Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL (SN:A50001 & UP) – PDF DOWNLOAD
Original price was: $73.95.$27.95Current price is: $27.95.
- KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A50001 & UP
- PUBLICATION NUMBER:CEBM004402
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL (SN:A50001 & UP)
KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL (SN:A50001 & UP) – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL (SN:A50001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL (SN:A50001 & UP)
MAIN MENU............................................................................................................... 0 COVER................................................................................................................... 1 CONTENTS................................................................................................................ 2 01 GENERAL.............................................................................................................. 31 GENERAL ASSEMBLY DRAWING............................................................................................ 32 SPECIFICATIONS...................................................................................................... 33 WEIGHT TABLE........................................................................................................ 36 LIST OF LUBRICANT AND WATER......................................................................................... 38 REMARKS............................................................................................................. 39 10 STRUCTURE AND FUNCTION............................................................................................... 41 POWER TRAIN SYSTEM.................................................................................................. 44 DAMPER.............................................................................................................. 46 OPERATION....................................................................................................... 46 TORQUE CONVERTER AND TRANSMISSION................................................................................... 48 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM........................................................................... 48 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM.......................................................................... 50 TORQUE CONVERTER AND TRANSMISSION PIPING........................................................................ 51 TORQUE CONVERTER AND PTO........................................................................................ 52 TRANSMISSION.................................................................................................... 55 OPERATION OF CLUTCH......................................................................................... 58 FORWARD 1ST................................................................................................. 59 FORWARD 2ND................................................................................................. 60 FORWARD 3RD................................................................................................. 61 FORWARD 4TH................................................................................................. 62 REVERSE 1ST................................................................................................. 63 TRANSMISSION CONTROL VALVE...................................................................................... 64 TRANSMISSION SOLENOID VALVE................................................................................. 65 UPPER VALVE................................................................................................. 66 MAIN RELIEF VALVE........................................................................................... 66 LOWER VALVE................................................................................................. 67 MAIN RELIEF VALVE........................................................................................... 68 PILOT REDUCING VALVE........................................................................................ 69 TRANSMISSION SOLENOID VALVE................................................................................. 70 PRIORITY VALVE.............................................................................................. 71 MODULATING VALVE AND QUICK RETURN VALVE..................................................................... 72 REDUCING VALVE.............................................................................................. 75 QUICK FILL VALVE (FOR 2ND CLUTCH)........................................................................... 76 TORQUE CONVERTER RELIEF VALVE............................................................................... 77 LUBRICATING RELIEF VALVE.................................................................................... 78 EMERGENCY MANUAL SPOOL...................................................................................... 79 LUBRICATION BYPASS VALVE.................................................................................... 80 HYDRAULIC CIRCUIT SCHEMATIC..................................................................................... 82 FORWARD 1ST................................................................................................. 82 TRANSFER............................................................................................................ 84 AXLE................................................................................................................ 85 FRONT AXLE...................................................................................................... 85 REAR AXLE....................................................................................................... 86 DIFFERENTIAL........................................................................................................ 87 FRONT DIFFERENTIAL.............................................................................................. 87 REAR DIFFERENTIAL............................................................................................... 88 FINAL DRIVE......................................................................................................... 89 STEERING............................................................................................................ 91 STEERING PIPING DIAGRAM......................................................................................... 91 STEERING AND SWITCH PUMP........................................................................................ 92 STEERING UNIT (ORBIT-ROLL VALVE)................................................................................ 94 STEERING DEMAND VALVE........................................................................................... 97 OVERLOAD RELIEF VALVE....................................................................................... 98 MAIN RELIEF VALVE........................................................................................... 100 OPERATION OF DEMAND VALVE................................................................................... 102 WHEN STEERING SPOOL IS OPERATED............................................................................. 103 OPERATION OF STEERING VALVE................................................................................. 105 TWO-WAY RESTRICTOR.................................................................................................. 108 STOP VALVE.......................................................................................................... 109 DIVERTER VALVE...................................................................................................... 110 GROUND DRIVEN STEERING RELIEF VALVE............................................................................. 113 BRAKE............................................................................................................... 114 BRAKE PIPING.................................................................................................... 114 BRAKE CIRCUIT DIAGRAM........................................................................................... 115 BRAKE VALVE..................................................................................................... 116 BRAKE VALVE (RIGHT)......................................................................................... 116 BRAKE VALVE (LEFT).......................................................................................... 117 CHARGE VALVE.................................................................................................... 122 ACCUMULATOR (FOR BRAKE)......................................................................................... 126 SLACK ADJUSTER.................................................................................................. 127 BRAKE........................................................................................................... 129 PARKING BRAKE....................................................................................................... 131 PARKING BRAKE CALIPER........................................................................................... 132 SPRING CYLINDER................................................................................................. 133 PARKING BRAKE SOLENOID VALVE.................................................................................... 134 HYDRAULIC........................................................................................................... 136 HYDRAULIC PIPING................................................................................................ 136 HYDRAULIC CIRCUIT DIAGRAM....................................................................................... 138 MAIN PISTON PUMP................................................................................................ 141 PISTON PUMP (HPV90 + HPF90)................................................................................. 142 CONTROL PUMP (BAR025)....................................................................................... 147 CONTROL PUMP RELIEF VALVE................................................................................... 148 ES VALVE (ENGINE SENSING VALVE)................................................................................. 149 SERVO VALVE..................................................................................................... 150 PRESSURE DIFFERENTIAL VALVE..................................................................................... 151 PPC VALVE (PROPORTIONAL PRESSURE VALVE)......................................................................... 152 PPC RELIEF VALVE................................................................................................ 156 ACCUMULATOR (FOR PPC VALVE)..................................................................................... 157 MAIN CONTROL VALVE.............................................................................................. 158 WORK EQUIPMENT...................................................................................................... 160 WORK EQUIPMENT LUBRICATION...................................................................................... 160 WORK EQUIPMENT LINKAGE.......................................................................................... 162 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................. 164 BUCKET POSITIONER........................................................................................... 165 BOOM KICK-OUT............................................................................................... 165 PROXIMITY SWITCH - OPERATION.................................................................................... 166 BOOM RAISE.................................................................................................. 166 BUCKET TILT................................................................................................. 168 AIR CONDITIONER..................................................................................................... 170 AIR CONDITIONER PIPING.......................................................................................... 170 AIR CONDITIONER CONDENSER....................................................................................... 171 AIR CONDITIONER COMPRESSOR...................................................................................... 172 DRY RESERVOIR................................................................................................... 173 MAIN MONITOR SYSTEM................................................................................................. 174 MAIN MONITOR.................................................................................................... 175 MAIN MONITOR DISPLAY FUNCTION TABLE............................................................................. 176 MAIN MONITOR SWITCH FUNCTION.................................................................................... 178 TROUBLE DATA DISPLAY MODE....................................................................................... 179 MAINTENANCE MONITOR................................................................................................. 180 MAINTENANCE MONITOR DISPLAY FUNCTION TABLE...................................................................... 181 AUTOMATIC TRANSMISSION SYSTEM (ATM)................................................................................. 183 SYSTEM STRUCTURE DIAGRAM........................................................................................ 184 JOYSTICK............................................................................................................ 197 JOYSTICK TRANSMISSION SYSTEM.................................................................................... 197 TRANSMISSION AND JOYSTICK CONTROLLER............................................................................ 198 ELECTRICAL.......................................................................................................... 201 ENGINE STARTING CIRCUIT......................................................................................... 201 ENGINE STOP CIRCUIT............................................................................................. 203 AUTO PRIMING SYSTEM (APS)....................................................................................... 204 APS CONTROLLER.............................................................................................. 205 APS ASSISTER................................................................................................ 205 ELECTRICAL TRANSMISSION CONTROL................................................................................. 208 COMBINATION SWITCH.......................................................................................... 210 KICK-DOWN, HOLD SWITCH...................................................................................... 212 KICK-DOWN ELECTRICAL CIRCUIT................................................................................ 213 PARKING BRAKE SWITCH........................................................................................ 220 PARKING BRAKE VALVE......................................................................................... 221 PARKING SAFETY RELAY........................................................................................ 221 NEUTRALIZER RELAY........................................................................................... 221 EMERGENCY BRAKE SWITCH...................................................................................... 221 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (1 0F 6)............................................................. 229 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (2 OF 6)............................................................. 231 ELECTRICALCIRCUIT DIAGRAM FOLDOUT (3 OF 6).............................................................. 233 ELECTRICAL CIRUIT DIAGRAM FOLDOUT (4 OF 6).............................................................. 235 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (5 OF 6)............................................................. 237 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (6 OF 6)............................................................. 239 ELECTRICAL CIRCUIT DIAGRAM (2) (1 OF 4)............................................................. 241 ELECTRICAL CIRCUIT DIAGRAM (2) (2 OF 4)............................................................. 243 ELECTRICAL CIRCUIT DIAGRAM (2) (3 OF 4)............................................................. 245 ELECTRICAL CIRCUIT DIAGRAM (2) (4 OF 4)............................................................. 247 20 TESTING, ADJUSTING AND TROUBLESHOOTING............................................................................... 249 STANDARD VALUE TABLE................................................................................................ 252 ENGINE TABLE - IN CHASSIS....................................................................................... 252 CHASSIS TABLE................................................................................................... 253 STANDARD VALUE TABLE FOR ELECTRICAL PARTS....................................................................... 258 SERVICE TOOLS....................................................................................................... 266 ENGINE.............................................................................................................. 268 ADJUSTING ENGINE STOP MOTOR CABLE............................................................................... 268 ADJUSTING ENGINE STOP SOLENOID.................................................................................. 268 MEASURING AND ADJUSTING VALVE CLEARANCE......................................................................... 268 MEASURING BLOW-BY PRESSURE...................................................................................... 268 MEASURING COMPRESSION PRESSURE.................................................................................. 268 MEASURING COOLANT TEMPERATURE................................................................................... 268 MEASURING ENGINE LUBRICATING OIL PRESSURE....................................................................... 268 MEASURING ENGINE SPEEDS......................................................................................... 268 MEASURING EXHAUST COLOR......................................................................................... 268 MEASURING EXHAUST GAS TEMPERATURE............................................................................... 268 MEASURING FUEL FILTER INLET RESTRICTION......................................................................... 268 TEST AND ADJUSTING FAN BELT TENSION............................................................................. 268 TEST AND ADJUSTING FUEL INJECTION TIMING........................................................................ 268 ACCELERATOR PEDAL................................................................................................... 269 OPERATING FORCE................................................................................................. 269 ADJUSTING PEDAL TRAVEL, POTENTIOMETER........................................................................... 270 ADJUSTING PEDAL MICRO SWITCH.................................................................................... 272 TORQUE CONVERTER & TRANSMISSION PRESSURE............................................................................ 273 EMERGENCY MANUAL SPOOL.............................................................................................. 276 OPERATION....................................................................................................... 276 STEERING............................................................................................................ 278 STEERING OIL PRESSURE........................................................................................... 278 MEASURING................................................................................................... 278 ADJUSTING................................................................................................... 278 STEERING STOPPER BOLT........................................................................................... 279 ADJUSTING................................................................................................... 279 JOYSTICK STEERING............................................................................................... 280 ADJUSTING................................................................................................... 280 JOYSTICK LEVER NEUTRAL DETECTION SWITCH......................................................................... 281 ADJUSTING................................................................................................... 281 BRAKE............................................................................................................... 282 BRAKE OIL PRESSURE.............................................................................................. 282 TESTING..................................................................................................... 282 BRAKE DISC...................................................................................................... 283 MEASURING WEAR.............................................................................................. 283 BRAKE PERFORMANCE............................................................................................... 284 MEASURING................................................................................................... 284 PARKING BRAKE....................................................................................................... 285 TESTING......................................................................................................... 285 MEASURING PAD............................................................................................... 285 MEASURING CLEARANCE......................................................................................... 285 ADJUSTING....................................................................................................... 286 ACCUMULATOR CHARGE PRESSURE......................................................................................... 287 TESTING......................................................................................................... 287 ADJUSTING....................................................................................................... 287 WORK EQUIPMENT...................................................................................................... 288 PPC RELIEF VALVE................................................................................................ 288 MEASURING HYDRUALIC PRESSURE................................................................................ 288 ADJUSTING HYDRAULIC PRESSURE................................................................................ 289 HYDRAULIC PRESSURE.............................................................................................. 290 TESTING..................................................................................................... 290 ADJUSTING................................................................................................... 291 PISTON PUMP..................................................................................................... 292 BLEEDING AIR................................................................................................ 292 LEVER LINKAGE................................................................................................... 293 ADJUSTING................................................................................................... 293 BUCKET POSITIONER............................................................................................... 295 TESTING..................................................................................................... 295 ADJUSTING................................................................................................... 295 BOOM KICK-OUT................................................................................................... 296 TESTING..................................................................................................... 296 ADJUSTING................................................................................................... 296 PROXIMITY SWITCH ACTUATION PILOT LAMP........................................................................... 297 LAMP (RED).................................................................................................. 297 MAIN MONITOR (SPEEDOMETER MODULE)................................................................................... 298 ADJUSTMENT PROCEDURE............................................................................................ 298 BLEEDING AIR........................................................................................................ 299 BLEEDING AIR FROM BRAKE SYSTEM.................................................................................. 299 BLEEDING AIR FROM HYDRAULIC CYLINDERS........................................................................... 299 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................... 300 BLEEDING AIR FROM HYDRAULIC TANK................................................................................ 300 BLEEDING AIR FROM THE PISTON PUMP............................................................................... 301 BLEEDING AIR FROM THE HYDRAULIC CIRCUIT......................................................................... 302 TROUBLESHOOTING GENERAL............................................................................................. 303 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................1026 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................... 0 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....................................................................... 49 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT................................................................ 49 HANDLING CONTROL BOX........................................................................................ 0 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT........................................................ 22 CHECKS BEFORE TROUBLESHOOTING................................................................................... 317 JUDGEMENT OF POWER TRAIN........................................................................................ 54 PRECAUTIONS WHEN TROUBLESHOOTING................................................................................ 24 SAFETY...................................................................................................... 0 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING............. 24 PREVENTING RECURRENCE OF TROUBLE................................................................................ 0 HYDRAULIC EQUIPMENT......................................................................................... 24 OIL CHECKS.............................................................................................. 320 CLEANING FRAGMENTS OF DAMAGED PARTS..................................................................... 25 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................... 25 CATEGORY OF TROUBLESHOOTING CODE NUMBER..................................................................... 25 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE......................................... 25 METHOD OF USING MATRIX TROUBLESHOOTING TABLES................................................................... 26 METHOD OF USING ENGINE RELATED CHARTS........................................................................... 325 TROUBLESHOOTING ELECTRICAL CONNECTORS............................................................................... 331 CONNECTOR TYPES................................................................................................. 333 CONNECTOR PIN ARRANGEMENT....................................................................................... 30 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................... 30 ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM.................................................................... 113 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE............................................................... 349 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ACTION.......................................................... 351 TRANSMISSION CONTROLLER LED DISPLAY............................................................................. 229 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................... 355 E-1 ENGINE DOES NOT START....................................................................................... 24 A. STARTING MOTOR DOES NOT TURN............................................................................. 358 B. STARTING MOTOR TURNS..................................................................................... 364 E-2 ABNORMALITY IN APS SYSTEM................................................................................... 367 A. WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOT LIGHT UP, BUT NO PILOT LED ON ........... 369 B. WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 2O° C, PREHEATING ........... 370 C. AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START, B........... 371 D. LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...................................................... 372 E. LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...................................................... 372 F. LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...................................................... 373 G. LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...................................................... 373 H. LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...................................................... 374 I. LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...................................................... 374 J. WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP................................................. 375 E-3 PARKING BRAKE DOES NOT HAVE EFFECT.......................................................................... 376 A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON....................................... 376 B. PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE D........... 376 E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.......................................................... 378 E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON................................................. 380 E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORK............... 380 E-7 TRANSMISSION DOES NOT WORK PROPERLY......................................................................... 382 A. ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY........... 384 B. NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT......................................................... 388 C. NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT......................................................... 390 D. SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT.......................................... 392 E. ABNORMALITY IN SHIFT SOLENOID CIRCUIT.................................................................... 398 F. SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT................................................ 401 E-8 KICK-DOWN SWITCH DOES NOT WORK.............................................................................. 406 E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON............................................... 409 E-10 KICK-DOWN ALWAYS WORKS..................................................................................... 410 E-11 KICK-DOWN SWICTH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND.................................................. 412 E-12 BOOM KICK-OUT DOES NOT WORK................................................................................ 414 E-13 DEFECTIVE BUCKET POSITIONER................................................................................ 416 E-14 POWER WINDOW DOES NOT WORK................................................................................. 418 A. WINDOW DOES NOT GO UP.................................................................................... 418 B. WINDOW DOES NOT GO DOWN.................................................................................. 419 E-15 ABNORMALITY IN FRONT WORKING LAMP.......................................................................... 421 E-16 ABNORMALITY IN REAR WORKING LAMP........................................................................... 421 E-17 ABNORMALITY IN TRANSMISSION CUT-OFF........................................................................ 421 E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.............................................................. 421 E-19 ABNORMALITY IN BUZZER...................................................................................... 421 TROUBLESHOOTING OF ELECTRIC ENGINE THROTTLE & APS CONTROLLERS (G MODE).............................................. 423 JUDGEMENT TABLE................................................................................................. 27 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS..................................... 427 ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS................................. 433 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................... 154 JUDGEMENT TABLE FOR ENGINE CONTROLLER........................................................................... 436 G-1 [90] [OFF or 101] ABNORMALITY IN POWER SOURCE SYSTEM........................................................ 437 G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM.................................................................. 437 G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR.................................................................. 438 G-4 G-4 [90] [56] ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM........................................ 438 G-5 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM........................................................ 439 G-6 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM......................................................... 440 G-7 [91] [14] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM........................................................... 441 G-8 [91] [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM.......................................................... 442 G-9 [91] [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM.............................................................. 443 G-10 [91] [1d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM........................................................ 444 G-11 [92] [12] ABNORMALITY IN RACK SENSOR SYSTEM................................................................ 445 G-12 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM................................................... 446 G-13 [93] [1b] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM...................................................... 447 G-14 [94] [1c] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM...................................................... 448 G-15 [93, 94] [1b, 1c] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM........................................... 449 G-16 [95] [40] ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM................................................... 449 G-17 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM......................................................... 450 G-18 [99] [22] ENGINE OVERRUN................................................................................... 452 G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY)............................................................ 452 G-20 ENGINE DOES NOT START...................................................................................... 454 G-21 ENGINE DOES NOT STOP....................................................................................... 457 G-22 DEFECTIVE ACTUATION OF APS................................................................................. 458 A. PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE AL........... 458 B. 1. PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20 C WHEN APS SWITCH IS ON (C........... 460 B. 2. PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20 C WHEN APS SWITCH IS ON ........... 460 C. NOZZLE DOES NOT INJECT FUEL WHEN STARTING SWITCH IS TURNED TO START AFTER COMPLETION OF PREHEA........... 460 D. APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY........................ 20 E. APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY........................ 20 F. APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY........................ 462 G. APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY........................ 462 H. APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) GIVES ABNORMAL DISPLAY........................ 463 I. APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY.................................... 20 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)........................................................ 465 POWER TRAIN..................................................................................................... 467 H-1 MACHINE DOES NOT START.................................................................................. 467 H-2 MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES).......................................... 468 H-3 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR.................................................... 469 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH................................................................ 470 STEERING........................................................................................................ 471 H-5 STEERING DOES NOT TURN.................................................................................. 471 H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK].......................................................... 472 H-7 TURNING, RESPONSE OF STEERING IS POOR................................................................... 473 H-8 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]........................................... 474 H-9 STEERING IS HEAVY....................................................................................... 476 H-10 STEERING WHEEL SHAKES OR JERKS......................................................................... 477 H-11 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK].................................... 478 H-12 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING................................. 478 BRAKES.......................................................................................................... 479 H-13 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR..................................................... 479 H-14 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG........................................................... 481 H-15 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR.................................................. 482 H-16 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS........................................................... 483 WORK EQUIPMENT.................................................................................................. 484 H-17 NEITHER BOOM NOR BUCKET MOVE........................................................................... 484 H-18 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER............................................................ 485 H-19 BOOM DOES NOT MOVE..................................................................................... 486 H-20 BOOM IS SLOW OR BOOM LACKS POWER....................................................................... 487 H-21 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT........................................... 488 H-22 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE............................... 488 H-23 EXCESSIVE HYDRAULIC DRIFT OF BOOM...................................................................... 489 H-24 BUCKET DOES NOT MOVE................................................................................... 490 H-25 BUCKET IS SLOW OR LACKS POWER.......................................................................... 491 H-26 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.................................................................... 492 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)..................................................... 493 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS.................................................... 495 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...................................... 496 ELECTRICAL CIRCUIT DIAGRAM...................................................................................... 500 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED....................... 501 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED............ 502 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED............. 503 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED......................... 504 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED.......................... 505 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DIS............... 506 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPL............... 507 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYST............... 508 J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE........................................................................ 509 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM...................................................... 510 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID................................................................... 511 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.................................................................... 512 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).............................................................. 513 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC............... 515 A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP................................................................. 515 B. SOME LAMPS DO NOT LIGHT UP............................................................................... 515 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OU............... 516 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO ............... 517 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH....................................... 518 A. ENGINE OIL LEVEL DISPLAY FLASHES......................................................................... 518 B. ENGINE WATER LEVEL DISPLAY FLASHES....................................................................... 519 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH..................................... 520 A. ENGINE OIL PRESSURE DISPLAY FLASHES...................................................................... 520 B. BATTERY CHARGE LEVEL DISPLAY FLASHES..................................................................... 521 C. BRAKE OIL PRESSURE DISPLAY FLASHES....................................................................... 522 D. AIR CLEANER (L.H.) DISPLAY FLASHES....................................................................... 523 E. AIR CLEANER (R.H.) DISPLAY FLASHES....................................................................... 524 K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND................................................ 525 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS........................................ 526 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH....................... 527 A. CHECK LAMP............................................................................................... 527 B. CAUTION LAMP............................................................................................. 527 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION ............... 528 A. CHECK LAMP............................................................................................... 528 B. CAUTION LAMP............................................................................................. 528 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE............... 529 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP..................... 530 K-12 SERVICE METER DOES NOT WORK................................................................................ 531 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED....................................................... 531 K-14 ABNORMALITY IN GAUGE ITEMS................................................................................. 533 A. ABNORMALITY IN FUEL GAUGE................................................................................ 533 B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE............................................................ 534 C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.................................................... 535 TROUBLESHOOTING OF MAIN MONITOR (M MODE)............................................................................ 537 M-1 MAIN MONITOR DOES NOT WORK.................................................................................. 539 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.............. 540 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.................................................................. 541 M-4 ABNORMALITY IN SHIFT INDICATOR.............................................................................. 542 A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F........................................................... 542 B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R........................................................... 542 C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER ........... 542 D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER ........... 543 E. DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R)......................... 543 F. DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R)......................... 543 G. DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R)......................... 544 H. DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R)......................... 544 M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP....................................................................... 546 A. L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................... 546 B. R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................... 546 M-6 ABNORMALITY IN PARKING DISPLAY.............................................................................. 547 A. PARKING LAMP DISPLAY DOES NOT LIGHT UP................................................................... 547 B. PARKING LAMP DISPLAY STAYS LIGHTED UP.................................................................... 547 M-7 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................ 548 M-8 ABNORMALITY IN FRONT WORKING LAMP........................................................................... 549 A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP.................................................. 549 B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP............................................. 549 C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP............................................. 549 M-9 ABNORMALITY IN REAR WORKING LAMP............................................................................ 551 A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP................................................... 551 B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP............................................. 551 C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP............................................. 551 M-10 ABNORMALITY IN TRANSMISSION CUT-OFF........................................................................ 553 STANDARD SPECIFICATION...................................................................................... 553 A. WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES....... 553 B. WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED.................. 553 C. TRANSMISSION CUT-OFF SWITCH TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED.......................... 554 AUTO-SHIFT SPECIFICATION.................................................................................... 555 A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED....... 555 B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF....... 555 C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION ....... 555 D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH....... 555 E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT....... 556 M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.............................................................. 557 A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WH........... 557 B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W........... 557 M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU............... 559 A. ACTUATED CONTINUOUSLY.................................................................................... 559 B. NOT ACTUATED............................................................................................. 559 M-13 ABNORMALITY IN BUZZER...................................................................................... 560 A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK).................. 560 B. BUZZER ALWAYS SOUNDS..................................................................................... 560 M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...................................................... 561 M-15 ABNORMALITY IN FAILURE DISPLAY MODE........................................................................ 562 A. DOES NOT ENTER FAILURE DISPLAY MODE...................................................................... 562 B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE............................ 562 M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY........................................... 563 A. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED...................................... 563 B. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED...................................... 563 C. PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED...................................... 563 D. PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED...................................... 564 M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY........................................................ 565 A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP................................................... 565 B. EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP.................................................... 565 M-18 ABNORMALITY IN AUTO-GREASING SYSTEM........................................................................ 566 A. FORCED GREASING CANNOT BE CARRIED OUT.................................................................... 566 B. MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SET)............................................................ 566 C. WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)............................... 566 D. MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC).............................................................. 567 E. MONITOR DISPLAY GOES OUT................................................................................. 567 M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM.................................................................... 568 A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED........................................................... 568 B. MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK................................... 568 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)........................................................................... 569 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................... 571 S-2 ENGINE DOES NOT START....................................................................................... 576 A. ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................................. 576 B. EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)............................... 578 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)........................................................ 579 S-4 ENGINE STOPS DURING OPERATIONS.............................................................................. 580 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................... 582 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)........................................................................ 583 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).............................................................. 584 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..................................................... 585 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................ 586 S-10 FUEL CONSUMPTION IS EXCESSIVE.............................................................................. 587 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.................................... 588 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................. 589 S-13 OIL LEVEL RISES............................................................................................ 590 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)........................................................... 591 S-15 ABNORMAL NOISE IS MADE..................................................................................... 592 S-16 VIBRATION IS EXCESSIVE..................................................................................... 594 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE).......................................................... 595 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS................................................ 596 CONTROLLER ACTIONS DURING ABNORMALITY........................................................................... 598 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LA............... 604 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI............... 605 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI............... 606 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN............... 607 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLEN............... 608 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN............... 609 T-7 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN............... 610 T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS............... 612 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.................. 614 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED....................... 616 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED............................... 618 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED................ 619 A. TRANSMISSION CONTROLLER SYSTEM........................................................................... 619 B. ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM............................................................... 619 T-13 HOLD SWITCH SYSTEM......................................................................................... 622 T-14 KICK-DOWN SWITCH SYSTEM.................................................................................... 622 T-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM......................................................................... 623 T-16 NEUTRALIZER RELAY SIGNAL SYSTEM............................................................................ 624 T-17 BUZZER SIGNAL SYSTEM....................................................................................... 625 T-18 NETWORK SYSTEM............................................................................................. 626 T-19 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM................................................................ 627 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM................................................................ 628 TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER.............................................................. 629 SERVICE TOOLS................................................................................................... 25 GAUGE MANIFOLD.............................................................................................. 961 STRUCTURE AND HANDLING OF GAUGE MANIFOLD................................................................ 632 CHARGING HOSES.......................................................................................... 63 GAS LEAK DETECTOR........................................................................................... 635 HALIDE TORCH LEAK DETECTOR.............................................................................. 26 ELECTRIC LEAK TESTER.................................................................................... 68 VALVE FOR SERVICE CANS...................................................................................... 639 MAINTENANCE PROCEDURE........................................................................................... 640 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING.............................................................. 79 PROHIBITED WORK......................................................................................... 79 OTHER PRECAUTIONS....................................................................................... 640 BLEEDING AIR FROM REFRIGERATION CIRCUIT..................................................................... 91 PURPOSE................................................................................................. 91 CONNECTING GAUGE MANIFOLD............................................................................... 98 EVACUATION.............................................................................................. 963 AIR-TIGHTNESS CHECK..................................................................................... 29 GAS-LEAK CHECK.......................................................................................... 29 EVACUATION (REPEATING).................................................................................. 29 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT......................................................... 29 CHARGING FROM THE HIGH-PRESSURE SIDE.................................................................... 92 CHARGING FROM THE LOW PRESSURE SIDE..................................................................... 646 WHEN THE AMBIENT TEMPERATURE IS LOW..................................................................... 647 WHEN THE AMBIENT TEMPERATURE IS HIGH.................................................................... 29 REPLACING SERVICE CANS...................................................................................... 30 CHECKING THE AMOUNT OF REFRIGERANT.......................................................................... 30 REMOVAL OF GAUGE MANIFOLD................................................................................... 30 DISCHARGING THE REFRIGERANT................................................................................. 650 DAILY CHECKS................................................................................................ 30 CHECK REFRIGERANT LEVEL................................................................................. 651 CLEANING THE CONDENSER.................................................................................. 651 CHECKING THE V-BELT......................................................................................... 651 CHECKING OIL LEVEL.......................................................................................... 652 PROCEDURE FOR CHECKING.................................................................................. 30 PROCEDURE FOR CHECKING OIL LEVEL........................................................................ 30 ADDING AND REMOVING OIL................................................................................. 653 ADDING OIL BY EVACUATION................................................................................ 30 TROUBLESHOOTING................................................................................................. 121 VISUAL AND ACOUSTICAL CHECKS................................................................................ 123 DEFECTIVE COOLING........................................................................................... 0 TROUBLESHOOTING TABLE....................................................................................... 25 DEFECTIVE HEATING........................................................................................... 25 TROUBLESHOOTING USING GAUGE MANIFOLD........................................................................ 660 PREPARATIONS BEFORE MEASURING........................................................................... 199 INSUFFICIENT REFRIGERANT................................................................................ 199 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER.............................................. 661 AIR INSIDE REFRIGERATION SYSTEM......................................................................... 662 MOISTURE IN REFRIGERATING SYSTEM........................................................................ 663 REFRIGERANT DOES NOT CIRCULATE.......................................................................... 664 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE....................... 665 DEFECTIVE COMPRESSION BY COMPRESSOR..................................................................... 666 30 DISASSEMBLY AND ASSEMBLY............................................................................................. 667 METHOD OF USING MANUAL.............................................................................................. 671 PRECAUTIONS DURING OPERATION........................................................................................ 672 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...................................................................... 672 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK................................................................. 673 PRECAUTIONS WHEN COMPLETING THE OPERATIONS...................................................................... 674 OTHER PRECAUTIONS............................................................................................... 26 SPECIAL TOOL LIST................................................................................................... 675 SKETCHES OF SPECIAL TOOLS........................................................................................... 679 ENGINE.............................................................................................................. 683 ALTERNATOR...................................................................................................... 683 CYLINDER HEAD................................................................................................... 683 ENGINE FRONT SEAL............................................................................................... 683 ENGINE OIL COOLER............................................................................................... 683 ENGINE REAR SEAL................................................................................................ 683 FUEL INJECTION PUMP............................................................................................. 683 NOZZLE HOLDER................................................................................................... 30 STARTING MOTOR.................................................................................................. 683 THERMOSTAT...................................................................................................... 683 TURBOCHARGER.................................................................................................... 30 WATER PUMP...................................................................................................... 30 HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER......................................................................... 684 REMOVAL......................................................................................................... 684 INSTALLATION.................................................................................................... 685 DAMPER, ENGINE...................................................................................................... 686 REMOVAL......................................................................................................... 686 INSTALLATION.................................................................................................... 688 DAMPER.............................................................................................................. 689 REMOVAL......................................................................................................... 689 INSTALLATION.................................................................................................... 690 DISASSEMBLY..................................................................................................... 691 ASSEMBLY........................................................................................................ 693 PTO................................................................................................................. 697 DISASSEMBLY..................................................................................................... 697 ASSEMBLY........................................................................................................ 699 TORQUE CONVERTER, TRANSMISSION...................................................................................... 702 REMOVAL......................................................................................................... 702 INSTALLATION.................................................................................................... 706 TORQUE CONVERTER.................................................................................................... 707 DISASSEMBLY..................................................................................................... 707 ASSEMBLY........................................................................................................ 711 TRANSMISSION........................................................................................................ 716 DISASSEMBLY..................................................................................................... 716 ASSEMBLY........................................................................................................ 730 TRANSMISSION VALVE.................................................................................................. 745 REMOVAL......................................................................................................... 745 INSTALLATION.................................................................................................... 745 TRANSMISSION CONTROL VALVE.......................................................................................... 746 LOWER VALVE..................................................................................................... 746 DISASSEMBLY................................................................................................. 747 ASSEMBLY.................................................................................................... 747 UPPER VALVE..................................................................................................... 748 DISASSEMBLY................................................................................................. 749 ASSEMBLY.................................................................................................... 751 MAIN RELIEF VALVE............................................................................................... 752 DISASSEMBLY................................................................................................. 753 ASSEMBLY.................................................................................................... 753 TRANSFER............................................................................................................ 754 DISASSEMBLY..................................................................................................... 754 ASSEMBLY........................................................................................................ 761 CENTER SUPPORT...................................................................................................... 771 REMOVAL......................................................................................................... 771 INSTALLATION.................................................................................................... 772 DISASSEMBLY..................................................................................................... 773 ASSEMBLY........................................................................................................ 775 DRIVE SHAFT......................................................................................................... 778 DISASSEMBLY..................................................................................................... 778 ASSEMBLY........................................................................................................ 780 FRONT AXLE.......................................................................................................... 782 REMOVAL......................................................................................................... 782 INSTALLATION.................................................................................................... 783 FRONT DIFFERENTIAL.................................................................................................. 784 REMOVAL......................................................................................................... 784 INSTALLATION.................................................................................................... 786 REAR AXLE........................................................................................................... 787 REMOVAL......................................................................................................... 787 INSTALLATION.................................................................................................... 792 REAR DIFFERENTIAL................................................................................................... 793 REMOVAL......................................................................................................... 793 INSTALLATION.................................................................................................... 794 DIFFERENTIAL........................................................................................................ 795 DISASSEMBLY..................................................................................................... 795 ASSEMBLY........................................................................................................ 799 FINAL DRIVE......................................................................................................... 808 DISASSEMBLY..................................................................................................... 808 ASSEMBLY........................................................................................................ 812 ORBITROL STEERING VALVE............................................................................................. 816 REMOVAL......................................................................................................... 816 INSTALLATION.................................................................................................... 817 STEERING CYLINDER................................................................................................... 818 REMOVAL......................................................................................................... 818 INSTALLATION.................................................................................................... 820 STEERING DEMAND VALVE............................................................................................... 821 REMOVAL......................................................................................................... 821 INSTALLATION.................................................................................................... 822 BRAKE VALVE......................................................................................................... 823 REMOVAL......................................................................................................... 823 INSTALLATION.................................................................................................... 824 BRAKE VALVE (RIGHT)................................................................................................. 825 DISASSEMBLY..................................................................................................... 825 ASSEMBLY........................................................................................................ 827 BRAKE VALVE (LEFT).................................................................................................. 829 DISASSEMBLY..................................................................................................... 829 ASSEMBLY........................................................................................................ 831 SLACK ADJUSTER...................................................................................................... 833 REMOVAL......................................................................................................... 833 INSTALLATION.................................................................................................... 833 DISASSEMBLY..................................................................................................... 834 ASSEMBLY........................................................................................................ 835 BRAKE............................................................................................................... 836 REMOVAL......................................................................................................... 836 INSTALLATION.................................................................................................... 837 DISASSEMBLY..................................................................................................... 838 ASSEMBLY........................................................................................................ 842 HYDRAULIC PUMP...................................................................................................... 848 REMOVAL......................................................................................................... 848 INSTALLATION.................................................................................................... 849 PISTON PUMP......................................................................................................... 850 DISASSEMBLY..................................................................................................... 850 ASSEMBLY........................................................................................................ 856 HYDRAULIC TANK...................................................................................................... 872 REMOVAL......................................................................................................... 872 INSTALLATION.................................................................................................... 873 PPC VALVE........................................................................................................... 874 REMOVAL......................................................................................................... 874 INSTALLATION.................................................................................................... 875 DISASSEMBLY..................................................................................................... 876 ASSEMBLY........................................................................................................ 876 WORK EQUIPMENT CONTROL VALVE........................................................................................ 877 REMOVAL......................................................................................................... 877 INSTALLATION.................................................................................................... 878 DISASSEMBLY..................................................................................................... 879 ASSEMBLY........................................................................................................ 881 DUMP CYLINDER....................................................................................................... 883 REMOVAL......................................................................................................... 883 INSTALLATION.................................................................................................... 883 LIFT CYLINDER....................................................................................................... 884 REMOVAL......................................................................................................... 884 INSTALLATION.................................................................................................... 885 STEERING, LIFT, DUMP CYLINDER....................................................................................... 886 DISASSEMBLY..................................................................................................... 886 ASSEMBLY........................................................................................................ 888 CENTER HINGE PIN.................................................................................................... 890 REMOVAL......................................................................................................... 890 INSTALLATION.................................................................................................... 896 WORK EQUIPMENT...................................................................................................... 900 REMOVAL......................................................................................................... 900 INSTALLATION.................................................................................................... 903 BULKHEAD............................................................................................................ 905 REMOVAL......................................................................................................... 905 INSTALLATION.................................................................................................... 906 FLOOR FRAME......................................................................................................... 907 REMOVAL......................................................................................................... 907 INSTALLATION.................................................................................................... 909 COUNTERWEIGHT....................................................................................................... 910 REMOVAL......................................................................................................... 910 INSTALLATION.................................................................................................... 911 FUEL TANK........................................................................................................... 912 REMOVAL......................................................................................................... 912 INSTALLATION.................................................................................................... 913 CAB................................................................................................................. 914 REMOVAL......................................................................................................... 914 INSTALLATION.................................................................................................... 916 STOP VALVE.......................................................................................................... 917 REMOVAL......................................................................................................... 917 INSTALLATION.................................................................................................... 917 ACCUMULATOR CHARGE VALVE............................................................................................ 918 REMOVAL......................................................................................................... 918 INSTALLATION.................................................................................................... 918 DISASSEMBLY..................................................................................................... 919 ASSEMBLY........................................................................................................ 920 PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH.................................................................... 922 REMOVAL......................................................................................................... 922 INSTALLATION.................................................................................................... 922 DIVERTER VALVE...................................................................................................... 923 REMOVAL......................................................................................................... 923 INSTALLATION.................................................................................................... 923 DISASSEMBLY..................................................................................................... 924 ASSEMBLY........................................................................................................ 925 EMERGENCY STEERING PUMP............................................................................................. 927 REMOVAL......................................................................................................... 927 INSTALLATION.................................................................................................... 927 PARKING BRAKE....................................................................................................... 928 REMOVAL......................................................................................................... 928 INSTALLATION.................................................................................................... 929 PARKING BRAKE CALIPERS.............................................................................................. 930 DISASSEMBLY..................................................................................................... 930 ASSEMBLY........................................................................................................ 932 PARKING BRAKE PAD................................................................................................... 934 REMOVAL......................................................................................................... 934 INSTALLATION.................................................................................................... 934 REAR TIRE........................................................................................................... 935 REMOVAL......................................................................................................... 935 INSTALLATION.................................................................................................... 935 AIR CONDITIONER COMPRESSOR.......................................................................................... 936 REMOVAL......................................................................................................... 936 INSTALLATION.................................................................................................... 936 AIR CONDITIONER CONDENSER........................................................................................... 937 REMOVAL......................................................................................................... 937 INSTALLATION.................................................................................................... 938 AIR CONDITIONER RECEIVER TANK....................................................................................... 939 REMOVAL......................................................................................................... 939 INSTALLATION.................................................................................................... 939 AIR CONDITIONER UNIT................................................................................................ 940 REMOVAL......................................................................................................... 940 INSTALLATION.................................................................................................... 941 MAIN MONITOR........................................................................................................ 942 REMOVAL......................................................................................................... 942 INSTALLATION.................................................................................................... 943 MAINTENANCE MONITOR................................................................................................. 944 REMOVAL......................................................................................................... 944 INSTALLATION.................................................................................................... 944 ENGINE, APS CONTROLLER.............................................................................................. 945 REMOVAL......................................................................................................... 945 INSTALLATION.................................................................................................... 945 40 MAINTENANCE STANDARD................................................................................................. 949 ENGINE AND TRANSMISSION MOUNT....................................................................................... 950 DAMPER.............................................................................................................. 952 TORQUE CONVERTER AND PTO............................................................................................ 954 TRANSMISSION CLUTCH................................................................................................. 956 TRANSMISSION GEAR................................................................................................... 958 TRANSMISSION CONTROL VALVE.......................................................................................... 960 UPPER VALVE..................................................................................................... 960 RELIEF VALVE.................................................................................................... 960 LOWER VALVE..................................................................................................... 962 SOLENOID VALVE.................................................................................................. 964 TRANSFER............................................................................................................ 966 DRIVE SHAFT......................................................................................................... 968 CENTER SUPPORT...................................................................................................... 969 DIFFERENTIAL........................................................................................................ 970 FINAL DRIVE......................................................................................................... 974 AXLE MOUNT.......................................................................................................... 976 CENTER HINGE PIN.................................................................................................... 978 STEERING COLUMN..................................................................................................... 981 STEERING DEMAND VALVE............................................................................................... 982 DIVERTER VALVE...................................................................................................... 985 STEERING CYLINDER MOUNT............................................................................................. 986 GROUND DRIVEN STEERING PUMP......................................................................................... 988 BRAKE VALVE......................................................................................................... 990 LEFT............................................................................................................ 990 RIGHT........................................................................................................... 992 SLACK ADJUSTER...................................................................................................... 994 CONTROL PUMP........................................................................................................ 995 BRAKE............................................................................................................... 996 PARKING BRAKE....................................................................................................... 998 MAIN CONTROL VALVE..................................................................................................1000 PPC VALVE...........................................................................................................1002 PPC RELIEF VALVE....................................................................................................1004 HYDRAULIC CYLINDER..................................................................................................1006 WORK EQUIPMENT LINKAGE..............................................................................................1008 BUCKET POSITIONER...................................................................................................1010 BOOM KICK-OUT.......................................................................................................1010 90 OTHERS...............................................................................................................1013 SHOP MANUAL FOLDOUTS................................................................................................1015 ELECTRICAL CIRCUIT DIAGRAM......................................................................................1015 DIAGRAM ONE (1/6)...........................................................................................1015 DIAGRAM ONE (2/6)...........................................................................................1017 DIAGRAM ONE (3/6)...........................................................................................1019 DIAGRAM ONE (4/6)...........................................................................................1021 DIAGRAM ONE (5/6)...........................................................................................1023 DIAGRAM ONE (6/6)...........................................................................................1025 DIAGRAM TWO (1/4)...........................................................................................1027 DIAGRAM TWO (2/4) ..........................................................................................1029 DIAGRAM TWO (3/4)...........................................................................................1031 DIAGRAM TWO (4/4)...........................................................................................1033 CONNECTOR PIN ARRANGMENT........................................................................................1035 CONNECTOR PIN DIGRAM (1/6)..................................................................................1035 CONNECTOR PIN DIAGRAM (2/6) ................................................................................1037 CONNECTOR PIN DIAGRAM (3/6).................................................................................1039 CONNECTOR PIN DIAGRAM (4/6).................................................................................1041 CONNECTOR PIN DIAGRAM (5/6).................................................................................1043 CONNECTOR PIN DIAGRAM (6/6).................................................................................1045 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM.........................................................1047
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
1 review for KOMATSU AVANCE LOADER WA700-3L WHEEL LOADER SERVICE REPAIR MANUAL (SN:A50001 & UP) – PDF DOWNLOAD
Add a review
Landry Ryker –