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KOMATSU AVANCE LOADER WA800-3 SHOP MANUAL SEBM013419 – PDF DOWNLOAD
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Description
KOMATSU AVANCE LOADER WA800-3 SHOP MANUAL SEBM013419 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU AVANCE LOADER WA800-3 SHOP MANUAL SEBM013419 – PDF DOWNLOAD
Language : English
Pages : 1388
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA800-3 SHOP MANUAL SEBM013419 – PDF DOWNLOAD
COVER........................................................................................................................................................................................ 1
CONTENTS..................................................................................................................................................................................... 2
01 GENERAL................................................................................................................................................................................... 31
GENERAL ASSEMBLY DRAWING................................................................................................................................................................. 32
SPECIFICATIONS........................................................................................................................................................................... 33
WEIGHT TABLE ............................................................................................................................................................................ 36
LIST OF LUBRICANT AND WATER.............................................................................................................................................................. 38
10 STRUCTURE AND FUNCTION.................................................................................................................................................................... 41
POWER TRAIN.............................................................................................................................................................................. 42
POWER TRAIN SYSTEM....................................................................................................................................................................... 43
ENGINE CONTROL........................................................................................................................................................................... 44
SERVO CYLINDER .......................................................................................................................................................................... 45
RADIATOR AND COOLER...................................................................................................................................................................... 49
DAMPER................................................................................................................................................................................... 50
TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................................................................. 51
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.................................................................................................................................................... 52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................... 53
TORQUE CONVERTER ....................................................................................................................................................................... 54
TRANSMISSION ........................................................................................................................................................................... 59
TRANSFER................................................................................................................................................................................. 69
TRANSMISSION CONTROL VALVE............................................................................................................................................................... 70
TORQUE CONVERTER OIL COOLER.............................................................................................................................................................. 88
DRIVE SHAFT.............................................................................................................................................................................. 89
CENTER SUPPORT........................................................................................................................................................................... 90
AXLE..................................................................................................................................................................................... 91
FINAL DRIVE.............................................................................................................................................................................. 96
AXLE MOUNT............................................................................................................................................................................... 98
CENTER HINGE PIN......................................................................................................................................................................... 100
TIRE AND WHEEL .......................................................................................................................................................................... 101
STEERING PIPING DIAGRAM.................................................................................................................................................................. 102
STEERING COLUMN.......................................................................................................................................................................... 105
JOYSTICK LINKAGE......................................................................................................................................................................... 106
STEERING PUMP............................................................................................................................................................................ 108
SWITCH PUMP.............................................................................................................................................................................. 112
STEERING DEMAND VALVE.................................................................................................................................................................... 124
STEERING UNIT (ORBIT-ROLL VALVE)......................................................................................................................................................... 135
PROPORTIONAL SOLENOID VALVE.............................................................................................................................................................. 138
EPC VALVE................................................................................................................................................................................ 139
ROTARY VALVE............................................................................................................................................................................. 140
TOW-WAY RESTRICTOR VALVE................................................................................................................................................................. 144
DIVERTER VALVE........................................................................................................................................................................... 145
BRAKE PIPING............................................................................................................................................................................. 150
BRAKE CIRCUIT DIAGRAM.................................................................................................................................................................... 152
BRAKE VALVE.............................................................................................................................................................................. 156
CHARGE VALVE............................................................................................................................................................................. 167
ACCUMULATOR (FOR BRAKE).................................................................................................................................................................. 171
SLACK ADJUSTER........................................................................................................................................................................... 172
BRAKE.................................................................................................................................................................................... 175
PARKING BRAKE............................................................................................................................................................................ 176
SPRING CYLINDER.......................................................................................................................................................................... 180
PARKING BRAKE SOLENOID VALVE............................................................................................................................................................. 181
HYDRAULIC PIPING ........................................................................................................................................................................ 182
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................. 188
WORK EQUIPMENT LEVER LINKAGE............................................................................................................................................................. 203
HYDRAULIC TANK........................................................................................................................................................................... 206
MAIN PISTON PUMP......................................................................................................................................................................... 209
ES VALVE................................................................................................................................................................................. 221
SERVO VALVE.............................................................................................................................................................................. 223
PPC VALVE................................................................................................................................................................................ 226
PPC RELIEF VALVE......................................................................................................................................................................... 230
ACCUMULATOR (FOR PPC VALVE).............................................................................................................................................................. 231
WORK EQUIPMENT CONTROL LEVER............................................................................................................................................................. 232
WORK EQUIPMENT EPC VALVE................................................................................................................................................................. 235
WORK EQUIPMENT NEUTRAL LOCK SOLENOID VALVE............................................................................................................................................... 238
MAIN CONTROL VALVE....................................................................................................................................................................... 240
LUBRICATION OF WORK EQUIPMENT............................................................................................................................................................ 266
WORK EQUIPMENT LINKAGE................................................................................................................................................................... 268
BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................... 270
OPERATION OF PROXIMITY SWITCH............................................................................................................................................................ 272
CAB...................................................................................................................................................................................... 276
ROPS CANOPY.............................................................................................................................................................................. 277
AIR CONDITIONER.......................................................................................................................................................................... 278
ELECTRIC CIRCUIT DIAGRAM................................................................................................................................................................. 281
MACHINE MONITOR SYSTEM................................................................................................................................................................... 282
MAIN MONITOR............................................................................................................................................................................. 284
MAINTENANCE MONITOR...................................................................................................................................................................... 290
MULTI MONITOR SYSTEM (IF EQUIPPED)....................................................................................................................................................... 296
WORK EQUIPMENT CONTROL SYSTEM............................................................................................................................................................ 318
WORK EQUIPMENT CONTROLLER ............................................................................................................................................................... 324
ENGINE STARTING CIRCUIT.................................................................................................................................................................. 326
ENGINE STOP CIRCUIT...................................................................................................................................................................... 329
PREHEATING CIRCUIT....................................................................................................................................................................... 330
ELECTRICAL TRANSMISSION CONTROL.......................................................................................................................................................... 331
KICK-DOWN, HOLD SWITCH................................................................................................................................................................... 334
JOYSTICK STEERING SYSTEM................................................................................................................................................................. 335
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)................................................................................................................................................. 340
ELECTRIC PARKING BRAKE CONTROL........................................................................................................................................................... 347
ENGINE CONTROL SYSTEM (FOR OPTIONAL ELECTRONIC GOVERNOR SPECIFICATION)................................................................................................................... 356
20 TESTING AND ADJUSTING..................................................................................................................................................................... 363
STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................................................... 364
STANDARD VALUE TABLE FOR CHASSIS......................................................................................................................................................... 365
STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................................................................ 373
TESTING AND ADJUSTING.................................................................................................................................................................... 393
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................................... 394
MEASURING ENGINE SPEED............................................................................................................................................................... 397
MEASURING EXHAUST GAS COLOR.......................................................................................................................................................... 399
ADJUSTING VALVE CLEARANCE............................................................................................................................................................ 400
MEASURING COMPRESSION PRESSURE....................................................................................................................................................... 401
MEASURING BLOW-BY PRESSURE........................................................................................................................................................... 402
TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................................................................... 403
MEASURING ENGINE OIL PRESSURE........................................................................................................................................................ 409
MEASURING EXHAUST TEMPERATURE........................................................................................................................................................ 410
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....................................................................................................................................... 411
TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................................................................ 412
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................................................................... 413
MEASURING ACCELERATOR PEDAL OPERATING EFFORT......................................................................................................................................... 414
MEASURING ACCELERATOR PEDAL OPERATING ANGLE.......................................................................................................................................... 415
ADJUSTING ACCELERATORPEDAL POTENTIOMETER (For optional electronic governor specification)............................................................................................ 416
ADJUSTING ACCELERATORPEDAL MICROSWITCH (For optional electronic governor specification).............................................................................................. 418
ADJUSTING FUEL CONTROL CABLE,LINKAGE,AND SERVO CYLINDER.............................................................................................................................. 420
ADJUSTING ENGINE STOPPING MOTOR CABLE................................................................................................................................................ 422
TESTING OF UPPER DRIVESHAFT SLIDING PART............................................................................................................................................. 424
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE................................................................................................................. 426
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS....................................................................................................... 429
TESTING AND ADJUSTING STEERING OIL PRESSRUE.......................................................................................................................................... 431
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE................................................................................................................................ 432
BLEEDING AIR FROM STEERING CIRCUIT .................................................................................................................................................. 434
TESTING AND ADJUSTING STEERING STOP VALVE............................................................................................................................................ 435
TESTING AND ADJUSTING STEERING STOPPER BOLT.......................................................................................................................................... 436
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR............................................................................................................. 437
TESTING WHEEL BRAKE PERFORMANCE ..................................................................................................................................................... 438
TESTING WHEEL BRAKE OIL PRESSURE DROP................................................................................................................................................ 439
MEASURING WEAR OF WHEEL BRAKE DISC................................................................................................................................................... 441
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE................................................................................................................. 442
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS................................................................................ 444
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT ............................................................................................................................................... 456
TESTING PARKING BRAKE PERFORMANCE.................................................................................................................................................... 457
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE..................................................................................................................................... 458
CHECKING AND ADJUSTING PARKING BRAKE PAD............................................................................................................................................. 459
TESTING AND ADJUSTING PPC PRESSURE .................................................................................................................................................. 461
ADJUSTING PPC VALVE LINKAGE.......................................................................................................................................................... 463
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................................................. 464
BLEEDING AIR FROM PISTON PUMP ....................................................................................................................................................... 466
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT............................................................................................................................................. 467
ADJUSTING WORK EQUIPMENT LEVER LINKAGE .............................................................................................................................................. 468
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ................................................................................................................................... 470
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH........................................................................................................................................ 471
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH.......................................................................................................................................... 472
TESTING PROXIMITY ACTUATION PILOT LAMP............................................................................................................................................... 473
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR ........................................................................................................................................ 474
ADJUSTING JOYSTICK LEVER POTENTIOMETER............................................................................................................................................... 475
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH.................................................................................................................................... 476
ADJUSTING WORK EQUIPMENT CONTROL LEVER............................................................................................................................................... 477
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER................................................................................................................. 481
ADJUSTING WORK EQUIPMENT BOOM ANGLE.................................................................................................................................................. 487
TROUBLESHOOTING.......................................................................................................................................................................... 489
POINTS TO REMEMBER WHEN TROUBLESHOOTING ............................................................................................................................................. 490
SEQUENCE OF EVENTS IN TROUBLESHOOTING ............................................................................................................................................... 491
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .................................................................................................................................... 492
CHECKS BEFORE TROUBLESHOOTING ....................................................................................................................................................... 500
TYPES AND LOCATIONS OF CONNECTORS ................................................................................................................................................... 501
CONNECTOR ARRANGEMENT DIAGRAM ....................................................................................................................................................... 510
WIRING TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................................... 521
T-ADAPTER BOX AND T-ADAPTER TABLE.................................................................................................................................................... 554
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM............................................................................................................................... 557
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE.................................................................................................................................... 564
CHART OF ACTION CODES AND FAILURE CODES,AND RE-ENACTION ............................................................................................................................. 566
TRANSMISSION CONTROLLER LED DISPLAY.................................................................................................................................................. 573
METHOD OF USING JUDGEMENT TABLE...................................................................................................................................................... 575
METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................... 576
METHOD OF USING MATRIX TROUBLESHOOTING TABLES........................................................................................................................................ 578
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................................................................ 581
METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................................... 582
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................................................................................... 586
S-2 ENGINE DOES NOT START........................................................................................................................................................ 587
(1) ENGINE DOES NOT TURN..................................................................................................................................................... 587
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)................................................................................................... 588
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................................................................................................. 589
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................................................................... 590
S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................................................... 591
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................................................... 592
S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................................................................................... 593
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)................................................................................................................................. 594
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)........................................................................................................................ 595
S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................................................. 596
S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................................................... 597
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN....................................................................................................... 598
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................... 599
S-13 OIL LEVEL RISES ............................................................................................................................................................ 600
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................ 601
S-15 ABNORMAL NOISE IS MADE...................................................................................................................................................... 602
S-16 VIBRATION IS EXCESSIVE...................................................................................................................................................... 603
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE).............................................................................................................................. 605
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS ................................................................................................................... 606
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...................................................................................................... 608
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM....................................................................................................................... 616
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED............................................................ 620
T-2 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED ........................................................... 621
T-3 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED................................................................... 622
T-4 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED................................................................... 623
T-5 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 1st SOLENOID) IS DISPLAYED................................................................. 624
T-6 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 2nd SOLENOID) IS DISPLAYED................................................................. 625
T-7 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 3rd SOLENOID) IS DISPLAYED................................................................. 626
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED........................................................................... 627
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.................................................................................... 628
T-10 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVER SWITCH SYSTEM) IS DISPLAYED............................................................................. 631
T-11 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED......................................................................................... 632
T-12 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED............................................................... 635
T-13 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED....................................................................................................... 636
T-14 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................. 637
T-15 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM................................................................................................................. 638
T-16 SHIFT-DOWN SWITCH SIGNAL SYSTEM AND SHIFT-UP SWITCH SIGNAL SYSTEM........................................................................................................... 639
T-17 TRANSMISSION CUT-OFF SIGNAL SYSTEM.......................................................................................................................................... 640
T-18 NEUTRALIZER SIGNAL SYSTEM................................................................................................................................................... 641
T-19 BUZZER SIGNAL SYSTEM........................................................................................................................................................ 642
T-20 NETWORK SYSTEM.............................................................................................................................................................. 643
T-21 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM................................................................................................................................. 644
T-22 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM................................................................................................................................. 645
T-23 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS............................................................................................................................. 646
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...................................................................................................................................... 647
TROUBLE DATA DISPLAY............................................................................................................................................................. 649
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM............................................................................................................................... 652
M-1 MAIN MONITOR DOES NOT WORK................................................................................................................................................... 654
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP............................................................. 655
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY................................................................................................................................... 656
M-4 ABNORMALITY IN SHIFT INDICATOR .............................................................................................................................................. 657
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F............................................................................................................................ 657
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R............................................................................................................................ 657
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N (DISPLAYS 1st-3rd)................................................................................................. 658
d) DOES NOT DISPLAY 1ST EVEN WHEN GEAR SHIFT LEVER IS AT 1st POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)............................................................... 658
e) DOES NOT DISPLAY 2nd EVEN WHEN GEAR SHIFT LEVER IS AT 2nd POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)............................................................... 658
f) DOES NOT DISPLAY 3rd EVEN WHEN GEAR SHIFT LEVER IS AT 3rd POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)............................................................... 659
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP.......................................................................................................................................... 660
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP........................................................................................................................................ 661
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................................ 661
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................................ 661
M-7 ABNORMALITY IN PARKING DISPLAY............................................................................................................................................... 662
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP.................................................................................................................................... 662
b) PARKING LAMP DISPLAY STAYS LIGHTED UP..................................................................................................................................... 662
M-8 ABNORMALITY IN PREHEATING SYSTEM............................................................................................................................................. 663
a) DOES NOT CARRY OUT PREHEATING............................................................................................................................................. 663
b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS.............................................................................................................................. 664
c) PREHEATING STAYS ON....................................................................................................................................................... 664
d) PREHEATING TIME BECOMES SHORTER,OR THERE IS VARIATION..................................................................................................................... 665
M-9 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................................................................................. 667
M-10 ABNORMALITY IN FRONT WORKING LAMP........................................................................................................................................... 668
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP................................................................................................................... 668
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.............................................................................................................. 668
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP........................................................................................................ 668
M-11 ABNORMALITY IN REAR WORKING LAMP............................................................................................................................................ 670
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.................................................................................................................... 670
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP......................................................................................................... 670
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP......................................................................................................... 670
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF......................................................................................................................................... 672
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH ) IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE................................................ 672
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH )IS OFF,MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED................................ 672
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF),CUT-OFF FUNCTION IS ALWAYS ACTUATED........................................................... 672
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)................................................................. 672
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON),BUT CUT-OFF FUNCTION IS NOT ACTUATED.................................................................... 673
M-13 ABNORMALITY IN LOW IDLING SELECTION......................................................................................................................................... 674
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON,THE LOW IDLING SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE................................................ 674
b) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH ) IS TURNED ON,THE MONITOR LIGHTS UP BUT THE LOW IDLING SPEED ODES NOT RISE............................................. 674
c) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH ) IS TURNED OFF,THE MONITOR GOES OFF BUT THE LOW IDLING SPEED DOES NOT LOWER............................................ 675
M-14 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY............................................................................................................................ 676
EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP.......................................................................................................................... 676
M-15 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY......................................................................................................................... 677
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP.................................................................................................................... 677
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP..................................................................................................................... 677
M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................................................................................... 678
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N................................................. 678
b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N............................ 678
M-17 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP))............................................................................................ 680
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N................................................. 680
b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N............................ 680
M-18 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED..................................................... 682
a) ACTUATED CONTINUOUSLY..................................................................................................................................................... 682
b) NOT ACTUATED.............................................................................................................................................................. 682
M-19 ABNORMALITY IN BUZZER....................................................................................................................................................... 683
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)................................................................................... 683
b) BUZZER ALWAYS SOUNDS...................................................................................................................................................... 683
M-20 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY....................................................................................................................... 684
M-21 ABNORMALITY IN FAILURE DISPLAY MODE......................................................................................................................................... 685
a) DOES NOT ENTER FAILURE DISPLAY MODE....................................................................................................................................... 685
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE............................................................................................. 685
M-22 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER.................................................................................................. 686
M-23 ABNORMALITY IN AUTO-GREASING SYSTEM (OP).................................................................................................................................... 687
a) CHECK POWER SUPPLY SYSTEM 1 (RELAY G1).................................................................................................................................... 687
b) CHECK POWER SUPPLY SYSTEM 2 (RELAY G2).................................................................................................................................... 687
c) FORCED GREASING DOES NOT START............................................................................................................................................ 688
d) MONITOR DOES NOT FLASH WHILE GREASE IS BEING SUPPLIED..................................................................................................................... 688
e) MONITOR IS STILL FLASHING AFTER GREASING IS FINISHED, OR IT FLASHES FOR PERIOD SET WITH TIMER WHEN STARTING SWITCH IS TURNED TO ON POSITION............................... 689
M-24 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP)...................................................................................................... 691
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)............................................................................................................................... 693
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM........................................................................................................................ 694
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK................................................... 696
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP.................................................................................................................................. 696
b) SOME LAMPS DO NOT LIGHT UP................................................................................................................................................ 696
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)................................................................. 697
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS),NO LAMPS ON MAINTENANCE MONITOR GO OUT.............................................. 698
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH......................................................................................................... 699
a) ENGINE OIL LEVEL DISPLAY FLASHES.......................................................................................................................................... 699
b) ENGINE WATER LEVEL DISPLAY FLASHES........................................................................................................................................ 700
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH....................................................................................................... 701
a) ENGINE OIL PRESSURE DISPLAY FLASHES....................................................................................................................................... 701
b) BATTERY CHARGE LEVEL DISPLAY FLASHES...................................................................................................................................... 702
c) BRAKE OIL PRESSURE DISPLAY FLASHES........................................................................................................................................ 703
d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES............................................................................................................................... 705
e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES............................................................................................................................... 706
f) TRANSMISSION OIL FILTER DISPLAY FLASHES................................................................................................................................... 707
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND......................................................................................................................... 708
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS......................................................................................................... 709
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES................................................................................................... 710
a) CHECK LAMP................................................................................................................................................................ 710
b) CAUTION LAMP.............................................................................................................................................................. 710
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP.............................................................................. 711
a) CHECK LAMP................................................................................................................................................................ 711
b) CAUTION LAMP.............................................................................................................................................................. 711
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON.............................................................................. 712
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF............................................................................................................ 713
K-12 SERVICE METER DOES NOT WORK................................................................................................................................................. 714
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED........................................................................................................................ 714
K-14 ABNORMALITY IN GAUGE DISPLAY................................................................................................................................................ 715
a) ABNORMALITY FUEL GAUGE.................................................................................................................................................... 715
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE............................................................................................................................. 716
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..................................................................................................................... 717
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................................................................ 719
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTING,ENGINE STOPPING AND PREHEATING....................................................................................... 720
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE..................................................................................................................................... 722
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER............................................................................................................... 723
E-1 ENGINE DOES NOT START........................................................................................................................................................ 724
a) STARTING MOTOR DOES NOT TURN.............................................................................................................................................. 724
b) STARTING MOTOR TURNS (STD SPEC.).......................................................................................................................................... 728
E-2 ENGINE DOES NOT STOP (STD SPEC.)............................................................................................................................................. 730
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (STD SPEC.)........................................................................................................................... 731
E-4 ABNORMALITY IN PREHEATING SYSTEM............................................................................................................................................. 733
a) DOES NOT CARRY OUT PREHEATING ............................................................................................................................................ 733
b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS.............................................................................................................................. 734
c) PREHEATING STAYS ON....................................................................................................................................................... 734
d) PREHEATING TIME BECOMES SHORTER,OR THERE IS FLUCTUATION................................................................................................................... 735
E-5 PARKING BRAKE DOES NOT HAVE EFFECT........................................................................................................................................... 737
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON........................................................................................................ 737
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)........................................................... 737
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING........................................................................................................................... 738
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.................................................................................................................. 740
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)..................................................................... 740
E-9 KICK-DOWN SWITCH DOES NOT WORK .............................................................................................................................................. 742
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY...................................................................................................... 742
b) KICK-DOWN CANNOT BE CANCELED.............................................................................................................................................. 743
E-10 BOOM KICK-OUT DOES NOT WORK................................................................................................................................................. 744
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION .................................................................................................................................. 748
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP............................................................................................................................ 751
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP............................................................................................................................. 751
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF......................................................................................................................................... 751
E-15 ABNORMALITY IN LOW IDLING SELECTION......................................................................................................................................... 751
E-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................................................................................... 751
E-17 ABNORMALITY IN BUZZER....................................................................................................................................................... 751
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).......................................................................................................................... 753
H-1 MACHINE DOES NOT MOVE........................................................................................................................................................ 754
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)............................................................................................................................. 755
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.................................................................................................................... 756
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................................................................... 757
H-5 STEERING DOES NOT TURN (STEERING WHEEL SPECIFICATION)........................................................................................................................ 758
H-6 STEERING DOES NOT TURN (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................................. 759
H-7 STEERING DOES NOT TURN (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).............................................................................................. 760
H-8 TURNING,RESPONSE OF STEERING IS POOR (STEERING WHEEL SPECIFICATION).......................................................................................................... 761
H-9 TURNING,RESPONSE OF STEERING IS POOR (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................... 762
H-10 TURNING,RESPONSE OF STEERING IS POOR (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)............................................................................... 763
H-11 STEERING IS HEAVY (STEERING WHEEL SPECIFICATION)............................................................................................................................ 764
H-12 JOYSTICK LEVER IS HEAVY (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)................................................................................................ 764
H-13 JOYSTICK LEVER IS HEAVY (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)............................................................................................ 765
H-14 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL SPECIFICATION)............................................................................................................... 766
H-15 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)......................................................................................... 767
H-16 STEERING WHEEL SHAKES OR JERKS (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)..................................................................................... 768
H-17 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)..................................... 769
H-18 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).............................................................. 769
H-19 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.......................................................................................................................... 770
H-20 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG................................................................................................................................ 771
H-21 BOOM DOES NOT RISE.......................................................................................................................................................... 772
H-22 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER................................................................................................................. 773
H-23 WHEN RAISING BOOM,BECOMES SLOW AT CERTAIN HEIGHT ........................................................................................................................... 774
H-24 BOOM CYLINDER CANNOT HOLD DOWN BUCKET....................................................................................................................................... 774
H-25 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT.................................................................................................................................... 774
H-26 BOOM FLUCTUATES WHILE WORKING............................................................................................................................................... 775
H-27 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE............................................................................................................ 775
H-28 BUCKET DOES NOT TILT BACK................................................................................................................................................... 776
H-29 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER..................................................................................................................... 777
H-30 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK............................................................................................................................... 778
H-31 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET..................................................................................................................................... 778
H-32 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT.................................................................................................................................. 778
H-33 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE "HOLD").................................................................................................. 779
H-34 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT........................................................................................................... 779
H-35 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY................................................................................................................................. 780
TROUBLESHOOTING OF JOYSTICK STEERING CONTROL SYSTEM (J MODE)......................................................................................................................... 781
JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL SYSTEM RELATED PARTS............................................................................................................... 782
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................... 784
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING CONTROL SYSTEM.................................................................................................................. 788
J-1 FAILURE CODE [56] (SHORT CIRCUIT,DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED......................................................................................... 790
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED................................................................... 791
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED.................................................................... 792
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................................................................ 793
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................................................................. 794
J-6 FAILURE CODE [61] (SHORT CIRCUIT,DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED........................................................................... 795
J-7 FAILURE CODE [62] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED............................................................................ 796
J-8 FAILURE CODE [63] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED........................................................................ 797
J-9 ABNORMALITY IN POWER SUPPLY,POWER SUPPLY VOLTAGE............................................................................................................................. 798
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT............................................................................................................................. 799
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID.................................................................................................................................... 800
J-12 DISCONNECTION IN STEERING LEFT SOLENOID..................................................................................................................................... 801
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE).................................................................................................. 803
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM...................................................................................................... 804
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY..................................................................................... 806
ELECTRIC CIRCUIT DIAGRAM FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL.................................................................................................... 810
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED........................................................... 812
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED.................................................... 813
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED..................................................................... 814
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED............................................................. 815
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED............................................ 816
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED............................................... 817
A-7 FAILURE CODE [63] (DISCONNECTION,SHORT CIRCUIT WITH CHASSIS GROUND,OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED.... 818
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT............................................................................................................................. 819
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)............................................................... 820
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE..................................................................................................................................... 821
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE).......................................................................................................................... 823
CONTENTS OF ABNORMALITY IN WORK EQUIPMENT CONTROL SYSTEM AND ACTIONS OF CONTROLLER AGAINST THEM.................................................................................. 826
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROL SYSTEM..................................................................................................................... 832
[WRK-1] LOWERING OF WORK EQUIPMENT CONTROLLER SOURCE VOLTAGE..................................................................................................................... 835
[WRK-2] ABNORMALITY IN SENSOR POWER SOURCE SYSTEM................................................................................................................................ 836
[WRK-3] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM.............................................................................................................................. 838
[WRK-4] GROUNDING FAULT IN REMOTE POSITIONER RAISE POSITION SET SWITCH SYSTEM.................................................................................................... 839
[WRK-5] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE POSITION SET SWITCH........................................................................ 840
[WRK-6] GROUNDING FAULT IN REMOTE POSITIONER LOWER POSITION SET SWITCH SYSTEM.................................................................................................... 841
[WRK-7] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER POSITION SET SWITCH SYSTEM................................................................. 842
[WRK-8] GROUNDING FAULT IN REMOTE POSITIONER RAISE/LOWER SELECTOR SWITCH SYSTEM.................................................................................................. 843
[WRK-9] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE/LOWER SELECTOR SWITCH SYSTEM............................................................... 844
[WRK-10] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM ANGLE POTENTIOMETER SIGNAL SYSTEM............................................................ 845
[WRK-11] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN MAIN CIRCUIT)................................................................... 846
[WRK-12] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM [SHORT CIRCUIT IN MAIN CIRCUIT (WITH SOURCE POWER)].................................................................. 847
[WRK-13] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN SUB CIRCUIT).................................................................... 848
[WRK-14] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM [SHORT CIRCUIT IN SUB CIRCUIT (WITH SOURCE POWER)]................................................................... 849
[WRK-15] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (SHIFTING OF MAIN CIRCUIT AND SUB CIRCUIT FORM EACH OTHER)........................................................... 850
[WRK-16] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN MAIN CIRCUIT)................................................................. 851
[WRK-17] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM {SHORT CIRCUIT IN MAIN CIRCUIT (WITH SOURCE POWER)]................................................................ 852
[WRK-18] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN SUB CIRCUIT).................................................................. 853
[WRK-19] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT CIRCUIT IN SUB CIRCUIT)..................................................................................... 854
[WRK-20] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHIFTING OF MAIN CIRCUIT AND SUB CIRCUIT FORM EACH OTHER)......................................................... 855
[WRK-21] DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM............................................................................................................................. 856
[WRK-22] GROUNDING FAULT IN ENGINE SPEED SENSOR SYSTEM........................................................................................................................... 857
[WRK-23] GROUNDING FAULT IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM.................................................................................................. 858
[WRK-24] DISCONNECTION IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM.................................................................................................... 859
[WRK-25] SHORT CIRCUIT (WITH POWER SOURCE)IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM................................................................................. 860
[WRK-26] GROUNDING FAULT IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM.................................................................................................. 861
[WRK-27] DISCONNECTION IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM.................................................................................................... 862
[WRK-28] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM................................................................................ 863
[WRK-29] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM........................................................................................ 864
[WRK-30] DISCONNECTION IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM............................................................................................................ 866
[WRK-31] GROUNDING FAULT IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM.......................................................................................................... 868
[WRK-32] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM........................................................................................ 870
[WRK-33] DISCONNECTION IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM............................................................................................................ 872
[WRK-34] GROUNDING FAULT IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM.......................................................................................................... 874
[WRK-35] DISCONNECTION IN BOOM RAISE MAGNET DETENT SYSTEM........................................................................................................................ 876
[WRK-36] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE MAGNET DETENT SYSTEM.................................................................................................... 877
[WRK-37] GROUNDING FAULT IN BOOM RAISE MAGNET DETENT SYSTEM...................................................................................................................... 878
[WRK-38] DISCONNECTION IN BOOM FLOAT MAGNET DETENT SYSTEM........................................................................................................................ 879
[WRK-39] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM FLOAT MAGNET DETENT SYSTEM.................................................................................................... 880
[WRK-40] GROUNDING FAULT IN BOOM FLOAT MAGNET DETENT SYSTEM...................................................................................................................... 881
[WRK-41] DISCONNECTION IN BUCKET TILT MAGNET DETENT SYSTEM....................................................................................................................... 882
[WRK-42] SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT MAGNET DETENT SYSTEM................................................................................................... 883
[WRK-43] GROUNDING FAULT IN BUCKET TILT MAGNET DETENT SYSTEM..................................................................................................................... 884
[WRK-44] DISCONNECTION OR GROUNDING FAULT IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID A SYSTEM....................................................................................... 885
[WRK-45] SHORT CIRCUIT (WITH POWER SOURCE) IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID A SYSTEM...................................................................................... 886
[WRK-46] DISCONNECTION OR GROUNDING FAULT IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID B SYSTEM....................................................................................... 887
[WRK-47] SHORT CIRCUIT (WITH POWER SOURCE) IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID B SYSTEM...................................................................................... 888
[WRK-48] DISCONNECTION IN ALARM BUZZER SYSTEM.................................................................................................................................... 889
[WRK-49] GROUNDING FAULT IN ALARM BUZZER SYSTEM.................................................................................................................................. 890
[WRK-50] SHORT CIRCUIT (WITH POWER SOURCE) IN ALARM BUZZER SYSTEM................................................................................................................ 891
[WRK-51] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE EPC SOLENOID A SYSTEM.................................................................................. 892
[WRK-52] GROUNDING FAULT IN BOOM RAISE EPC SOLENOID A SYSTEM..................................................................................................................... 893
[WRK-53] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE EPC SOLENOID B SYSTEM.................................................................................. 894
[WRK-54] GROUNDING FAULT IN BOOM RAISE EPC SOLENOID B SYSTEM..................................................................................................................... 895
[WRK-55] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOWER EPC SOLENOID A SYSTEM.................................................................................. 896
[WRK-56] GROUNDING FAULT IN BOOM LOWER EPC SOLENOID A SYSTEM..................................................................................................................... 897
[WRK-57] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOWER EPC SOLENOID B SYSTEM.................................................................................. 898
[WRK-58] GROUNDING FAULT IN BOOM LOWER EPC SOLENOID B SYSTEM..................................................................................................................... 899
[WRK-59] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT EPC SOLENOID A SYSTEM................................................................................. 900
[WRK-60] GROUNDING FAULT IN BUCKET TILT EPC SOLENOID A SYSTME.................................................................................................................... 901
[WRK-61] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT EPC SOLENOID B SYSTEM................................................................................. 902
[WRK-62] GROUNDING FAULT IN BUCKET TILT EPC SOLENOID B SYSTEM.................................................................................................................... 903
[WRK-63] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET DUMP EPC SOLENOID A SYSTEM................................................................................. 904
[WRK-64] GROUNDING FAULT IN BUCKET DUMP EPC SOLENOID A SYSTEM.................................................................................................................... 905
[WRK-65] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET DUMP EPC SOLENOID B SYSTEM................................................................................. 906
[WRK-66] GROUNDING FAULT IN BUCKET DUMP EPC SOLENOID B SYSTEM.................................................................................................................... 907
[WRK-67] ABNORMALITY IN WORK EQUIPMENT LEVER NEUTRAL CAUTION SYSTEM.............................................................................................................. 908
[WRK-68] DISCONNECTION OR GROUNDING FAULT IN BOOM LOCK SWITCH SYSTEM............................................................................................................. 909
[WRK-69] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOCK SWITCH SYSTEM............................................................................................................ 910
[WRK-70] ABNORMALITY IN BUCKET CYLINDER PROXIMITY SWITCH SYSTEM.................................................................................................................. 911
[WRK-71] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN EPC LEVER ADJUSTMENT MODE INPUT SYSTEM............................................................ 912
[WRK-72] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM ANGLE ADJUSTMENT MODE INPUT SYSTEM........................................................... 913
TROUBLESHOOTING OF ELECTRONIC GOVERNOR SYSTEM (G MODE)............................................................................................................................... 915
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS................................................................................................................... 916
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...................................................................................................... 918
ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS.................................................................................................. 926
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM................................................................................................. 927
JUDGEMENT TABLE FOR ENGINE CONTROLLER............................................................................................................................................ 929
G-1 [90] [10] Abnormality in power source system................................................................................................................................. 930
G-2 [90] [11] Abnormality in controller system................................................................................................................................... 930
G-3 [90] [21] Mistaken connection of connector................................................................................................................................... 931
G-4 [90] [56] Abnormality in right bank solenoid power source system............................................................................................................. 931
G-5 [90] [57] Abnormality in left bank solenoid power source system.............................................................................................................. 931
G-6 [90] [58] Abnormality in back-up power source system......................................................................................................................... 932
G-7 [90] [59] Abnormality in switch power source system.......................................................................................................................... 933
G-8 [91] [14] Abnormality in right bank governor solenoid system................................................................................................................. 934
G-9 [91] [15] Abnormality in left bank governor solenoid system.................................................................................................................. 935
G-10 [91] [16] Abnormality in right bank governor cut relay system............................................................................................................... 936
G-11 [91] [17] Abnormality in left bank governor cut relay system................................................................................................................ 937
G-12 [91] [19] Abnormality in right bank governor servo system................................................................................................................... 938
G-13 [91] [1A] Abnormality in left bank governor servo system.................................................................................................................... 939
G-14 [91] [1d] Abnormality in right bank pre-stroke solenoid system.............................................................................................................. 940
G-15 [91] [1E] Abnormality in left bank pre-stroke solenoid system............................................................................................................... 941
G-16 [92] [12] Abnormality in right bank rack sensor system...................................................................................................................... 942
G-17 [92] [13] Abnormality in left bank rack sensor system....................................................................................................................... 943
G-18 [92] [18] Abnormality in rack sensor power source system.................................................................................................................... 944
G-19 [93] [1b] Abnormality in engine speed sensor A system....................................................................................................................... 945
G-20 [94] [1c] Abnormality in engine speed sensor B system....................................................................................................................... 946
G-21 [93, 94] [1b, 1c] Abnormality in engine speed sensor A, B system............................................................................................................ 947
G-22 [95] [40] Abnormality in engine water temperature sensor system............................................................................................................. 947
G-23 [97] [31] Abnormality in accelerator sensor system.......................................................................................................................... 948
G-24 [98] [18] Abnormality in model selection.................................................................................................................................... 950
G-25 [99] [22] Engine overrun.................................................................................................................................................... 951
G-26 Engine does not start....................................................................................................................................................... 951
G-27 Engine does not stop........................................................................................................................................................ 955
30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................. 957
HOW TO READ THIS MANUAL.................................................................................................................................................................. 959
STANDARD TIGHTENING TORQUE TABLE......................................................................................................................................................... 961
PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................................. 965
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER............................................................................................................................ 968
COATING MATERIALS LIST................................................................................................................................................................... 971
SPECIAL TOOL LIST........................................................................................................................................................................ 974
SKETCHES OF SPECIAL TOOLS................................................................................................................................................................ 983
STARTING MOTOR........................................................................................................................................................................... 991
REMOVAL AND INSTALLATION............................................................................................................................................................. 991
ALTERNATOR............................................................................................................................................................................... 992
REMOVAL AND INSTALLATION............................................................................................................................................................. 992
ENGINE OIL COOLER........................................................................................................................................................................ 993
REMOVAL AND INSTALLATION............................................................................................................................................................. 993
FUEL INJECTION PUMP FOR LEFT BANK (WITH GOVERNOR)........................................................................................................................................ 994
REMOVAL AND INSTALLATION............................................................................................................................................................. 994
FUEL INJECTION PUMP FOR RIGHT BANK (WITH GOVERNOR)....................................................................................................................................... 995
REMOVAL AND INSTALLATION............................................................................................................................................................. 995
WATER PUMP............................................................................................................................................................................... 996
REMOVAL AND INSTALLATION............................................................................................................................................................. 996
NOZZLE HOLEDR............................................................................................................................................................................ 997
REMOVAL AND INSTALLATION............................................................................................................................................................. 997
TURBOCHARGER............................................................................................................................................................................. 998
REMOVAL AND INSTALLATION............................................................................................................................................................. 998
ENGINE FRONT SEAL ....................................................................................................................................................................... 999
REMOVAL AND INSTALLATION............................................................................................................................................................. 999
ENGINE REAR SEAL.........................................................................................................................................................................1001
REMOVAL AND INSTALLATION.............................................................................................................................................................1001
CYLINDER HEAD............................................................................................................................................................................1003
REMOVAL..............................................................................................................................................................................1003
INSTALLATION.........................................................................................................................................................................1007
RADIATOR.................................................................................................................................................................................1010
REMOVAL..............................................................................................................................................................................1010
INSTALLATION.........................................................................................................................................................................1013
ENGINE...................................................................................................................................................................................1014
REMOVAL..............................................................................................................................................................................1014
INSTALLATION.........................................................................................................................................................................1020
DAMPER...................................................................................................................................................................................1021
REMOVAL AND INSTALLATION.............................................................................................................................................................1021
DISASSEMBLY..........................................................................................................................................................................1022
ASSEMBLY.............................................................................................................................................................................1024
TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...............................................................................................................................................1028
REMOVAL..............................................................................................................................................................................1028
INSTALLATION.........................................................................................................................................................................1035
TORQUE CONVERTER.........................................................................................................................................................................1037
DISASSEMBLY..........................................................................................................................................................................1037
ASSEMBLY.............................................................................................................................................................................1041
TORQUE CONVERTER VALVE...................................................................................................................................................................1046
DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1046
TRANSMISSION.............................................................................................................................................................................1047
DISASSEMBLY..........................................................................................................................................................................1047
ASSEMBLY.............................................................................................................................................................................1064
TRANSMISSION VALVE.......................................................................................................................................................................1082
REMOVAL AND INSTALLATION.............................................................................................................................................................1082
DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1083
TRANSFER.................................................................................................................................................................................1087
DISASSEMBLY..........................................................................................................................................................................1087
ASSEMBLY.............................................................................................................................................................................1095
PTO......................................................................................................................................................................................1107
DISASSEMBLY..........................................................................................................................................................................1107
ASSEMBLY.............................................................................................................................................................................1109
CENTER SUPPORT...........................................................................................................................................................................1112
REMOVAL..............................................................................................................................................................................1112
INSTALLATION.........................................................................................................................................................................1113
DISASSEMBLY..........................................................................................................................................................................1114
ASSEMBLY.............................................................................................................................................................................1116
DRIVE SHAFT..............................................................................................................................................................................1119
DISASSEMBLY..........................................................................................................................................................................1119
ASSEMBLY.............................................................................................................................................................................1121
FRONT AXLE...............................................................................................................................................................................1123
REMOVAL..............................................................................................................................................................................1123
INSTALLATION.........................................................................................................................................................................1125
REAR AXLE................................................................................................................................................................................1126
REMOVAL..............................................................................................................................................................................1126
INSTALLATION.........................................................................................................................................................................1132
DIFFERENTIAL.............................................................................................................................................................................1133
REMOVAL..............................................................................................................................................................................1133
INSTALLATION.........................................................................................................................................................................1135
DISASSEMBLY..........................................................................................................................................................................1136
ASSEMBLY.............................................................................................................................................................................1140
FINAL DRIVE..............................................................................................................................................................................1146
DISASSEMBLY..........................................................................................................................................................................1146
ASSEMBLY.............................................................................................................................................................................1149
ORBIT-ROLL...............................................................................................................................................................................1154
REMOVAL..............................................................................................................................................................................1154
INSTALLATION.........................................................................................................................................................................1155
EMERGENCY STEERING PUMP..................................................................................................................................................................1156
REMOVAL AND INSTALLATION.............................................................................................................................................................1156
DIVERTER VALVE...........................................................................................................................................................................1157
REMOVAL AND INSTALLATION.............................................................................................................................................................1157
DISASSEMBLY..........................................................................................................................................................................1158
ASSEMBLY.............................................................................................................................................................................1159
ACCUMULATOR CHARGE VALVE.................................................................................................................................................................1161
REMOVAL AND INSTALLATION.............................................................................................................................................................1161
DISASSEMBLY..........................................................................................................................................................................1162
ASSEMBLY.............................................................................................................................................................................1163
STEERING STOP VALVE......................................................................................................................................................................1165
REMOVAL AND INSTALLATION.............................................................................................................................................................1165
STEERING CYLINDER........................................................................................................................................................................1166
REMOVAL..............................................................................................................................................................................1166
INSTALLATION.........................................................................................................................................................................1167
STEERING VALVE...........................................................................................................................................................................1174
REMOVAL..............................................................................................................................................................................1174
INSTALLATION.........................................................................................................................................................................1175
BRAKE VALVE..............................................................................................................................................................................1176
REMOVAL AND INSTALLATION.............................................................................................................................................................1176
SLACK ADJUSTER...........................................................................................................................................................................1177
REMOVAL AND INSTALLATION.............................................................................................................................................................1177
DISASSEMBLY..........................................................................................................................................................................1178
ASSEMBLY.............................................................................................................................................................................1179
BRAKE....................................................................................................................................................................................1180
REMOVAL AND INSTALLATION.............................................................................................................................................................1180
DISASSEMBLY..........................................................................................................................................................................1181
ASSEMBLY.............................................................................................................................................................................1184
PARKING BRAKE CALIPERS...................................................................................................................................................................1188
REMOVAL AND INSTALLATION.............................................................................................................................................................1188
DISASSEMBLY..........................................................................................................................................................................1189
ASSEMBLY.............................................................................................................................................................................1191
PARKING BRAKE PAD........................................................................................................................................................................1193
REMOVAL AND INSTALLATION.............................................................................................................................................................1193
PARKING BRAKE SPRING CYLINDER............................................................................................................................................................1194
REMOVAL AND INSTALLATION.............................................................................................................................................................1194
BRAKE OIL TANK...........................................................................................................................................................................1195
REMOVAL AND INSTALLATION.............................................................................................................................................................1195
HYDRAULIC PUMP ..........................................................................................................................................................................1196
REMOVAL..............................................................................................................................................................................1196
INSTALLATION.........................................................................................................................................................................1198
PISTON PUMP..............................................................................................................................................................................1200
DISASSEMBLY..........................................................................................................................................................................1200
ASSEMBLY.............................................................................................................................................................................1206
SERVO CYLINDER...........................................................................................................................................................................1222
REMOVAL AND INSTALLATION.............................................................................................................................................................1222
HYDRAULIC TANK AND FILTER CASE ASSEMBLY .................................................................................................................................................1223
REMOVAL..............................................................................................................................................................................1223
INSTALLATION.........................................................................................................................................................................1224
PPC VALVE................................................................................................................................................................................1225
REMOVAL..............................................................................................................................................................................1225
INSTALLATION.........................................................................................................................................................................1226
DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1227
WORK EQUIPMENT CONTROL VALVE.............................................................................................................................................................1228
REMOVAL..............................................................................................................................................................................1228
INSTALLATION.........................................................................................................................................................................1229
DISASSEMBLY..........................................................................................................................................................................1230
ASSEMBLY.............................................................................................................................................................................1232
CAB......................................................................................................................................................................................1234
REMOVAL..............................................................................................................................................................................1234
INSTALLATION.........................................................................................................................................................................1236
FLOOR FRAME..............................................................................................................................................................................1237
REMOVAL..............................................................................................................................................................................1237
INSTALLATION.........................................................................................................................................................................1239
CENTER HINGE PIN ........................................................................................................................................................................1240
REMOVAL..............................................................................................................................................................................1240
INSTALLATION.........................................................................................................................................................................1246
WORK EQUIPMENT .........................................................................................................................................................................1252
REMOVAL..............................................................................................................................................................................1252
INSTALLATION.........................................................................................................................................................................1257
BOOM FRONT END BUSH......................................................................................................................................................................1258
REPLACEMENT..........................................................................................................................................................................1258
BUCKET CYLIMDER..........................................................................................................................................................................1259
REMOVAL AND INSTALLATION.............................................................................................................................................................1259
LIFT CYLINDER............................................................................................................................................................................1260
REMOVAL..............................................................................................................................................................................1260
INSTALLATION.........................................................................................................................................................................1261
HYDRAULIC CYLINDER.......................................................................................................................................................................1262
DISASSEMBLY..........................................................................................................................................................................1262
ASSEMBLY.............................................................................................................................................................................1264
AIR CONDITIONER UNIT.....................................................................................................................................................................1266
REMOVAL..............................................................................................................................................................................1266
INSTALLATION.........................................................................................................................................................................1267
AIR CONDITIONER COMPRESSOR...............................................................................................................................................................1268
REMOVAL AND INSTALLATION.............................................................................................................................................................1268
RECEIVER TANK............................................................................................................................................................................1269
REMOVAL AND INSTALLATION.............................................................................................................................................................1269
AIR CONDITIONER CONDENSER................................................................................................................................................................1270
REMOVAL AND INSTALLATION.............................................................................................................................................................1270
TRANSMISSION AND STEERING CONTROLLER.....................................................................................................................................................1271
REMOVAL AND INSTALLATION.............................................................................................................................................................1271
MAIN MONITOR.............................................................................................................................................................................1272
REMOVAL..............................................................................................................................................................................1272
INSTALLATION.........................................................................................................................................................................1273
FUEL TANK................................................................................................................................................................................1274
REMOVAL..............................................................................................................................................................................1274
INSTALLATION.........................................................................................................................................................................1275
COUNTERWEIGHT............................................................................................................................................................................1276
REMOVAL AND INSTALLATION.............................................................................................................................................................1276
AJSS LEVER SWITCH ASSEMBLY...............................................................................................................................................................1277
REMOVAL..............................................................................................................................................................................1277
INSTALLATION.........................................................................................................................................................................1280
40 MAINTENANCE STANDARD......................................................................................................................................................................1285
ENGINE MOUNT.............................................................................................................................................................................1286
TRANSMISSION MOUNT.......................................................................................................................................................................1287
DAMPER...................................................................................................................................................................................1288
TORQUE CONVERTER CHARGING,PPC AND BRAKE PUMP.............................................................................................................................................1290
TORQUE CONVERTER .......................................................................................................................................................................1292
TORQUE CONVERTER REGULATOR VALVE.........................................................................................................................................................1293
TRANSMISSION.............................................................................................................................................................................1294
TRANSFER.................................................................................................................................................................................1297
TRANSMISSION CONTROL VALVE...............................................................................................................................................................1300
DRIVE SHAFT..............................................................................................................................................................................1305
CENTER SUPPORT...........................................................................................................................................................................1306
DIFFERENTIAL.............................................................................................................................................................................1307
FINAL DRIVE..............................................................................................................................................................................1310
AXLE MOUNT...............................................................................................................................................................................1312
CENTER HINGE PIN.........................................................................................................................................................................1314
STEERING COLUMN..........................................................................................................................................................................1316
STEERING DEMAND VALVE....................................................................................................................................................................1318
DIVERTER VALVE...........................................................................................................................................................................1320
STEERING CYLINDER MOUNT..................................................................................................................................................................1321
EMERGENCY STEERING PUMP..................................................................................................................................................................1322
BRAKE VALVE..............................................................................................................................................................................1324
SLACK ADJUSTER...........................................................................................................................................................................1328
BRAKE....................................................................................................................................................................................1330
PARKING BRAKE............................................................................................................................................................................1332
PPC VALVE................................................................................................................................................................................1334
PPC RELIEF VALVE.........................................................................................................................................................................1336
CONTROL PUMP.............................................................................................................................................................................1337
STEERING PUMP............................................................................................................................................................................1338
SWITCH PUMP..............................................................................................................................................................................1339
MAIN PISTON PUMP.........................................................................................................................................................................1340
MAIN CONTROL VALVE.......................................................................................................................................................................1342
HYDRAULIC CYLINDER.......................................................................................................................................................................1346
BUCKET LINKAGE...........................................................................................................................................................................1348
BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................................................................1350
90 OTHERS....................................................................................................................................................................................1351
ELECTRIC CIRCUIT DIAGRAM (1/16)..........................................................................................................................................................1353
ELECTRIC CIRCUIT DIAGRAM (2/16)..........................................................................................................................................................1355
ELECTRIC CIRCUIT DIAGRAM (3/16)..........................................................................................................................................................1357
ELECTRIC CIRCUIT DIAGRAM (4/16)..........................................................................................................................................................1359
ELECTRIC CIRCUIT DIAGRAM (5/16)..........................................................................................................................................................1361
ELECTRIC CIRCUIT DIAGRAM (6/16)..........................................................................................................................................................1363
ELECTRIC CIRCUIT DIAGRAM (7/16)..........................................................................................................................................................1365
ELECTRIC CIRCUIT DIAGRAM (8/16)..........................................................................................................................................................1367
ELECTRIC CIRCUIT DIAGRAM (9/16)..........................................................................................................................................................1369
ELECTRIC CIRCUIT DIAGRAM (10/16).........................................................................................................................................................1371
ELECTRIC CIRCUIT DIAGRAM (11/16).........................................................................................................................................................1373
ELECTRIC CIRCUIT DIAGRAM (12/16).........................................................................................................................................................1375
ELECTRIC CIRCUIT DIAGRAM (13/16).........................................................................................................................................................1377
ELECTRIC CIRCUIT DIAGRAM (14/16).........................................................................................................................................................1379
ELECTRIC CIRCUIT DIAGRAM (15/16).........................................................................................................................................................1381
ELECTRIC CIRCUIT DIAGRAM (16/16).........................................................................................................................................................1383
ELECTRIC CIRCUIT DIAGRAM (REMOTE BOOM POSITIONER)........................................................................................................................................1385
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING SPECIFICATION)...................................................................................................................................1387DESCRIPTION:
KOMATSU AVANCE LOADER WA800-3 SHOP MANUAL SEBM013419 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
S.S 26/12/24
