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KOMATSU AVANCE LOADER WA700-3 SHOP MANUAL SEBM013316 – PDF DOWNLOAD
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Description
KOMATSU AVANCE LOADER WA700-3 SHOP MANUAL SEBM013316 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU AVANCE LOADER WA700-3 SHOP MANUAL SEBM013316 – PDF DOWNLOAD
Language : English
Pages : 1382
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA700-3 SHOP MANUAL SEBM013316 – PDF DOWNLOAD
COVER.......................................................................................................................................................................................................................................................................................... 1
CONTENTS....................................................................................................................................................................................................................................................................................... 2
01 GENERAL..................................................................................................................................................................................................................................................................................... 31
GENERAL ASSEMBLY DRAWING................................................................................................................................................................................................................................................................... 32
SPECIFICATIONS............................................................................................................................................................................................................................................................................. 35
WEIGHT TABLE............................................................................................................................................................................................................................................................................... 38
LIST OF LUBRICANT AND WATER................................................................................................................................................................................................................................................................ 40
10 STRUCTURE AND FUNCTION...................................................................................................................................................................................................................................................................... 43
OUTLINE.................................................................................................................................................................................................................................................................................... 44
POWER TRAIN SYSTEM......................................................................................................................................................................................................................................................................... 46
DAMPER..................................................................................................................................................................................................................................................................................... 48
RADIATOR AND OIL COOLER.................................................................................................................................................................................................................................................................... 49
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...................................................................................................................................................................................................................................................... 52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................................................................................................................... 56
TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................................................................................................................................................................... 58
TORQUE CONVERTER AND PTO................................................................................................................................................................................................................................................................... 60
TORQUE CONVERTER REGULATOR VALVE........................................................................................................................................................................................................................................................... 67
TRANSMISSION............................................................................................................................................................................................................................................................................... 68
TRANSMISSION CONTROL VALVE................................................................................................................................................................................................................................................................. 80
TORQUE CONVERTER OIL COOLER................................................................................................................................................................................................................................................................ 104
TRANSMISSION OIL FILTER.................................................................................................................................................................................................................................................................... 105
TRANSFER................................................................................................................................................................................................................................................................................... 107
AXLE....................................................................................................................................................................................................................................................................................... 108
DIFFERENTIAL............................................................................................................................................................................................................................................................................... 110
FINAL DRIVE................................................................................................................................................................................................................................................................................ 112
STEERING PIPING DIAGRAM.................................................................................................................................................................................................................................................................... 115
STEERING AND SWITCH PUMP................................................................................................................................................................................................................................................................... 116
STEERING UNIT (ORBIT-ROLL VALVE)........................................................................................................................................................................................................................................................... 120
STEERING DEMAND VALVE...................................................................................................................................................................................................................................................................... 123
TWO-WAY RESTRICTOR VALVE................................................................................................................................................................................................................................................................... 134
STOP VALVE................................................................................................................................................................................................................................................................................. 135
DIVERTER VALVE............................................................................................................................................................................................................................................................................. 136
BRAKE PIPING............................................................................................................................................................................................................................................................................... 140
BRAKE CIRCUIT DIAGRAM...................................................................................................................................................................................................................................................................... 141
BRAKE VALVE................................................................................................................................................................................................................................................................................ 142
CHARGE VALVE............................................................................................................................................................................................................................................................................... 148
ACCUMULATOR (FOR BRAKE).................................................................................................................................................................................................................................................................... 152
SLACK ADJUSTER............................................................................................................................................................................................................................................................................. 153
BRAKE...................................................................................................................................................................................................................................................................................... 156
PARKING BRAKE.............................................................................................................................................................................................................................................................................. 159
SPRING CYLINDER............................................................................................................................................................................................................................................................................ 163
PARKING BRAKE SOLENOID VALVE............................................................................................................................................................................................................................................................... 164
HYDRAULIC PIPING........................................................................................................................................................................................................................................................................... 166
HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................................. 168
MAIN PISTON PUMP........................................................................................................................................................................................................................................................................... 171
ES VALVE (ENGINE SENSING VALVE)............................................................................................................................................................................................................................................................ 183
SERVO VALVE................................................................................................................................................................................................................................................................................ 184
PRESSURE DIFFERENTIAL VALVE................................................................................................................................................................................................................................................................ 185
PPC VALVE (PROPORTIONAL PRESSURE VALVE).................................................................................................................................................................................................................................................... 186
PPC RELIEF VALVE........................................................................................................................................................................................................................................................................... 190
ACCUMULATOR (FOR PPC VALVE)................................................................................................................................................................................................................................................................ 191
MAIN CONTROL VALVE......................................................................................................................................................................................................................................................................... 192
LUBRICATION OF WORK EQUIPMENT.............................................................................................................................................................................................................................................................. 216
WORK EQUIPMENT LINKAGE..................................................................................................................................................................................................................................................................... 218
BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................................................................................................................................................................................ 220
OPERATION OF PROXIMITY SWITCH.............................................................................................................................................................................................................................................................. 222
AIR CONDITIONER............................................................................................................................................................................................................................................................................ 226
ELECTRIC CIRCUIT DIAGRAM................................................................................................................................................................................................................................................................... 230
MACHINE MONITOR SYSTEM..................................................................................................................................................................................................................................................................... 230
MAIN MONITOR............................................................................................................................................................................................................................................................................... 231
MAINTENANCE MONITOR........................................................................................................................................................................................................................................................................ 235
AUTOMATIC TRANSMISSION SYSTEM (ATM)........................................................................................................................................................................................................................................................ 237
JOYSTICK STEERING SYSTEM................................................................................................................................................................................................................................................................... 250
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)................................................................................................................................................................................................................................................... 252
TRANSMISSION AND JOYSTICK CONTROLLER....................................................................................................................................................................................................................................................... 256
ENGINE STARTING CIRCUIT.................................................................................................................................................................................................................................................................... 259
ENGINE STOP CIRCUIT........................................................................................................................................................................................................................................................................ 262
AUTO PRIMING SYSTEM (APS).................................................................................................................................................................................................................................................................. 264
PREHEATING CIRCUIT......................................................................................................................................................................................................................................................................... 268
FUEL SYSTEM................................................................................................................................................................................................................................................................................ 269
ELECTRICAL TRANSMISSION CONTROL............................................................................................................................................................................................................................................................ 270
KICK-DOWN, HOLD SWITCH..................................................................................................................................................................................................................................................................... 273
KICK-DOWN ELECTRICAL CIRCUIT............................................................................................................................................................................................................................................................... 274
ELECTRIC PARKING BRAKE CONTROL............................................................................................................................................................................................................................................................. 280
ELECTRIC CIRCUIT DIAGRAM OF ACTIVE POWER MAXIMIZING SYSTEM................................................................................................................................................................................................................................. 289
VHMS CONTROLLER............................................................................................................................................................................................................................................................................ 295
BLOW-BY PRESSURE SENSOR.................................................................................................................................................................................................................................................................... 295
ENGINE OIL TEMPERATURE SENSOR.............................................................................................................................................................................................................................................................. 296
EXHAUST TEMPERATURE SENSOR/AMP............................................................................................................................................................................................................................................................. 297
AMBIENT TEMPERATURE SENSOR................................................................................................................................................................................................................................................................. 297
TRANSMISSION PUMP OIL PRESSURE SENSOR...................................................................................................................................................................................................................................................... 298
BRAKE OIL TEMPERATURE SENSOR............................................................................................................................................................................................................................................................... 299
HYDRAULIC OIL TEMPERATURE SENSOR........................................................................................................................................................................................................................................................... 299
BRAKE OIL PRESSURE SENSOR.................................................................................................................................................................................................................................................................. 300
STEERING OIL PRESSURE SENSOR............................................................................................................................................................................................................................................................... 300
WORK EQUIPMENT PUMP OIL PRESSURE SENSOR.................................................................................................................................................................................................................................................... 300
COMMUNICATIONS (ORB: ORBCOMM) CONTROLLER/ANTENNA........................................................................................................................................................................................................................................... 301
20 TESTING AND ADJUSTING....................................................................................................................................................................................................................................................................... 303
STANDARD VALUE TABLE FOR ENGINE............................................................................................................................................................................................................................................................ 304
STANDARD VALUE TABLE FOR CHASSIS........................................................................................................................................................................................................................................................... 306
STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................................................................................................................................................. 313
TESTING AND ADJUSTING...................................................................................................................................................................................................................................................................... 331
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................................................................................................................................................. 332
ADJUSTING VALVE CLEARANCE.............................................................................................................................................................................................................................................................. 337
TESTING AND ADJUSTING INJECTOR LIFT.................................................................................................................................................................................................................................................... 339
MEASURING COMPRESSION PRESSURE......................................................................................................................................................................................................................................................... 341
MEASURING BLOW-BY PRESSURE............................................................................................................................................................................................................................................................. 344
TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................................................................................................................................................................ 345
MEASURING EXHAUST GAS COLOR............................................................................................................................................................................................................................................................ 347
TESTING AND ADJUSTING ALTERNATOR BELT TENSION.......................................................................................................................................................................................................................................... 348
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.......................................................................................................................................................................................................................... 349
HANDLING EQUIPMENT IN FUEL CIRCUIT..................................................................................................................................................................................................................................................... 350
MEASURING FUEL PUMP OUTLET PORT PRESSURE............................................................................................................................................................................................................................................... 350
BLEEDING AIR FROM FUEL CIRCUIT......................................................................................................................................................................................................................................................... 351
MEASURING EXHAUST TEMPERATURE.......................................................................................................................................................................................................................................................... 353
MEASURING EXHAUST TEMPERATURE (OVERALL ENGINE)......................................................................................................................................................................................................................................... 354
MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER)...................................................................................................................................................................................................................................... 355
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)......................................................................................................................................................................................................................................... 356
MEASURING ACCELERATOR PEDAL............................................................................................................................................................................................................................................................ 357
ADJUSTING ACCELERATOR PEDAL TRAVEL, POTENTIOMETER...................................................................................................................................................................................................................................... 358
ADJUSTING ACCELERATOR PEDAL MICRO SWITCH............................................................................................................................................................................................................................................... 360
TESTING OF UPPER DRIVE SHAFT SLIDING PART.............................................................................................................................................................................................................................................. 361
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE.................................................................................................................................................................................................................................. 363
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL......................................................................................................................................................................................................................................... 365
TESTING AND ADJUSTING STEERING OIL PRESSURE............................................................................................................................................................................................................................................ 367
ADJUSTING STEERING STOPPER BOLT........................................................................................................................................................................................................................................................ 368
ADJUSTING JOYSTICK STEERING............................................................................................................................................................................................................................................................ 369
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH...................................................................................................................................................................................................................................... 371
TESTING BRAKE OIL PRESSURE............................................................................................................................................................................................................................................................. 372
MEASURING WEAR OF BRAKE DISC........................................................................................................................................................................................................................................................... 373
MEASURING BRAKE PERFORMANCE............................................................................................................................................................................................................................................................ 374
TESTING AND ADJUSTING PARKING BRAKE.................................................................................................................................................................................................................................................... 375
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...................................................................................................................................................................................................................................... 377
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS.................................................................................................................................................................................. 378
MEASURING PPC RELIEF VALVE HYDRAULIC PRESSURE.......................................................................................................................................................................................................................................... 390
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE................................................................................................................................................................................................................................ 392
BLEEDING AIR FROM PISTON PUMP.......................................................................................................................................................................................................................................................... 394
ADJUSTING WORK EQUIPMENT LEVER LINKAGE................................................................................................................................................................................................................................................. 395
TESTING AND ADJUSTING BUCKET POSITIONER................................................................................................................................................................................................................................................ 397
TESTING AND ADJUSTING BOOM KICK-OUT.................................................................................................................................................................................................................................................... 398
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP.......................................................................................................................................................................................................................................... 399
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)............................................................................................................................................................................................................................................ 400
BLEEDING AIR........................................................................................................................................................................................................................................................................... 401
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...................................................................................................................................................................................................................................... 402
BASIC PRECAUTIONS...................................................................................................................................................................................................................................................................... 403
OUTLINE................................................................................................................................................................................................................................................................................ 406
SETTING UP VHMS CONTROLLER............................................................................................................................................................................................................................................................. 412
COLLECTION, TRANSMISSION OF DATA....................................................................................................................................................................................................................................................... 414
INSPECTION AND MAINTENANCE............................................................................................................................................................................................................................................................. 419
REPLACING PARTS........................................................................................................................................................................................................................................................................ 419
TROUBLESHOOTING............................................................................................................................................................................................................................................................................ 421
POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................................................................................................................................................................ 422
SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................................................................................................................................................................. 423
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................................................................................................................................................................................... 424
CHECKS BEFORE TROUBLESHOOTING.......................................................................................................................................................................................................................................................... 432
CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................................................................................................................. 434
CONNECTOR ARRANGEMENT DIAGRAM.......................................................................................................................................................................................................................................................... 440
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................................................................................................................................. 451
ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM............................................................................................................................................................................................................................................. 474
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE...................................................................................................................................................................................................................................... 477
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION............................................................................................................................................................................................................................... 479
TRANSMISSION CONTROLLER LED DISPLAY.................................................................................................................................................................................................................................................... 481
METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................................................................................................................. 482
TROUBLESHOOTING OF ENGINE BODY (S MODE)................................................................................................................................................................................................................................................ 485
METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................................................................................................................. 486
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...................................................................................................................................................................................................................... 490
S-2 ENGINE DOES NOT START.......................................................................................................................................................................................................................................................... 492
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT................................................................................................................................................................................................................................. 492
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START........................................................................................................................................................................................................................... 493
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)........................................................................................................................................................................................................................... 494
S-4 ENGINE STOPS DURING OPERATIONS................................................................................................................................................................................................................................................. 496
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...................................................................................................................................................................................................................................... 498
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)........................................................................................................................................................................................................................................... 499
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................................................................................................................................................................................................................................. 500
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................................................................................................................................................................ 501
S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................................................................................................................................................... 502
S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................................................................................................................................................................. 503
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....................................................................................................................................................................................................... 504
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).................................................................................................................................................................................................................... 505
S-13 OIL LEVEL RISES............................................................................................................................................................................................................................................................... 506
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).............................................................................................................................................................................................................................. 507
S-15 ABNORMAL NOISE IS MADE........................................................................................................................................................................................................................................................ 508
S-16 VIBRATION IS EXCESSIVE........................................................................................................................................................................................................................................................ 510
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)........................................................................................................................................................................................................................................ 511
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....................................................................................................................................................................................................................................... 514
M-1 MAIN MONITOR DOES NOT WORK..................................................................................................................................................................................................................................................... 518
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP................................................................................................................................................................................. 519
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY..................................................................................................................................................................................................................................... 520
M-4 ABNORMALITY IN SHIFT INDICATOR................................................................................................................................................................................................................................................. 521
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F.............................................................................................................................................................................................................................. 521
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R.............................................................................................................................................................................................................................. 521
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F....................................................................................................................................................................... 521
d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R....................................................................................................................................................................... 522
e) DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R)............................................................................................................................................................................................ 522
f) DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R)............................................................................................................................................................................................ 522
g) DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R)............................................................................................................................................................................................ 523
h) DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R)............................................................................................................................................................................................ 523
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP.......................................................................................................................................................................................................................................... 525
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP.................................................................................................................................................................................................................................. 525
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP.................................................................................................................................................................................................................................. 525
M-6 ABNORMALITY IN PARKING DISPLAY................................................................................................................................................................................................................................................. 526
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP...................................................................................................................................................................................................................................... 526
b) PARKING LAMP DISPLAY STAYS LIGHTED UP....................................................................................................................................................................................................................................... 526
M-7 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................................................................................................................................................................................... 527
M-8 ABNORMALITY IN FRONT WORKING LAMP.............................................................................................................................................................................................................................................. 528
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP..................................................................................................................................................................................................................... 528
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................................................................................................................................................................................................................ 528
c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP................................................................................................................................................................................................................ 528
M-9 ABNORMALITY IN REAR WORKING LAMP............................................................................................................................................................................................................................................... 530
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...................................................................................................................................................................................................................... 530
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................................................................................................................................................................................................................ 530
c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP................................................................................................................................................................................................................ 530
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF........................................................................................................................................................................................................................................... 532
STANDARD SPECIFICATION......................................................................................................................................................................................................................................................... 532
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE............................................................................................................................................................... 532
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED..................................................................................................................................................................................... 532
c) TRANSMISSION CUT-OFF SWITCH TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED............................................................................................................................................................................................. 533
AUTO-SHIFT SPECIFICATION....................................................................................................................................................................................................................................................... 534
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE 5............................................................................................................................................ 534
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED............................................................................................................................. 534
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED........................................................................................................................................................ 534
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)............................................................................................................................................................... 534
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED................................................................................................................................................................. 535
M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING................................................................................................................................................................................................................................. 536
a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N.................................................................................................................................................. 536
b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N............................................................................................................................. 536
M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED..................................................................................................................................................... 538
a) ACTUATED CONTINUOUSLY....................................................................................................................................................................................................................................................... 538
b) NOT ACTUATED................................................................................................................................................................................................................................................................ 538
M-13 ABNORMALITY IN BUZZER......................................................................................................................................................................................................................................................... 539
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)..................................................................................................................................................................................... 539
b) BUZZER ALWAYS SOUNDS........................................................................................................................................................................................................................................................ 539
M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY......................................................................................................................................................................................................................... 540
M-15 ABNORMALITY IN FAILURE DISPLAY MODE........................................................................................................................................................................................................................................... 541
a) DOES NOT ENTER FAILURE DISPLAY MODE......................................................................................................................................................................................................................................... 541
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE............................................................................................................................................................................................... 541
M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY.............................................................................................................................................................................................................. 542
a) THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED......................................................................................................................................................................................................... 542
b) THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED......................................................................................................................................................................................................... 542
c) PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED......................................................................................................................................................................................................... 542
d) PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED......................................................................................................................................................................................................... 543
M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY........................................................................................................................................................................................................................... 544
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP...................................................................................................................................................................................................................... 544
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP....................................................................................................................................................................................................................... 544
M-18 ABNORMALITY IN AUTO-GREASING SYSTEM........................................................................................................................................................................................................................................... 545
a) CHECK POWER SUPPLY SYSTEM 1 (RELAY G1)...................................................................................................................................................................................................................................... 545
b) CHECK POWER SUPPLY SYSTEM 2 (RELAY G2)...................................................................................................................................................................................................................................... 545
c) FORCED GREASING DOES NOT START.............................................................................................................................................................................................................................................. 546
d) MONITOR DOES NOT FLASH WHILE GREASE IS BEING SUPPLIED....................................................................................................................................................................................................................... 546
e) MONITOR IS STILL FLASHING AFTER GREASING IS FINISHED, OR IT FLASHES FOR PERIOD SET WITH TIMER WHEN STARTING SWITCH IS TURNED TO ON POSITION................................................................................................................................. 547
M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM....................................................................................................................................................................................................................................... 549
a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................. 549
b) MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK (SERIAL NO.: 50001 – 51000).......................................................................................................................................................................... 549
a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED (SERIAL NO.: 51001 AND UP)................................................................................................................................................................................................... 550
b) MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK (SERIAL NO.: 51001 AND UP)........................................................................................................................................................................... 550
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)................................................................................................................................................................................................................................. 551
ELECTRICAL CIRCUIT DIAGRAM FOR K MODE SYSTEM....................................................................................................................................................................................................................................... 552
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK........................................................................................................................................... 554
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP.................................................................................................................................................................................................................................... 554
b) SOME LAMPS DO NOT LIGHT UP.................................................................................................................................................................................................................................................. 554
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS).......................................................................................................................................................... 555
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT............................................................................................................................................... 556
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH.......................................................................................................................................................................................................... 557
a) ENGINE OIL LEVEL DISPLAY FLASHES............................................................................................................................................................................................................................................ 557
b) ENGINE WATER LEVEL DISPLAY FLASHES (SERIAL NO.: 50001 – 51000).............................................................................................................................................................................................................. 558
b) ENGINE WATER LEVEL DISPLAY FLASHES (SERIAL NO.: 51001 AND UP)............................................................................................................................................................................................................... 559
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH........................................................................................................................................................................................................ 560
a) ENGINE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE ENGINE OIL PRESSURE IS CORRECT.) (SERIAL NO.: 50001 – 51000)............................................................................................................................................................ 560
a) ENGINE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE ENGINE OIL PRESSURE IS CORRECT.) (SERIAL NO.: 51001 AND UP)............................................................................................................................................................. 561
b) BATTERY CHARGE LEVEL DISPLAY FLASHES........................................................................................................................................................................................................................................ 562
c) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE BRAKE OIL PRESSURE IS CORRECT.).......................................................................................................................................................................................... 563
d) AIR CLEANER (L.H.) DISPLAY FLASHES.......................................................................................................................................................................................................................................... 564
e) AIR CLEANER (R.H.) DISPLAY FLASHES.......................................................................................................................................................................................................................................... 565
f) AIR CLEANER DISPLAY FLASHES................................................................................................................................................................................................................................................. 566
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND................................................................................................................................................................................................................... 567
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS........................................................................................................................................................................................................... 568
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH.......................................................................................................................................................................................... 569
a) CHECK LAMP.................................................................................................................................................................................................................................................................. 569
b) CAUTION LAMP................................................................................................................................................................................................................................................................ 569
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP................................................................................................................................................................... 570
a) CHECK LAMP.................................................................................................................................................................................................................................................................. 570
b) CAUTION LAMP................................................................................................................................................................................................................................................................ 570
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)....................................................................................................................................................... 571
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP........................................................................................................................................................................................ 572
K-12 SERVICE METER DOES NOT WORK................................................................................................................................................................................................................................................... 573
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.......................................................................................................................................................................................................................... 573
K-14 ABNORMALITY IN GAUGE ITEMS.................................................................................................................................................................................................................................................... 575
a) ABNORMALITY IN FUEL GAUGE................................................................................................................................................................................................................................................... 575
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE............................................................................................................................................................................................................................... 576
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE....................................................................................................................................................................................................................... 577
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).......................................................................................................................................................................................................................................... 579
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM....................................................................................................................................................................................................................................... 582
E-1 ENGINE DOES NOT START.......................................................................................................................................................................................................................................................... 586
a) STARTING MOTOR DOES NOT TURN................................................................................................................................................................................................................................................ 586
b) STARTING MOTOR TURNS........................................................................................................................................................................................................................................................ 592
E-2 ABNORMALITY IN APS SYSTEM...................................................................................................................................................................................................................................................... 602
a) WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOT LIGHT UP, BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP...................................................................................................................................................... 604
b) WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20ºC, PREHEATING LAMP FLASHES, BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL..................................................................................................................... 605
c) AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START, BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL................................................................................................................................... 606
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL......................................................................................................................................................................................................................... 607
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL......................................................................................................................................................................................................................... 607
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL......................................................................................................................................................................................................................... 608
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL......................................................................................................................................................................................................................... 608
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL......................................................................................................................................................................................................................... 609
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL......................................................................................................................................................................................................................... 609
j) WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP.................................................................................................................................................................................................................... 610
E-3 PARKING BRAKE DOES NOT HAVE EFFECT............................................................................................................................................................................................................................................. 611
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON.......................................................................................................................................................................................................... 611
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS.......................................................................................................................................................................... 611
E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING............................................................................................................................................................................................................................. 612
E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.................................................................................................................................................................................................................... 614
E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORKS NORMALLY........................................................................................................................................................................ 614
E-7 TRANSMISSION DOES NOT WORK PROPERLY............................................................................................................................................................................................................................................ 617
a) ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT...................................................................................................................................................................... 618
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT............................................................................................................................................................................................................................ 622
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT............................................................................................................................................................................................................................ 624
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT............................................................................................................................................................................................................. 626
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT....................................................................................................................................................................................................................................... 632
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT................................................................................................................................................................................................................... 635
E-8 KICK-DOWN SWITCH DOES NOT WORK................................................................................................................................................................................................................................................. 640
E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON.................................................................................................................................................................................................................. 643
E-10 KICK-DOWN ALWAYS WORKS........................................................................................................................................................................................................................................................ 644
E-11 KICK-DOWN SWICH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND...................................................................................................................................................................................................................... 646
E-12 BOOM KICK-OUT DOES NOT WORK................................................................................................................................................................................................................................................... 648
E-13 DEFECTIVE BUCKET POSITIONER................................................................................................................................................................................................................................................... 650
E-14 POWER WINDOW DOES NOT WORK.................................................................................................................................................................................................................................................... 652
a) WINDOW DOES NOT GO UP....................................................................................................................................................................................................................................................... 652
b) WINDOW DOES NOT GO DOWN..................................................................................................................................................................................................................................................... 653
E-15 ABNORMALITY IN FRONT WORKING LAMP............................................................................................................................................................................................................................................. 655
E-16 ABNORMALITY IN REAR WORKING LAMP.............................................................................................................................................................................................................................................. 655
E-17 ABNORMALITY IN TRANSMISSION CUT-OFF........................................................................................................................................................................................................................................... 655
E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING................................................................................................................................................................................................................................. 655
E-19 ABNORMALITY IN BUZZER......................................................................................................................................................................................................................................................... 655
TROUBLESHOOTING OF ELECTRIC ENGINE THROTTLE CONTROLLER & APS CONTROLLER SYSTEM SYSTEM (G MODE)......................................................................................................................................................................................... 657
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS..................................................................................................................................................................................................................... 658
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS........................................................................................................................................................................................................ 660
ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS.................................................................................................................................................................................................... 666
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM................................................................................................................................................................................................... 667
JUDGEMENT TABLE FOR ENGINE CONTROLLER.............................................................................................................................................................................................................................................. 669
G-1 [90] [OFF OR 10] ABNORMALITY IN POWER SOURCE SYSTEM............................................................................................................................................................................................................................ 670
G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM..................................................................................................................................................................................................................................... 670
G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR..................................................................................................................................................................................................................................... 671
G-4 [90] [56] ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM............................................................................................................................................................................................................... 671
G-5 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM........................................................................................................................................................................................................................... 672
G-6 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM............................................................................................................................................................................................................................ 673
G-7 [91] [14] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM.............................................................................................................................................................................................................................. 674
G-8 [91] [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM............................................................................................................................................................................................................................. 675
G-9 [91] [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM................................................................................................................................................................................................................................. 676
G-10 [91] [1D] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM........................................................................................................................................................................................................................... 677
G-11 [92] [12] ABNORMALITY IN RACK SENSOR SYSTEM................................................................................................................................................................................................................................... 678
G-12 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM...................................................................................................................................................................................................................... 679
G-13 [93] [1B] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM......................................................................................................................................................................................................................... 680
G-14 [94] [1C] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM......................................................................................................................................................................................................................... 681
G-15 [93,94] [1B, 1C] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM............................................................................................................................................................................................................... 682
G-16 [95] [40] ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM...................................................................................................................................................................................................................... 682
G-17 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM............................................................................................................................................................................................................................ 683
G-18 [99] [22] ENGINE OVERRUN...................................................................................................................................................................................................................................................... 685
G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY)............................................................................................................................................................................................................................... 685
G-20 ENGINE DOES NOT START......................................................................................................................................................................................................................................................... 686
G-21 ENGINE DOES NOT STOP.......................................................................................................................................................................................................................................................... 689
G-22 DEFECTIVE ACTUATION OF APS.................................................................................................................................................................................................................................................... 690
a) PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE ALSO OFF)....................................................................................................................................................................... 690
b) PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20ºC WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY)
PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20ºC WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY).... 692
c) NOZZLE DOES NOT INJECT FUEL WHEN STARTING SWITCH IS TURNED TO START AFTER COMPLETION OF PREHEATING WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY).......................................................................................................... 692
d) APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY........................................................................................................................................................................................... 693
e) APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY........................................................................................................................................................................................... 693
f) APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY........................................................................................................................................................................................... 694
g) APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY........................................................................................................................................................................................... 694
h) APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) GIVES ABNORMAL DISPLAY........................................................................................................................................................................................... 695
i) APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY....................................................................................................................................................................................................... 695
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)............................................................................................................................................................................................................................ 697
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...................................................................................................................................................................................................................................... 700
H-1 MACHINE DOES NOT START......................................................................................................................................................................................................................................................... 702
H-2 MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES)................................................................................................................................................................................................................. 703
H-3 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR........................................................................................................................................................................................................................... 704
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH....................................................................................................................................................................................................................................... 705
H-5 STEERING DOES NOT TURN (STEERING WHEEL SPECIFICATION).......................................................................................................................................................................................................................... 706
H-6 STEERING DOES NOT TURN (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................................................................................................................................... 707
H-7 STEERING DOES NOT TURN (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)................................................................................................................................................................................................ 708
H-8 TURNING, RESPONSE OF STEERING IS POOR (STEERING WHEEL SPECIFICATION)........................................................................................................................................................................................................... 709
H-9 TURNING, RESPONSE OF STEERING IS POOR (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)..................................................................................................................................................................................... 710
H-10 TURNING, RESPONSE OF STEERING IS POOR (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)................................................................................................................................................................................ 712
H-11 STEERING IS HEAVY (STEERING WHEEL SPECIFICATION).............................................................................................................................................................................................................................. 713
H-12 JOYSTICK LEVER IS HEAVY (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................................................................................................................................. 713
H-13 JOYSTICK LEVER IS HEAVY (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).............................................................................................................................................................................................. 714
H-14 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL SPECIFICATION)................................................................................................................................................................................................................. 715
H-15 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).............................................................................................................................................................................. 716
H-16 STEERING WHEEL SHAKES OR JERKS (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)....................................................................................................................................................................................... 717
H-17 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (STEERING WHEEL SPECIFICATION, STEERIG WHEEL AND JOYSTICK STEERING SPECIFICATION)....................................................................................................................................... 718
H-18 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)................................................................................................................................................................ 718
H-19 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR............................................................................................................................................................................................................................ 720
H-20 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG.................................................................................................................................................................................................................................. 722
H-21 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR......................................................................................................................................................................................................................... 723
H-22 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS.................................................................................................................................................................................................................................. 724
H-23 NEITHER BOOM NOR BUCKET MOVE.................................................................................................................................................................................................................................................. 725
H-24 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER................................................................................................................................................................................................................................... 726
H-25 BOOM DOES NOT MOVE............................................................................................................................................................................................................................................................ 727
H-26 BOOM IS SLOW OR BOOM LACKS POWER.............................................................................................................................................................................................................................................. 728
H-27 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT.................................................................................................................................................................................................................. 729
H-28 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...................................................................................................................................................................................................... 729
H-29 EXCESSIVE HYDRAULIC DRIFT OF BOOM............................................................................................................................................................................................................................................. 730
H-30 BUCKET DOES NOT MOVE.......................................................................................................................................................................................................................................................... 731
H-31 BUCKET IS SLOW OR LACKS POWER................................................................................................................................................................................................................................................. 732
H-32 EXCESSIVE HYDRAULIC DRIFT OF BUCKET........................................................................................................................................................................................................................................... 733
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)................................................................................................................................................................................................................................ 735
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS................................................................................................................................................................................................................... 738
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................................................................................................................................................................................... 742
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM......................................................................................................................................................................................................................... 752
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED............................................................................................................................................................ 756
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED................................................................................................................................................................... 757
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED................................................................................................................................................................... 758
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED................................................................................................................................................................. 759
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED................................................................................................................................................................. 760
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED................................................................................................................................................................. 761
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED................................................................................................................................................................. 762
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)....................................................................................................................... 763
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED (STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................................. 764
T-10 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)................................................................................................................ 767
T-11 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED (STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)....................................................................................................... 768
T-12 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)........................................................................................................ 772
T-13 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED (STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)............................................................................................................... 774
T-14 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)......................................................................................................................................... 775
T-15 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED................................................................................................................................................................................... 776
a) TRANSMISSION CONTROLLER SYSTEM.............................................................................................................................................................................................................................................. 776
b) ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM.................................................................................................................................................................................................................................. 776
T-16 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM (STEERING WHEEL SPECIFICATION, AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)............................................................................................................................ 780
T-17 SHIFT-DOWN SWITCH SIGNAL SYSTEM AND SHIFT-UP SWITCH SIGNAL SYSTEM (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)........................................................................................................................................................ 781
T-18 TRANSMISSION CUT-OFF SIGNAL SYSTEM............................................................................................................................................................................................................................................ 782
T-19 NEUTRALIZER RELAY SIGNAL SYSTEM (STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)............................................................................................................................................................ 783
T-20 NEUTRALIZER RELAY SIGNAL SYSTEM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)...................................................................................................................................................................................... 784
T-21 BUZZER SIGNAL SYSTEM.......................................................................................................................................................................................................................................................... 786
T-22 NETWORK SYSTEM................................................................................................................................................................................................................................................................ 787
T-23 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM (STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)................................................................................................................................................ 788
T-24 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).......................................................................................................................................................................... 789
T-25 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM (STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)................................................................................................................................................ 790
T-26 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).......................................................................................................................................................................... 791
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)........................................................................................................................................................................................................................ 793
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS....................................................................................................................................................................................................................... 794
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................................................................................................................................................................................... 796
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM............................................................................................................................................................................................................................ 800
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED.......................................................................................................................................................................................... 801
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED............................................................................................................................................................................... 802
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED................................................................................................................................................................................ 803
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED............................................................................................................................................................................................ 804
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED............................................................................................................................................................................................. 805
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED............................................................................................................................................................................ 806
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED.............................................................................................................................................................................. 807
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DISPLAYED.................................................................................................................................................................. 808
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE........................................................................................................................................................................................................................................... 809
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM......................................................................................................................................................................................................................... 810
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID...................................................................................................................................................................................................................................... 811
J-12 DISCONNECTION IN STEERING LEFT SOLENOID....................................................................................................................................................................................................................................... 812
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE).................................................................................................................................................................................................... 813
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM........................................................................................................................................................................................................ 814
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY....................................................................................................................................................................................... 816
ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL............................................................................................................................................................................................... 820
A-1 ERROR CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED............................................................................................................................................................... 822
A-2 ERROR CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED........................................................................................................................................................ 823
A-3 ERROR CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED......................................................................................................................................................................... 824
A-4 ERROR CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED................................................................................................................................................................. 825
A-5 ERROR CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED................................................................................................................................................ 826
A-6 ERROR CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED................................................................................................................................................... 827
A-7 ERROR CODE [63] (DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND, OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED...................................................................................................... 828
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT............................................................................................................................................................................................................................... 829
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)................................................................................................................................................................. 830
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE....................................................................................................................................................................................................................................... 831
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (EA MODE)..................................................................................................................................................................................................................................... 833
METHOD OF ERROR CODE DISPLAY....................................................................................................................................................................................................................................................... 835
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED................................................................................................................................................................................................... 838
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROL SYSTEM............................................................................................................................................................................................................................... 846
EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)........................................................................................................................................................................................................................... 848
EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)........................................................................................................................................................................................................................ 848
EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)........................................................................................................................................................................................... 849
EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)................................................................................................................................................................................................................ 850
EA-5 ERROR CODE [116] (ABNORMALITY [HIGH LEVEL] IN TIMING RAIL PRESSURE SENSOR SYSTEM)............................................................................................................................................................................................. 852
EA-6 ERROR CODE [117] (ABNORMALITY [LOW LEVEL] IN TIMING RAIL PRESSURE SENSOR SYSTEM).............................................................................................................................................................................................. 853
EA-7 ERROR CODE [118] (ABNORMALITY [HIGH LEVEL] IN FUEL PUMP PRESSURE SENSOR SYSTEM)............................................................................................................................................................................................... 854
EA-8 ERROR CODE [119] (ABNORMALITY [LOW LEVEL] IN FUEL PUMP PRESSURE SENSOR SYSTEM)................................................................................................................................................................................................ 855
EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)................................................................................................................................................................................................................ 856
EA-10 ERROR CODE [122] (ABNORMALITY [HIGH LEVEL] IN BOOST PRESSURE SENSOR SYSTEM).................................................................................................................................................................................................. 857
EA-11 ERROR CODE [123] (ABNORMALITY [LOW LEVEL] IN BOOST PRESSURE SENSOR SYSTEM)................................................................................................................................................................................................... 858
EA-12 ERROR CODE [131] (ABNORMALITY [HIGH LEVEL] IN ACCELERATOR SENSOR SYSTEM)..................................................................................................................................................................................................... 859
EA-13 ERROR CODE [132] (ABNORMALITY [LOW LEVEL] IN ACCELERATOR SENSOR SYSTEM)...................................................................................................................................................................................................... 860
EA-14 ERROR CODE [135] (ABNORMALITY [HIGH LEVEL] IN OIL PRESSURE SENSOR SYSTEM).................................................................................................................................................................................................... 861
EA-15 ERROR CODE [141] (ABNORMALITY [LOW LEVEL] IN OIL PRESSURE SENSOR SYSTEM)..................................................................................................................................................................................................... 862
EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))................................................................................................................................................................................................................... 863
EA-17 ERROR CODE [144] (ABNORMALITY [HIGH LEVEL] IN WATER TEMPERATURE SENSOR SYSTEM)............................................................................................................................................................................................... 864
EA-18 ERROR CODE [145] (ABNORMALITY [LOW LEVEL] IN WATER TEMPERATURE SENSOR SYSTEM)................................................................................................................................................................................................ 865
EA-19 ERROR CODE [151] (ABNORMAL RISE IN WATER TEMPERATURE)........................................................................................................................................................................................................................ 865
EA-20 ERROR CODE [153] (ABNORMALITY [HIGH LEVEL] IN INTAKE AIR TEMPERATURE SENSOR SYSTEM).......................................................................................................................................................................................... 866
EA-21 ERROR CODE [154] (ABNORMALITY [LOW LEVEL] IN INTAKE AIR TEMPERATURE SENSOR SYSTEM)........................................................................................................................................................................................... 866
EA-22 ERROR CODE [221] (ABNORMALITY [HIGH LEVEL] IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)............................................................................................................................................................................................ 867
EA-23 ERROR CODE [222] (ABNORMALITY [LOW LEVEL] IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)............................................................................................................................................................................................. 868
EA-24 ERROR CODE [234] (OVERSPEED)................................................................................................................................................................................................................................................. 870
EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)......................................................................................................................................................................................................... 871
EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)........................................................................................................................................................................................................................ 872
EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)......................................................................................................................................................................................................................... 872
EA-28 ERROR CODE [263] (ABNORMALITY [HIGH LEVEL] IN FUEL TEMPERATURE SENSOR SYSTEM)................................................................................................................................................................................................ 873
EA-29 ERROR CODE [265] (ABNORMALITY [LOW LEVEL] IN FUEL TEMPERATURE SENSOR SYSTEM)................................................................................................................................................................................................. 873
EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT).......................................................................................................................................................................................................... 874
EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)......................................................................................................................................................................................................................... 875
EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION).......................................................................................................................................................................................................... 875
EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)...................................................................................................................................................................................................................... 876
EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)........................................................................................................................................................................................................... 877
EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))................................................................................................................................................................................................................... 878
EA-36 ERROR CODE [423] (ABNORMALITY [IN RANGE] IN TIMING RAIL PRESSURE SENSOR SYSTEM).............................................................................................................................................................................................. 878
EA-37 ERROR CODE [431] (ABNORMALITY [1] IN IDLING VALIDATION SWITCH SYSTEM)........................................................................................................................................................................................................ 880
EA-38 ERROR CODE [432] (IDLING VALIDATION PROCESS ERROR)........................................................................................................................................................................................................................... 882
EA-39 ERROR CODE [441] (ABNORMALITY [LOW LEVEL] IN BATTERY VOLTAGE)................................................................................................................................................................................................................ 884
EA-40 ERROR CODE [442] (ABNORMALITY [HIGH LEVEL] IN BATTERY VOLTAGE)............................................................................................................................................................................................................... 884
EA-41 ERROR CODE [451] (ABNORMALITY [HIGH LEVEL] IN FUEL RAIL PRESSURE SENSOR SYSTEM).............................................................................................................................................................................................. 885
EA-42 ERROR CODE [452] (ABNORMALITY [LOW LEVEL] IN FUEL RAIL PRESSURE SENSOR SYSTEM)............................................................................................................................................................................................... 886
EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT).......................................................................................................................................................................................................... 887
EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)............................................................................................................................................................................................................... 888
EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)................................................................................................................................................................................................................. 888
EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)......................................................................................................................................................................................................................... 888
EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM).............................................................................................................................................................................................................. 889
EA-48 ERROR CODE [551] (ABNORMALITY [2] IN IDLING VALIDATION SWITCH SYSTEM)........................................................................................................................................................................................................ 889
EA-49 ERROR CODE [554] (ABNORMALITY [IN RANGE] IN FUEL RAIL PRESSURE SENSOR)....................................................................................................................................................................................................... 890
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE).................................................................................................................................................................................................................................. 893
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER.................................................................................................................................................................................................................................. 896
INFORMATION GIVEN IN TROUBLESHOOTING CHART......................................................................................................................................................................................................................................... 898
PHENOMENON TYPE CODE LIST.......................................................................................................................................................................................................................................................... 899
[DBB0KK] (OR VHMS_LED INDICATES [N901]) ABNORMALITY IN SOURCE VOLTAGE.............................................................................................................................................................................................................. 900
[DBB5KP] (OR VHMS_LED INDICATES [N904]) ABNORMALITY IN SENSOR POWER SOURCE (5 V) SYSTEM............................................................................................................................................................................................ 902
[DBB6KP] (OR VHMS_LED INDICATES [N902]) ABNORMALITY IN SENSOR POWER SOURCE (24 V) SYSTEM........................................................................................................................................................................................... 904
[DBBRKR] (OR VHMS_LED DISPLAYS [N801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)................................................................................................................................. 906
[DGE1KB] (OR VHMS_LED DISPLAYS [N242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN. (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}......................................................................................... 908
[DGE1KY] (OR VHMS_LED DISPLAYS [N242]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY).................................................................................................................................................... 909
[DGE5KX] (OR VHMS_LED DISPLAYS [N401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)............................................................................................................................................................... 910
[DGT4KA] (OR VHMS_LED DISPLAYS [N312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA).............................................................................................................................. 912
[DGT4KB] (OR VHMS_LED DISPLAYS [N311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB).................................................................................................................................... 914
[DGT5KA] (OR VHMS_LED DISPLAYS [N322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA).............................................................................................................................. 916
[DGT5KB] (OR VHMS_LED DISPLAYS [N321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)................................................................................................................................... 918
[DHE5KB] (OR VHMS_LED DISPLAYS [N332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA).............................................................................................................................................. 920
[DHE5KY] (OR VHMS_LED DISPLAYS [N331]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)................................................................................................................................................... 922
[DHT3KX] (OR VHMS_LED DISPLAYS [N614]) TROUBLE IN TRANSMISSION OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX).......................................................................................................................................................... 924
[DHP2KX] (OR VHMS_LED DISPLAYS [N531]) TROUBLE IN MAIN PUMP OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................................................................. 926
[DHT8KX] (OR VHMS_LED DISPLAYS [N533]) TROUBLE IN STEERING OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX).............................................................................................................................................................. 928
[DGH2KX] (OR VHMS_LED DISPLAYS [N537]) TROUBLE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX).......................................................................................................................................................... 930
[DHU2KX] (OR VHMS_LED DISPLAYS [N711]) TROUBLE IN FRONT BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)........................................................................................................................................................... 932
[DHU3KX] (OR VHMS_LED DISPLAYS [N712]) TROUBLE IN REAR BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)............................................................................................................................................................ 934
[DGR4KX] (OR VHMS_LED DISPLAYS [N717]) TROUBLE IN FRONT BRAKE OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)........................................................................................................................................................ 936
[F@BBZL] (OR VHMS_LED DISPLAYS [N338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)....................................................................................................................................................................................................... 937
[F@BYNR] (OR VHMS_LED DISPLAYS [N362]) NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (2): (NR).................................................................................................................................................................................... 938
[F@BYNS] (OR VHMS_LED DISPLAYS [N361]) NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (1): (NS).................................................................................................................................................................................... 939
[F@BZNR] (OR VHMS_LED DISPLAYS [N372]) NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (2): (NR)................................................................................................................................................................................... 940
[F@BZNS] (OR VHMS_LED DISPLAYS [N371]) NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (1): (NS)................................................................................................................................................................................... 941
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION................................................................................................................................................................................................................................. 942
a) SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED............................................................................................................................................................................................................................ 942
b) ABNORMALITY IN DOWNLOADING INTO PC OR SETTING OF PC......................................................................................................................................................................................................................... 946
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED).......................................................................................................................................................................................................... 948
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL).................................................................................................................................................... 950
30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................................................................................... 951
METHOD OF USING MANUAL..................................................................................................................................................................................................................................................................... 955
PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................................................................................................................................... 957
SPECIAL TOOLS LIST......................................................................................................................................................................................................................................................................... 960
SKETCHES OF SPECIAL TOOLS.................................................................................................................................................................................................................................................................. 966
REMOVAL OF STARTING MOTOR ASSEMBLY......................................................................................................................................................................................................................................................... 970
INSTALLATION OF STARTING MOTOR............................................................................................................................................................................................................................................................. 970
REMOVAL OF ALTERNATOR ASSEMBLY (SERIAL NO.: 50001 – 51000)................................................................................................................................................................................................................................. 971
INSTALLATION OF ALTERNATOR ASSEMBLY (SERIAL NO.: 50001 – 51000)............................................................................................................................................................................................................................ 971
REMOVAL OF ALTERNATOR ASSEMBLY (SERIAL NO.: 51001 AND UP).................................................................................................................................................................................................................................. 972
INSTALLATION OF ALTERNATOR ASSEMBLY (SERIAL NO.: 51001 AND UP)............................................................................................................................................................................................................................. 972
REMOVAL OF ENGINE OIL COOLER ASSEMBLY (SERIAL NO.: 50001 – 51000).......................................................................................................................................................................................................................... 974
INSTALLATION OF ENGINE OIL COOLER ASSEMBLY (SERIAL NO.: 50001 – 51000)..................................................................................................................................................................................................................... 974
REMOVAL OF ENGINE OIL COOLER ASSEMBLY (SERIAL NO.: 51001 AND UP)........................................................................................................................................................................................................................... 975
INSTALLATION OF ENGINE OIL COOLER ASSEMBLY (SERIAL NO.: 51001 AND UP)...................................................................................................................................................................................................................... 975
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY.................................................................................................................................................................................................................................................... 977
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY............................................................................................................................................................................................................................................... 978
REMOVAL OF WATER PUMP ASSEMBLY............................................................................................................................................................................................................................................................. 979
INSTALLATION OF WATER PUMP ASSEMBLY........................................................................................................................................................................................................................................................ 979
REMOVAL OF NOZZLE HOLDER ASSEMBLY.......................................................................................................................................................................................................................................................... 980
INSTALLATION OF NOZZLE HOLDER ASSEMBLY..................................................................................................................................................................................................................................................... 980
REMOVAL OF TURBOCHARGER ASSEMBLIES......................................................................................................................................................................................................................................................... 981
INSTALLATION OF TURBOCHARGER ASSEMBLY...................................................................................................................................................................................................................................................... 982
REMOVAL OF ENGINE FRONT SEAL............................................................................................................................................................................................................................................................... 983
REPLACEMENT OF ENGINE REAR SEAL............................................................................................................................................................................................................................................................ 985
REMOVAL OF CYLINDER HEAD................................................................................................................................................................................................................................................................... 987
INSTALLATION OF CYLINDER HEAD ASSEMBLY..................................................................................................................................................................................................................................................... 990
REMOVAL OF THERMOSTAT ASSEMBLY............................................................................................................................................................................................................................................................. 992
INSTALLATION OF THERMOSTAT ASSEMBLY........................................................................................................................................................................................................................................................ 992
REMOVAL OF HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER ASSEMBLY............................................................................................................................................................................................................................ 993
INSTALLATION OF HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER ASSEMBLY....................................................................................................................................................................................................................... 994
REMOVAL OF HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER, FUEL COOLER ASSEMBLY............................................................................................................................................................................................................... 995
INSTALLATION OF HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER, FUEL COOLER ASSEMBLY.......................................................................................................................................................................................................... 997
REMOVAL OF ENGINE, DAMPER ASSEMBLY (SERIAL NO.: 50001 – 51000)............................................................................................................................................................................................................................. 999
INSTALLATION OF ENGINE, DAMPER ASSEMBLY (SERIAL NO.: 50001 – 51000)........................................................................................................................................................................................................................1001
REMOVAL OF ENGINE, DAMPER ASSEMBLY (SERIAL NO.: 51001 AND UP)..............................................................................................................................................................................................................................1002
INSTALLATION OF ENGINE, DAMPER ASSEMBLY (SERIAL NO.: 51001 AND UP).........................................................................................................................................................................................................................1004
REMOVAL OF DAMPER..........................................................................................................................................................................................................................................................................1006
INSTALLATION OF DAMPER ASSEMBLY............................................................................................................................................................................................................................................................1006
DISASSEMBLY OF DAMPER......................................................................................................................................................................................................................................................................1007
ASSEMBLY OF DAMPER.........................................................................................................................................................................................................................................................................1009
DISASSEMBLY OF PTO ASSEMBLY................................................................................................................................................................................................................................................................1013
ASSEMBLY OF PTO ASSEMBLY...................................................................................................................................................................................................................................................................1015
REMOVAL OF TORQUE CONVERTER, TRANSMISSION ASSEMBLY.........................................................................................................................................................................................................................................1018
INSTALLATION OF TORQUE CONVERTER, TRANSMISSION ASSEMBLY....................................................................................................................................................................................................................................1022
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY...................................................................................................................................................................................................................................................1023
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY......................................................................................................................................................................................................................................................1027
DISASSEMBLY OF TRANSMISSION ASSEMBLY.......................................................................................................................................................................................................................................................1032
ASSEMBLY OF TRANSMISSION...................................................................................................................................................................................................................................................................1046
REMOVAL OF TRANSMISSION VALVE ASSEMBLY.....................................................................................................................................................................................................................................................1061
INSTALLATION OF TRANSMISSION VALVE ASSEMBLY................................................................................................................................................................................................................................................1061
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE.....................................................................................................................................................................................................................................1062
DISASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................................................................................................................................................................1067
ASSEMBLY OF TRANSFER ASSEMBLY..............................................................................................................................................................................................................................................................1074
REMOVAL OF CENTER SUPPORT ASSEMBLY.........................................................................................................................................................................................................................................................1083
INSTALLATION OF CENTER SUPPORT.............................................................................................................................................................................................................................................................1084
DISASSEMBLY OF CENTER SUPPORT..............................................................................................................................................................................................................................................................1085
ASSEMBLY OF CENTER SUPPORT.................................................................................................................................................................................................................................................................1087
DISASSEMBLY OF DRIVE SHAFT.................................................................................................................................................................................................................................................................1090
ASSEMBLY OF DRIVE SHAFT....................................................................................................................................................................................................................................................................1092
REMOVAL OF FRONT AXLE......................................................................................................................................................................................................................................................................1094
INSTALLATION OF FRONT AXLE ASSEMBLY........................................................................................................................................................................................................................................................1095
REMOVAL OF FRONT DIFFERENTIAL ASSEMBLY (SERIAL NO.: 50001 – 50044).........................................................................................................................................................................................................................1096
INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY (SERIAL NO.: 50001 – 50044)....................................................................................................................................................................................................................1097
REMOVAL OF FRONT DIFFERENTIAL ASSEMBLY (SERIAL NO.: 50045 AND UP)..........................................................................................................................................................................................................................1098
INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY (SERIAL NO.: 50045 AND UP).....................................................................................................................................................................................................................1099
REMOVAL OF REAR AXLE ASSEMBLY..............................................................................................................................................................................................................................................................1100
INSTALLATION OF REAR AXLE ASSEMBLY.........................................................................................................................................................................................................................................................1104
REMOVAL OF REAR DIFFERENTIAL ASSEMBLY......................................................................................................................................................................................................................................................1105
INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY.................................................................................................................................................................................................................................................1106
DISASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................................................................................................................................................................1107
ASSEMBLY OF DIFFERENTIAL ASSEMBLY..........................................................................................................................................................................................................................................................1111
DISASSEMBLY OF FINAL DRIVE.................................................................................................................................................................................................................................................................1120
ASSEMBLY OF FINAL DRIVE....................................................................................................................................................................................................................................................................1124
REMOVAL OF ORBIT ROLL ASSEMBLY.............................................................................................................................................................................................................................................................1130
INSTALLATION OF ORBIT ROLL ASSEMBLY........................................................................................................................................................................................................................................................1130
REMOVAL OF STEERING CYLINDER ASSEMBLY......................................................................................................................................................................................................................................................1131
INSTALLATION OF STEERING CYLINDER ASSEMBLY.................................................................................................................................................................................................................................................1133
REMOVAL OF STEERING DEMAND VALVE ASSEMBLY..................................................................................................................................................................................................................................................1134
INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY.............................................................................................................................................................................................................................................1135
REMOVAL OF BRAKE VALVE ASSEMBIES...........................................................................................................................................................................................................................................................1136
INSTALLATION OF BRAKE VALVE ASSEMBLY.......................................................................................................................................................................................................................................................1136
DISASSEMBLY OF BRAKE VALVE (RIGHT).........................................................................................................................................................................................................................................................1137
ASSEMBLY OF BRAKE VALVE (RIGHT)............................................................................................................................................................................................................................................................1139
DISASSEMBLY OF BRAKE VALVE (LEFT)..........................................................................................................................................................................................................................................................1141
ASSEMBLY OF BRAKE VALVE (LEFT).............................................................................................................................................................................................................................................................1143
REMOVAL OF SLACK ADJUSTER ASSEMBLY.........................................................................................................................................................................................................................................................1145
INSTALLATION OF SLACK ADJUSTER ASSEMBLY....................................................................................................................................................................................................................................................1145
DISASSEMBLY OF SLACK ADJUSTER..............................................................................................................................................................................................................................................................1146
ASSEMBLY OF SLACK ADJUSTER.................................................................................................................................................................................................................................................................1147
REMOVAL OF BRAKE ASSEMBLY..................................................................................................................................................................................................................................................................1148
INSTALLATION OF BRAKE ASSEMBLY.............................................................................................................................................................................................................................................................1149
DISASSEMBLY OF BRAKE ASSEMBLY..............................................................................................................................................................................................................................................................1150
ASSEMBLY OF BRAKE ASSEMBLY.................................................................................................................................................................................................................................................................1154
REMOVAL OF HYDRAULIC PUMP..................................................................................................................................................................................................................................................................1160
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY....................................................................................................................................................................................................................................................1161
DISASSEMBLY OF PISTON PUMP ASSEMBLY........................................................................................................................................................................................................................................................1162
ASSEMBLY OF PISTON PUMP ASSEMBLY...........................................................................................................................................................................................................................................................1168
REMOVAL OF HYDRAULIC TANK ASSEMBLY.........................................................................................................................................................................................................................................................1184
INSTALLATION OF HYDRAULIC TANK.............................................................................................................................................................................................................................................................1185
REMOVAL OF PPC VALVE.......................................................................................................................................................................................................................................................................1186
INSTALLATION OF PPC VALVE..................................................................................................................................................................................................................................................................1187
DISASSEMBLY OF PPC VALVE...................................................................................................................................................................................................................................................................1188
ASSEMBLY OF PPC VALVE......................................................................................................................................................................................................................................................................1188
REMOVAL OF WORK EQUIPMENT VALVE ASSEMBLY...................................................................................................................................................................................................................................................1189
INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY..............................................................................................................................................................................................................................................1190
DISASSEMBLY OF WORK EQUIPMENT CONTROL VALVE................................................................................................................................................................................................................................................1191
ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE...................................................................................................................................................................................................................................................1193
REMOVAL OF DUMP CYLINDER...................................................................................................................................................................................................................................................................1195
INSTALLATION OF DUMP CYLINDER..............................................................................................................................................................................................................................................................1195
REMOVAL OF LIFT CYLINDER...................................................................................................................................................................................................................................................................1196
INSTALLATION OF LIFT CYLINDER..............................................................................................................................................................................................................................................................1197
DISASSEMBLY OF STEERING, LIFT, DUMP CYLINDER...............................................................................................................................................................................................................................................1198
ASSEMBLY STEERING, LIFT, DUMP CYLINDER.....................................................................................................................................................................................................................................................1200
REMOVAL OF CENTER HINGE PIN................................................................................................................................................................................................................................................................1202
INSTALLATION OF CENTER HINGE PIN...........................................................................................................................................................................................................................................................1208
REMOVAL OF WORK EQUIPMENT ASSEMBLY.........................................................................................................................................................................................................................................................1212
INSTALLATION OF WORK EQUIPMENT ASSEMBLY....................................................................................................................................................................................................................................................1215
REMOVAL OF BULKHEAD ASSEMBLY (SERIAL NO.: 50001 – 51000)...................................................................................................................................................................................................................................1217
INSTALLATION OF BULKHEAD ASSEMBLY (SERIAL NO.: 50001 – 51000)..............................................................................................................................................................................................................................1218
REMOVAL OF BULKHEAD ASSEMBLY (SERIAL NO.: 51001 AND UP)....................................................................................................................................................................................................................................1219
INSTALLATION OF BULKHEAD ASSEMBLY (SERIAL NO.: 51001 AND UP)...............................................................................................................................................................................................................................1221
REMOVAL OF FLOOR FRAME ASSEMBLY............................................................................................................................................................................................................................................................1223
INSTALLATION OF FLOOR FRAME ASSEMBLY.......................................................................................................................................................................................................................................................1226
REMOVAL OF COUNTERWEIGHT...................................................................................................................................................................................................................................................................1228
INSTALLATION OF COUNTERWEIGHT..............................................................................................................................................................................................................................................................1228
REMOVAL OF FUEL TANK ASSEMBLY (SERIAL NO.: 50001 – 51000)..................................................................................................................................................................................................................................1229
INSTALLATION OF FUEL TANK ASSEMBLY (SERIAL NO.: 50001 – 51000).............................................................................................................................................................................................................................1230
REMOVAL OF FUEL TANK ASSEMBLY (SERIAL NO.: 51001 AND UP)...................................................................................................................................................................................................................................1231
INSTALLATION OF FUEL TANK ASSEMBLY (SERIAL NO.: 51001 AND UP)..............................................................................................................................................................................................................................1232
REMOVAL OF CAB.............................................................................................................................................................................................................................................................................1233
INSTALLATION OF CAB........................................................................................................................................................................................................................................................................1235
REMOVAL OF STOP VALVE ASSEMBLY.............................................................................................................................................................................................................................................................1236
INSTALLATION OF STOP VALVE ASSEMBLY........................................................................................................................................................................................................................................................1236
REMOVAL OF ACCUMULATOR CHARGE VALVE ASSEMBLY...............................................................................................................................................................................................................................................1237
INSTALLATION OF ACCUMULATOR CHARGE VALVE ASSEMBLY..........................................................................................................................................................................................................................................1237
DISASSEMBLY OF ACCUMULATOR CHARGE VALVE....................................................................................................................................................................................................................................................1238
ASSEMBLY OF ACCUMULATOR CHARGE VALVE.......................................................................................................................................................................................................................................................1239
REMOVAL OF PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH ASSEMBLY.......................................................................................................................................................................................................................1241
INSTALLATION OF PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH ASSEMBLY..................................................................................................................................................................................................................1241
REMOVAL OF DIVERTER VALVE ASSEMBLY.........................................................................................................................................................................................................................................................1242
INSTALLATION OF DIVERTER VALVE ASSEMBLY....................................................................................................................................................................................................................................................1242
DISASSEMBLY OF DIVERTER VALVE..............................................................................................................................................................................................................................................................1243
ASSEMBLY OF DIVERTER VALVE.................................................................................................................................................................................................................................................................1244
REMOVAL OF EMERGENCY STEERING PUMP ASSEMBLY................................................................................................................................................................................................................................................1246
INSTALLATION OF EMERGENCY STEERING PUMP ASSEMBLY...........................................................................................................................................................................................................................................1246
REMOVAL OF PARKING BRAKE ASSEMBLY..........................................................................................................................................................................................................................................................1247
INSTALLATION OF PARKING BRAKE ASSEMBLY.....................................................................................................................................................................................................................................................1248
DISASSEMBLY OF PARKING BRAKE CALIPERS......................................................................................................................................................................................................................................................1250
ASSEMBLY OF PARKING BRAKE CALIPERS.........................................................................................................................................................................................................................................................1252
REMOVAL OF PARKING BRAKE PAD (SERIAL NO.: 50001 – 50044)...................................................................................................................................................................................................................................1254
INSTALLATION PARKING BRAKE PAD (SERIAL NO.: 50001 – 50044).................................................................................................................................................................................................................................1254
REMOVAL OF PARKING BRAKE PAD (SERIAL NO.: 50045 AND UP)....................................................................................................................................................................................................................................1255
INSTALLATION PARKING BRAKE PAD (SERIAL NO.: 50045 AND UP)..................................................................................................................................................................................................................................1256
REMOVAL OF REAR TIRE ASSEMBLY..............................................................................................................................................................................................................................................................1257
INSTALLATION OF REAR TIRE ASSEMBLY.........................................................................................................................................................................................................................................................1257
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................................1258
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY (SERIAL NO.: 50001 – 51000)............................................................................................................................................................................................................1259
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................1260
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY (SERIAL NO.: 51001 AND UP).............................................................................................................................................................................................................1260
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLIES............................................................................................................................................................................................................................................1261
INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY.........................................................................................................................................................................................................................................1262
REMOVAL OF RECEIVER TANK ASSEMBLY..........................................................................................................................................................................................................................................................1264
INSTALLATION OF RECEIVER TANK ASSEMBLY.....................................................................................................................................................................................................................................................1264
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY...................................................................................................................................................................................................................................................1265
INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY..............................................................................................................................................................................................................................................1266
REMOVAL OF MAIN MONITOR....................................................................................................................................................................................................................................................................1267
INSTALLATION OF MAIN MONITOR...............................................................................................................................................................................................................................................................1268
REMOVAL OF MAINTENANCE MONITOR ASSEMBLY....................................................................................................................................................................................................................................................1269
INSTALLATION OF MAINTENANCE MONITOR ASSEMBLY...............................................................................................................................................................................................................................................1269
REMOVAL OF ENGINE, APS CONTROLLER ASSEMBLY.................................................................................................................................................................................................................................................1270
INSTALLATION OF ENGINE, APS CONTROLLER ASSEMBLY............................................................................................................................................................................................................................................1270
REMOVAL OF AJSS LEVER SWITCH ASSEMBLY......................................................................................................................................................................................................................................................1271
INSTALLATION OF AJSS LEVER SWITCH ASSEMBLY.................................................................................................................................................................................................................................................1274
40 MAINTENANCE STANDARD........................................................................................................................................................................................................................................................................1279
ENGINE AND TANSMISSION MOUNT...............................................................................................................................................................................................................................................................1281
DAMPER.....................................................................................................................................................................................................................................................................................1282
TORQUE CONVERTER AND PTO...................................................................................................................................................................................................................................................................1284
TORQUE CONVERTER REGULATOR VALVE...........................................................................................................................................................................................................................................................1285
TRANSMISSION...............................................................................................................................................................................................................................................................................1286
TRANSMISSION CONTROL VALVE.................................................................................................................................................................................................................................................................1290
TRANSFER...................................................................................................................................................................................................................................................................................1296
DRIVE SHAFT................................................................................................................................................................................................................................................................................1298
CENTER SUPPORT.............................................................................................................................................................................................................................................................................1299
DIFFERENTIAL...............................................................................................................................................................................................................................................................................1300
FINAL DRIVE................................................................................................................................................................................................................................................................................1302
AXLE MOUNT.................................................................................................................................................................................................................................................................................1304
CENTER HINGE PIN...........................................................................................................................................................................................................................................................................1306
STEERING COLUMN............................................................................................................................................................................................................................................................................1308
STEERING DEMAND VALVE......................................................................................................................................................................................................................................................................1310
DIVERTER VALVE.............................................................................................................................................................................................................................................................................1312
STEERING CYLINDER MOUNT....................................................................................................................................................................................................................................................................1313
EMERGENCY STEERING PUMP....................................................................................................................................................................................................................................................................1314
BRAKE VALVE................................................................................................................................................................................................................................................................................1316
SLACK ADJUSTER.............................................................................................................................................................................................................................................................................1323
BRAKE......................................................................................................................................................................................................................................................................................1324
PARKING BRAKE..............................................................................................................................................................................................................................................................................1328
CONTROL PUMP...............................................................................................................................................................................................................................................................................1329
STEERING AND SWITCH PUMP...................................................................................................................................................................................................................................................................1330
MAIN PISTON PUMP...........................................................................................................................................................................................................................................................................1331
MAIN CONTROL VALVE.........................................................................................................................................................................................................................................................................1332
PPC VALVE..................................................................................................................................................................................................................................................................................1336
PPC RELIEF VALVE...........................................................................................................................................................................................................................................................................1338
HYDRAULIC CYLINDER.........................................................................................................................................................................................................................................................................1339
WORK EQUIPMENT LINKAGE.....................................................................................................................................................................................................................................................................1340
BUCKET.....................................................................................................................................................................................................................................................................................1342
BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................................................................................................................................................................................1343
90 OTHERS......................................................................................................................................................................................................................................................................................1345
ELECTRIC CIRCUIT DIAGRAM (1/5) (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................................................1347
ELECTRIC CIRCUIT DIAGRAM (2/5) (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................................................1349
ELECTRIC CIRCUIT DIAGRAM (3/5) (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................................................1351
ELECTRIC CIRCUIT DIAGRAM (4/5) (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................................................1353
ELECTRIC CIRCUIT DIAGRAM (5/5) (SERIAL NO.: 50001 – 51000).................................................................................................................................................................................................................................1355
ELECTRIC CIRCUIT DIAGRAM (1/6) (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................................1357
ELECTRIC CIRCUIT DIAGRAM (2/6) (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................................1359
ELECTRIC CIRCUIT DIAGRAM (3/6) (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................................1361
ELECTRIC CIRCUIT DIAGRAM (4/6) (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................................1363
ELECTRIC CIRCUIT DIAGRAM (5/6) (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................................1365
ELECTRIC CIRCUIT DIAGRAM (6/6) (SERIAL NO.: 51001 AND UP)..................................................................................................................................................................................................................................1367
ELECTRIC CIRCUIT DIAGRAM (1/3) (WITH AUTO SHIFT AND JOYSTICK STEERING) (SERIAL NO.: 50001 – 51000).........................................................................................................................................................................................1369
ELECTRIC CIRCUIT DIAGRAM (2/3) (WITH AUTO SHIFT AND JOYSTICK STEERING) (SERIAL NO.: 50001 – 51000).........................................................................................................................................................................................1371
ELECTRIC CIRCUIT DIAGRAM (3/3) (WITH AUTO SHIFT AND JOYSTICK STEERING) (SERIAL NO.: 50001 – 51000).........................................................................................................................................................................................1373
ELECTRIC CIRCUIT DIAGRAM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION) (1/3) (SERIAL NO.: 51001 AND UP).........................................................................................................................................................................1375
ELECTRIC CIRCUIT DIAGRAM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION) (2/3) (SERIAL NO.: 51001 AND UP).........................................................................................................................................................................1377
ELECTRIC CIRCUIT DIAGRAM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION) (3/3) (SERIAL NO.: 51001 AND UP).........................................................................................................................................................................1379
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING SPECIFICATION).....................................................................................................................................................................................................................................1381DESCRIPTION:
KOMATSU AVANCE LOADER WA700-3 SHOP MANUAL SEBM013316 – PDF DOWNLOAD
General
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 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.
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.
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”.
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.
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 24/12/24
