.................................................................................................................................................... 688 H-1 MACHINE DOES NOT START................................................................................................................................. 688 H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES................................................................................................ 689 H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.............................................................................................. 690 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH .............................................................................................................. 691 STEERING SYSTEM................................................................................................................................................ 692 H-5 STEERING WHEEL DOES NOT TURN........................................................................................................................... 692 H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]......................................................................................................... 693 H-7 TURNING,RESPONSE OF STEERING IS POOR................................................................................................................... 694 H-8 TURNING,RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]........................................................................................... 695 H-9 STEERING IS HEAVY...................................................................................................................................... 697 H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]............................................................................................................. 697 H-11 STEERING WHEEL SHAKES OR JERKS........................................................................................................................ 698 H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]................................................................................... 699 H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING................................................................................ 699 BRAKE SYSTEM................................................................................................................................................... 700 H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.................................................................................................... 700 H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG.......................................................................................................... 702 H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR................................................................................................. 703 H-17 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)..................................................................... 704 WORK EQUIPMENT................................................................................................................................................. 705 H-18 NEITHER LIFT ARM NOR BUCKET MOVE...................................................................................................................... 705 H-19 BOTH LIFT ARM AND BUCKET ARE SLOW OR LACK POWER....................................................................................................... 706 H-20 LIFT ARM DOES NOT MOVE................................................................................................................................ 707 H-21 LIFT ARM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]............................................................................................ 708 H-22 LIFT ARM IS SLOW OR BOOM LACKS POWER.................................................................................................................. 709 H-23 LIFT ARM IS SLOW OR BOOM LACKS POWER [MACHINES WITH REMOTE BOOM CONTROL].............................................................................. 710 H-24 LIFT ARM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT...................................................................................... 711 H-25 LIFT ARM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.......................................................................... 711 H-26 REMOTE LIFT ARM CONTROL DOES NOT WORK [MACHINES WITH REMOTE BOOM CONTROL]............................................................................. 712 H-27 EXCESSIVE HYDRAULIC DRIFT OF LIFT ARM................................................................................................................. 713 H-28 BUCKET DOES NOT MOVE.................................................................................................................................. 714 H-29 BUCKET IS SLOW OR LACKS POWER......................................................................................................................... 715 H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET................................................................................................................... 716 H-31 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]........................................................................... 717 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)............................................... 719 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE ............................................................................................................. 720 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM................................................................................................................ 721 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE..................................................................................... 722 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM..................................................................................................... 726 T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED........................................ 730 T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED............................................... 731 T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED............................................... 732 T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED............................................. 733 T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED............................................. 734 T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED............................................. 735 T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED............................................. 736 T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED.......................................................... 737 T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED................................................................... 738 T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED........................................................................ 742 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED............................................................................... 745 T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED................................................................. 746 T-13 SHIFT-UP DOES NOT WORK.................................................................................................................................... 748 T-14 SHIFT-DOWN DOES NOT WORK.................................................................................................................................. 748 T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING........................................................................................................ 749 T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING................................................................................................................ 750 T-17 BUZZER DOES NOT WORK...................................................................................................................................... 751 T-18 ABNORMALITY IN NETWORK SYSTEM............................................................................................................................. 752 T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY....................................................................................................... 753 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM............................................................................................................... 754 T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS........................................................................................................... 755 TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL).................................................. 756 JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM.................................................................................................................... 757 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..................................................................................... 758 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM........................................................................................................ 762 J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED..................................................................... 764 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED.................................................. 765 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED................................................... 766 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED............................................................... 767 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED................................................................ 768 J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED....................................................... 769 J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED........................................................ 770 J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED.................................................... 771 J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE........................................................................................................ 772 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT........................................................................................................... 773 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID.................................................................................................................. 774 J-12 DISCONNECTION IN STEERING LEFT SOLENOID................................................................................................................... 775 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)..................................................................................... 776 ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................ 777 ELECTRICAL CIRCUIT DIAGRAM FOR ECSS............................................................................................................................ 781 D-1 ECSS DOES NOT WORK......................................................................................................................................... 783 a) ERROR CODE [d0] IS DISPLAYED............................................................................................................................ 784 b) ERROR CODE [d1] IS DISPLAYED............................................................................................................................ 784 c) ERROR CODE [d2] IS DISPLAYED............................................................................................................................ 785 d) ERROR CODE [d3] IS DISPLAYED............................................................................................................................ 785 e) ERROR CODE [d4] IS DISPLAYED............................................................................................................................ 786 f) ERROR CODE [d5] IS DISPLAYED............................................................................................................................ 786 g) ERROR CODE [d6] IS DISPLAYED............................................................................................................................ 787 h) NO ABNORMALITY DISPLAY IS GIVEN......................................................................................................................... 790 D-2 ECSS CANNOT BE CANCELED.................................................................................................................................... 796 30 DISASSEMBLY AND ASSEMBLY................................................................................................................................................ 797 METHOD OF USING MANUAL................................................................................................................................................. 799 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................................................................................ 800 SPECIAL TOOL LIST...................................................................................................................................................... 802 SKETCHES OF SPECIAL TOOLS.............................................................................................................................................. 811 STARTING MOTOR......................................................................................................................................................... 821 REMOVAL AND INSTALLATION........................................................................................................................................... 821 ALTERNATOR............................................................................................................................................................. 822 REMOVAL AND INSTALLATION........................................................................................................................................... 822 ENGINE OIL COOLER (SERIAL NO.:50001-52000)............................................................................................................................. 824 REMOVAL AND INSTALLATION........................................................................................................................................... 824 FUEL INJECTION PUMP (SERIAL NO.:50001-52000)........................................................................................................................... 825 REMOVAL AND INSTALLATION........................................................................................................................................... 825 WATER PUMP (SERIAL NO.:50001-52000).................................................................................................................................... 826 REMOVAL AND INSTALLATION........................................................................................................................................... 826 NOZZLE HOLDER (SERIAL NO.:50001-52000)................................................................................................................................. 827 REMOVAL AND INSTALLATION........................................................................................................................................... 827 TURBOCHARGER (SERIAL NO.:50001-52000).................................................................................................................................. 828 REMOVALL........................................................................................................................................................... 828 INSTALLATION....................................................................................................................................................... 829 ENGINE FRONT SEAL (SERIAL NO.:50001-52000)............................................................................................................................. 830 REPLACEMENT........................................................................................................................................................ 830 ENGINE REAR SEAL (SERIAL NO.:50001-52000).............................................................................................................................. 832 REPLACEMENT........................................................................................................................................................ 832 CYLINDER HEAD (SERIAL NO.:50001-52000)................................................................................................................................. 834 REMOVAL............................................................................................................................................................ 834 INSTALLATION....................................................................................................................................................... 839 THERMOSTAT (SERIAL NO.:50001-52000).................................................................................................................................... 841 REMOVAL AND INSTALLATION........................................................................................................................................... 841 AFTERCOOLER CORE (SERIAL NO.:50001-52000).............................................................................................................................. 842 REMOVAL............................................................................................................................................................ 842 INSTALLATION....................................................................................................................................................... 843 RADIATOR............................................................................................................................................................... 844 REMOVAL............................................................................................................................................................ 844 INSTALLATION....................................................................................................................................................... 846 RADIATOR (WITH SUCTION FAN)............................................................................................................................................ 851 REMOVAL............................................................................................................................................................ 851 INSTALLATION....................................................................................................................................................... 854 ENGINE AND TORQUE CONVERTER ASSEMBLY................................................................................................................................... 855 REMOVAL............................................................................................................................................................ 855 INSTALLATION....................................................................................................................................................... 857 TORQUE CONVERTER....................................................................................................................................................... 862 REMOVAL AND INSTALLATION........................................................................................................................................... 862 DISASSEMBLY........................................................................................................................................................ 865 ASSEMBLY........................................................................................................................................................... 870 TRANSMISSION........................................................................................................................................................... 889 REMOVAL............................................................................................................................................................ 889 INSTALLATION....................................................................................................................................................... 891 DISASSEMBLY........................................................................................................................................................ 892 ASSEMBLY........................................................................................................................................................... 907 TRANSMISSION VALVE..................................................................................................................................................... 923 REMOVAL AND ASSEMBLY............................................................................................................................................... 923 TRANSFER............................................................................................................................................................... 924 DISASSEMBLY........................................................................................................................................................ 924 ASSEMBLY........................................................................................................................................................... 933 CENTER SUPPORT......................................................................................................................................................... 944 REMOVAL AND INSTALLATION........................................................................................................................................... 944 DISASSEMBLY........................................................................................................................................................ 946 ASSEMBLY........................................................................................................................................................... 948 DRIVE SHAFT............................................................................................................................................................ 951 DISASSEMBLY........................................................................................................................................................ 951 ASSEMBLY........................................................................................................................................................... 954 FRONT AXLE............................................................................................................................................................. 957 REMOVAL............................................................................................................................................................ 957 INSTALLATION....................................................................................................................................................... 958 FRONT DIFFERENTIAL..................................................................................................................................................... 959 REMOVAL............................................................................................................................................................ 959 INSTALLATION....................................................................................................................................................... 960 REAR AXLE.............................................................................................................................................................. 961 REMOVAL............................................................................................................................................................ 961 INSTALLATION....................................................................................................................................................... 964 REAR DIFFERENTIAL...................................................................................................................................................... 965 REMOVAL............................................................................................................................................................ 965 INSTALLATION....................................................................................................................................................... 966 DIFFERENTIAL GEAR ..................................................................................................................................................... 967 DISASSEMBLY........................................................................................................................................................ 967 ASSEMBLY........................................................................................................................................................... 971 LIMITED SLIP DIFFERENTIAL.............................................................................................................................................. 979 DISASSEMBLY........................................................................................................................................................ 979 ASSEMBLY........................................................................................................................................................... 984 FINAL DRIVE............................................................................................................................................................1005 REMOAL.............................................................................................................................................................1005 ASSEMBLY...........................................................................................................................................................1007 ORBIT-ROLL.............................................................................................................................................................1010 REMOVAL AND INSTALLATION...........................................................................................................................................1010 STEERING CYLINFER......................................................................................................................................................1011 REMOVAL............................................................................................................................................................1011 INSTALLATION.......................................................................................................................................................1012 DISASSEMBLY........................................................................................................................................................1013 ASSEMBLY...........................................................................................................................................................1015 STEERING VALVE.........................................................................................................................................................1017 REMOVAL............................................................................................................................................................1017 INSTALLATION.......................................................................................................................................................1018 CUT-OFF VALVE..........................................................................................................................................................1019 REMOVAL AND INSTALLATION...........................................................................................................................................1019 BRAKE VALVE............................................................................................................................................................1020 REMOVAL AND INSTALLATION...........................................................................................................................................1020 BRAKE VALVE (R.H.).....................................................................................................................................................1021 DISASSEMBLY........................................................................................................................................................1021 ASSEMBLY...........................................................................................................................................................1023 BRAKE VALVE (L.H.).....................................................................................................................................................1025 DISASSEMBLY........................................................................................................................................................1025 ASSEMBLY...........................................................................................................................................................1027 SLACK ADJUSTER.........................................................................................................................................................1029 REMOVAL AND INSTALLATION...........................................................................................................................................1029 DISASSEMBLY........................................................................................................................................................1030 ASSEMBLY...........................................................................................................................................................1031 BRAKE..................................................................................................................................................................1032 REMOVAL AND INSTALLATION...........................................................................................................................................1032 DISASSEMBLY........................................................................................................................................................1033 ASSEMBLY...........................................................................................................................................................1036 HYDRAULIC PUMP.........................................................................................................................................................1040 REMOVAL............................................................................................................................................................1040 INSTALLATION.......................................................................................................................................................1041 HYDRAULIC TANK.........................................................................................................................................................1044 REMOVAL............................................................................................................................................................1044 INSTALLATION.......................................................................................................................................................1045 HUDRAULIC FILTER.......................................................................................................................................................1046 REMOVAL AND INSTALLATION...........................................................................................................................................1046 PPC VALVE..............................................................................................................................................................1047 REMOVAL AND INSTALLATION...........................................................................................................................................1047 DISADDEMBLY AND ASSEMBLY...........................................................................................................................................1048 WORK EQUIPMENT VALVE...................................................................................................................................................1049 REMOVAL............................................................................................................................................................1049 INSTALLATION.......................................................................................................................................................1050 MAIN CONTROL VALVE.....................................................................................................................................................1051 DISASSEMBLY........................................................................................................................................................1051 ASSEMBLY...........................................................................................................................................................1054 DUMP CYLINDER..........................................................................................................................................................1057 REMOVAL............................................................................................................................................................1057 INSTALLATION.......................................................................................................................................................1058 LIFT CYLINDER..........................................................................................................................................................1059 REMOVAL............................................................................................................................................................1059 INSTALLATION.......................................................................................................................................................1060 LIFT DYLINDER AND DUMP CYLINDER........................................................................................................................................1061 DISASSEMBLY........................................................................................................................................................1061 ASSEMBLY...........................................................................................................................................................1063 CENTER HINGE PIN.......................................................................................................................................................1066 REMOVAL............................................................................................................................................................1066 INSTALLATION.......................................................................................................................................................1071 WORK EQUIPMENT.........................................................................................................................................................1074 REMOVAL............................................................................................................................................................1074 INSTALLATION.......................................................................................................................................................1078 BULKHEAD...............................................................................................................................................................1080 REMOVAL............................................................................................................................................................1080 INSTALLATION.......................................................................................................................................................1081 FLOOR FRAME............................................................................................................................................................1082 REMOVAL............................................................................................................................................................1082 INSTALLATION.......................................................................................................................................................1084 COUNTERWEIGHT..........................................................................................................................................................1085 REMOVAL AND INSTALLATION...........................................................................................................................................1085 FUEL TANK..............................................................................................................................................................1086 REMOVAL............................................................................................................................................................1086 INSTALLATION.......................................................................................................................................................1087 CAB....................................................................................................................................................................1090 REMOVAL............................................................................................................................................................1090 INSTALLATION.......................................................................................................................................................1092 STOP VALVE.............................................................................................................................................................1093 REMOVAL AND INSTALLATION...........................................................................................................................................1093 ACCUMULATOR............................................................................................................................................................1094 REMOVAL AND INSTALLATION...........................................................................................................................................1094 ASSUMULATOR CHARGR VALVE...............................................................................................................................................1095 REMOVAL AND INTALLATION............................................................................................................................................1095 PARKING BRAKE SOLENOID VALVE...........................................................................................................................................1096 REMOVAL AND SINTALLATION...........................................................................................................................................1096 DIVERTER VALVE.........................................................................................................................................................1097 REMOVAL AND INSTALLATION...........................................................................................................................................1097 EMERGENCY STEERING PUMP................................................................................................................................................1098 REMOVAL AND INSTALLATION...........................................................................................................................................1098 PARKING BRAKE..........................................................................................................................................................1099 REMOVAL AND INSTALLATION...........................................................................................................................................1099 PARKING BRAKE CALIPERS.................................................................................................................................................1100 DISASSEMBLY........................................................................................................................................................1100 ASSEMBLY...........................................................................................................................................................1101 PARKING BRAKE PAD......................................................................................................................................................1102 REMOVAL AND INSTALLATION...........................................................................................................................................1102 REAR TIRES.............................................................................................................................................................1103 REMOVAL AND INSTALLATION...........................................................................................................................................1103 AIR CONDITIONER COMPRESSOR.............................................................................................................................................1104 REMOVAL............................................................................................................................................................1104 INSTALLATION.......................................................................................................................................................1105 AIR CONDITIONER CONDENSER..............................................................................................................................................1106 REMOVAL AND INSTALLATION...........................................................................................................................................1106 RECEIVER TANK..........................................................................................................................................................1107 REMOVAL AND INSTALLATION...........................................................................................................................................1107 AIR CONDITIONER UNIT...................................................................................................................................................1108 REMOVAL............................................................................................................................................................1108 INSTALLATION.......................................................................................................................................................1109 MONITOR................................................................................................................................................................1110 REMOVAL AND INSTALLATION...........................................................................................................................................1110 40 MAINTENANCE STANDARD....................................................................................................................................................1111 ENGINE MOUNT...........................................................................................................................................................1112 TRANSMISSION MOUNT.....................................................................................................................................................1114 TORQUE CONVERTER ......................................................................................................................................................1116 TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP).............................................................................................................1119 TRANSMISSION...........................................................................................................................................................1120 TRANSFER...............................................................................................................................................................1123 TRANSMISSION CONTROL VALVE.............................................................................................................................................1125 DRIVE SHAFT............................................................................................................................................................1130 CENTER SUPPORT.........................................................................................................................................................1131 DIFFERENTIAL...........................................................................................................................................................1132 LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)................................................................................................................................1136 FINAL DRIVE............................................................................................................................................................1140 AXLE MOUNT.............................................................................................................................................................1144 STEERING COLUMN........................................................................................................................................................1148 STEERING VLAVE.........................................................................................................................................................1149 EMERGENCY STEERING PUMP................................................................................................................................................1150 DIVERTER VALVE.........................................................................................................................................................1151 STEERING CYLINDER MOUNT................................................................................................................................................1152 BRAKE VALVE............................................................................................................................................................1153 SLACK ADJUSTER.........................................................................................................................................................1159 BRAKE..................................................................................................................................................................1161 PARKING BRAKE..........................................................................................................................................................1165 HYDRAULIC PUMP.........................................................................................................................................................1166 PPC VALVE..............................................................................................................................................................1171 CUT-OFF VALVE..........................................................................................................................................................1173 MAIN CONTROL VALVE.....................................................................................................................................................1174 HYDRAULIC CYLINDER.....................................................................................................................................................1176 WORK EQUIPMENT LINKAGE.................................................................................................................................................1178 BUCKET.................................................................................................................................................................1180 BUCKET POSITIONER AND BOOM KICK-OUT....................................................................................................................................1181 ROPS CANOPY............................................................................................................................................................1183 90 OTHERS..................................................................................................................................................................1184 FOR STANDARD MACHINE (SERIAL NO.:50001-52000)..........................................................................................................................1185 ELECTRIC CIRCUIT DIAGRAM (1/4).....................................................................................................................................1185 ELECTRIC CIRCUIT DIAGRAM (2/4).....................................................................................................................................1186 ELECTRIC CIRCUIT DIAGRAM (3/4).....................................................................................................................................1187 ELECTRIC CIRCUIT DIAGRAM (4/4).....................................................................................................................................1188 FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.50001-52000)..........................................................................................1189 ELECTRIC CIRCUIT DIAGRAM (1/4).....................................................................................................................................1189 ELECTRIC CIRCUIT DIAGRAM (2/4).....................................................................................................................................1190 ELECTRIC CIRCUIT DIAGRAM (3/4).....................................................................................................................................1191 ELECTRIC CIRCUIT DIAGRAM (4/4).....................................................................................................................................1192 FOR STANKARD MACHINE (SERIAL NO.52001 AND UP)..........................................................................................................................1193 ELECTRIC CIRCUIT DIAGAM (1/5)......................................................................................................................................1193 ELECTRIC CIRCUIT DIAGAM (2/5)......................................................................................................................................1194 ELECTRIC CIRCUIT DIAGAM (3/5)......................................................................................................................................1195 ELECTRIC CIRCUIT DIAGAM (4/5)......................................................................................................................................1196 ELECTRIC CIRCUIT DIAGAM (5/5)......................................................................................................................................1197 FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.52001 AND UP).........................................................................................1198 ELECTRIC CIRCUIT DIAGRAM (1/3).....................................................................................................................................1198 ELECTRIC CIRCUIT DIAGRAM (2/3).....................................................................................................................................1199 ELECTRIC CIRCUIT DIAGRAM (3/3).....................................................................................................................................1200
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