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KOMATSU AVANCE LOADER WA800L-3 SHOP MANUAL SEBM035607 – PDF DOWNLOAD
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Description
KOMATSU AVANCE LOADER WA800L-3 SHOP MANUAL SEBM035607 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU AVANCE LOADER WA800L-3 SHOP MANUAL SEBM035607 – PDF DOWNLOAD
Language : English
Pages : 858
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA800L-3 SHOP MANUAL SEBM035607 – PDF DOWNLOAD
COVER.......................................................................................................................................................................................... 1 CONTENTS....................................................................................................................................................................................... 2 01 GENERAL..................................................................................................................................................................................... 29 GENERAL ASSEMBLY DRAWING................................................................................................................................................................... 30 SPECIFICATIONS............................................................................................................................................................................. 31 WEIGHT TABLE............................................................................................................................................................................... 34 LIST OF LUBRICANT AND WATER................................................................................................................................................................ 36 10 STRUCTURE AND FUNCTION...................................................................................................................................................................... 45 POWER TRAIN................................................................................................................................................................................ 46 POWER TRAIN SYSTEM......................................................................................................................................................................... 47 ENGINE CONTROL............................................................................................................................................................................. 48 RADIATOR AND COOLER........................................................................................................................................................................ 50 DAMPER..................................................................................................................................................................................... 52 TORQUE CONVERTER AND TRNSMISSION PIPING.................................................................................................................................................... 53 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...................................................................................................................................................... 54 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................... 55 TORQUE CONVERTER........................................................................................................................................................................... 56 TRANSMISSION............................................................................................................................................................................... 61 TRANSFER................................................................................................................................................................................... 69 TRANSMISSION CONTROL VALVE................................................................................................................................................................. 70 TORQUE CONVERTER OIL COOLER................................................................................................................................................................ 86 DRIVE SHAFT................................................................................................................................................................................ 87 CENTER SUPPORT............................................................................................................................................................................. 88 AXLE....................................................................................................................................................................................... 89 DIFFERENTIAL............................................................................................................................................................................... 91 FINAL DRIVE................................................................................................................................................................................ 94 CENTER HINGE PIN........................................................................................................................................................................... 95 AXLE MOUNT................................................................................................................................................................................. 96 TIRE AND WHEEL............................................................................................................................................................................. 98 STEERING PIPING............................................................................................................................................................................ 99 JOYSTICK STEERING LINKAGE..................................................................................................................................................................100 STEERING PUMP..............................................................................................................................................................................102 SWITCH PUMP................................................................................................................................................................................104 STEERING DEMAND VALVE......................................................................................................................................................................106 EPC VALVE..................................................................................................................................................................................117 ROTARY VALVE...............................................................................................................................................................................118 TWO-WAY RESTRICTOR VALVE...................................................................................................................................................................120 DIVERTER VALVE.............................................................................................................................................................................121 BRAKE PIPING...............................................................................................................................................................................125 BRAKE CIRCUIT DIAGRAM......................................................................................................................................................................126 BRAKE VALVE................................................................................................................................................................................128 CHARGE VALVE...............................................................................................................................................................................133 ACCUMULATOR (FOR BRAKE)....................................................................................................................................................................137 SLACK ADJUSTER.............................................................................................................................................................................138 BRAKE......................................................................................................................................................................................141 PARKING BRAKE..............................................................................................................................................................................142 SPRING CYLINDER............................................................................................................................................................................144 PARKING BRAKE SOLENOID VALVE...............................................................................................................................................................145 HYDRAULIC PIPING...........................................................................................................................................................................146 WORK EQUIPMENT LEVER LINKAGE...............................................................................................................................................................149 HYDRAULIC TANK.............................................................................................................................................................................150 MAIN PISTON PUMP...........................................................................................................................................................................153 ES VALVE (ENGINE SENSING VALVE)............................................................................................................................................................161 SERVO VALVE................................................................................................................................................................................163 PPC VALVE (PROPORTIONAL PRESSURE VALVE)....................................................................................................................................................166 PPC RELIEF VALVE...........................................................................................................................................................................170 ACCUMULATOR (FOR PPC VALVE)................................................................................................................................................................171 MAIN CONTROL VALVE.........................................................................................................................................................................172 LUBRICATION OF WORK EQUIPMENT..............................................................................................................................................................185 WORK EQUIPMENT LINKAGE.....................................................................................................................................................................188 BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................................................................................190 OPERATION OF PROXIMITY SWITCH..............................................................................................................................................................192 CAB AND ROPS CANOPY........................................................................................................................................................................196 AIR CONDITIONER............................................................................................................................................................................198 MACHINE MONITOR SYSTEM.....................................................................................................................................................................202 MAIN MONITOR...............................................................................................................................................................................203 MAINTENANCE MONITOR........................................................................................................................................................................207 ENGINE STARTING CIRCUIT....................................................................................................................................................................210 ENGINE STOP CIRCUIT........................................................................................................................................................................213 PREHEATING CIRCUIT.........................................................................................................................................................................214 ELECTRICAL TRANSMISSION CONTROL............................................................................................................................................................215 KICK-DOWN, HOLD SWITCH.....................................................................................................................................................................216 AUTOMATIC TRANSMISSION (ATM) SYTEM.........................................................................................................................................................217 AJSS (ADVANCED JOYSTICK STEERING SYSTEM)...................................................................................................................................................227 ELECTRIC PARKING BRAKE CONTROL.............................................................................................................................................................232 20 TESTING AND ADJUSTING.......................................................................................................................................................................241 STANDARD VALUE TABLE FOR ENGINE............................................................................................................................................................242 STANDARD VALUE TABLE FOR CHASSIS...........................................................................................................................................................243 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..................................................................................................................................................249 TESTING AND ADJUSTING......................................................................................................................................................................259 TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..............................................................................................................................260 MEASURING ENGINE SPEED.................................................................................................................................................................262 MEASURING EXHAUST GAS COLOR............................................................................................................................................................263 ADJUSTING VALVE CLEARANCE..............................................................................................................................................................264 MEASURING COMPRESSION PRESSURE.........................................................................................................................................................264 MEASURING BLOW-BY PRESSURE.............................................................................................................................................................264 TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................................................................264 MEASURING ENGINE OIL PRESSURE..........................................................................................................................................................264 MEASURING EXHAUST TEMPERATURE..........................................................................................................................................................264 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).........................................................................................................................................264 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..........................................................................................................................................265 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR......................................................................................................................266 MEASURING ACCELERATOR PEDAL ...........................................................................................................................................................267 TESTING OF UPPER DRIVE SHAFT SLIDING PART..............................................................................................................................................268 TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE...................................................................................................................270 PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS.........................................................................................................272 TESTING AND ADJUSTING STEERING OIL PRESSURE ...........................................................................................................................................274 TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE .................................................................................................................................275 BLEEDING AIR FROM STEERING CIRCUIT.....................................................................................................................................................277 TESTING AND ADJUSTING STEERING STOPPER BOLT............................................................................................................................................278 TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR...............................................................................................................279 TESTING WHEEL BRAKE PERFORMANCE........................................................................................................................................................280 TESTING WHEEL BRAKE OIL PRESSURE DROP..................................................................................................................................................281 MEASURING WEAR OF WHEEL BRAKE DISC.....................................................................................................................................................283 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...................................................................................................................284 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS..................................................................................286 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT..................................................................................................................................................294 TESTING PARKING BRAKE PERFORMANCE......................................................................................................................................................295 MEASURING PARKING RAKE SOLENOID OUTPUT PRESSURE........................................................................................................................................296 CHECKING AND ADJUSTING PARKING BRAKE PAD...............................................................................................................................................297 TESTING AND ADJUSTING PPC PRESSURE.....................................................................................................................................................299 ADJUSTING PPC VALVE LINKAGE............................................................................................................................................................300 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE................................................................................................................................301 BLEEDING AIR FROM PISTON PUMP..........................................................................................................................................................303 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT...............................................................................................................................................304 ADJUSTING WORK EQUIPMENT LEVER LINKAGE.................................................................................................................................................305 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT......................................................................................................................................306 TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH..........................................................................................................................................307 TESTING AND ADJUSTING BOOM PROXIMITY SWITCH............................................................................................................................................307 TESTING PROXIMITY ACTUATION PILOT LAMP.................................................................................................................................................308 ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR...........................................................................................................................................309 TROUBLESHOOTING............................................................................................................................................................................311 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................................................................312 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................................................................313 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................314 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................................................................322 TYPES AND LOCATIONS OF CONNECTORS......................................................................................................................................................323 CONNECTOR LOCATION STEREOGRAM..........................................................................................................................................................330 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................................................................336 T-BRANCH BOX AND T-BRANCH TABLE........................................................................................................................................................361 EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM.................................................................................................................................364 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE......................................................................................................................................368 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION...............................................................................................................................370 TRANSMISSION CONTROLLER LED DISPLAY....................................................................................................................................................372 METHOD OF USING JUDGEMENT TABLE........................................................................................................................................................373 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................................................374 METHOD OF USING MATRIX TROUBLESHOOTING TABLES..........................................................................................................................................376 TROUBLESHOOTING OF ENGINE (S MODE).....................................................................................................................................................379 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................................................380 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................................................................384 S-2 ENGINE DOES NOT START..........................................................................................................................................................385 (1) ENGINE DOES NOT TURN.......................................................................................................................................................385 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (INCLUDING CASES WITH V-TYPE ENGINE WHERE THERE IS NO FUEL INJECTION FOR THE BANK ON ONE SIDE)......386 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...................................................................................................387 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...........................................................................................................................388 S-4 ENGINE STOPS DURING OPERATIONS (FOR V TYPE ENGINE, INCLUDING CASES WHERE ONE BANK STOPS).......................................................................................389 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)......................................................................................................................................390 S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH V-TYPE ENGINE, FOR CASES WHERE THERE IS INJECTION FOR ONLY ONE BANK, GO TO TROUBLESHOOTING S-2-(2) OR S-4.)...............................391 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...................................................................................................................................392 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..........................................................................................................................393 S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................................................................394 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................................................................395 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................................................................................................396 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................................................................................397 S-13 OIL LEVEL RISES...............................................................................................................................................................398 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..............................................................................................................................399 S-15 ABNORMAL NOISE IS MADE........................................................................................................................................................400 S-16 VIBRATION IS EXCESSIVE........................................................................................................................................................401 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)................................................................................................................................403 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS......................................................................................................................404 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................................................................................406 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM.........................................................................................................................410 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED............................................................412 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...................................................................413 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED...................................................................414 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED.................................................................415 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED.................................................................416 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED.................................................................417 T-7 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVER SWITCH SYSTEM) IS DISPLAYED................................................................................418 T-8 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED..................................................................419 T-9 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED..........................................................................................................420 T-10 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...................................................................................421 T-11 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM...................................................................................................................422 T-12 TRANSMISSION CUT-OFF SIGNAL SYSTEM............................................................................................................................................423 T-13 NEUTRALIZER SIGNAL SYSTEM.....................................................................................................................................................424 T-14 BUZZER SIGNAL SYSTEM..........................................................................................................................................................425 T-15 NETWORK SYSTEM................................................................................................................................................................426 T-16 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM...................................................................................................................................427 T-17 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...................................................................................................................................428 T-18 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS...............................................................................................................................429 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)........................................................................................................................................431 TROUBLE DATA DISPLAY...............................................................................................................................................................433 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM.................................................................................................................................436 M-1 MAIN MONITOR DOES NOT WORK.....................................................................................................................................................438 M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE S STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP...............................................................439 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.....................................................................................................................................440 M-4 ABNORMALITY IN SHIFT INDICATOR.................................................................................................................................................441 a) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT F.............................................................................................................................441 b) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT R.............................................................................................................................441 c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL SWITCH IS AT N (DISPLAY 1ST-3RD)...................................................................................................441 M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP..........................................................................................................................................443 a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP..................................................................................................................................443 b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP..................................................................................................................................443 M-6 ABNORMALITY IN PARKING DISPLAY.................................................................................................................................................445 a) PARKING LAMP DISPLAY DOES NOT LIGHT UP......................................................................................................................................445 b) PARKING LAMP DISPLAY STAYS LIGHTED UP.......................................................................................................................................445 M-7 NIGHT LIGHTING DOES NOT LIGHT UP...............................................................................................................................................446 M-8 ABNORMALITY IN FRONT WORKING LAMP..............................................................................................................................................448 a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP.....................................................................................................................448 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................................................................................................................448 c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP..........................................................................................................448 M-9 ABNORMALITY IN REAR WORKING LAMP...............................................................................................................................................450 a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP......................................................................................................................450 b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...........................................................................................................450 c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP...........................................................................................................450 M-10 ABNORMALITY IN TRANSMISSION CUT-OFF...........................................................................................................................................452 a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE..................................................452 b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED.................................452 c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED............................................................452 d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)...................................................................452 e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED.....................................................................453 M-11 ABNORMALITY IN LOW IDLE SELECTION.............................................................................................................................................454 a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLE SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE...................................................454 b) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLE SPEED DOES NOT RISE.....................................................454 c) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLE SPEED DOES NOT LOWER....................................................455 M-12 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY..............................................................................................................................456 M-13 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY...........................................................................................................................457 a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP......................................................................................................................457 b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP.......................................................................................................................457 M-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.................................................................................................................................458 a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL SWITCH IS AT N.................................................458 b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL SWITCH IS AT POSITION OTHER THAN N............................458 M-15 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED.....................................................459 a) ACTUATED CONTINUOUSLY.......................................................................................................................................................459 b) NOT ACTUATED................................................................................................................................................................459 M-16 ABNORMALITY IN BUZZER.........................................................................................................................................................460 a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK).....................................................................................460 b) BUZZER ALWAYS SOUNDS........................................................................................................................................................460 M-17 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY.........................................................................................................................461 M-18 ABNORMALITY IN FAILURE DISPLAY MODE...........................................................................................................................................462 a) DOES NOT ENTER FAILURE DISPLAY MODE.........................................................................................................................................462 b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE...............................................................................................462 M-19 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER....................................................................................................463 M-20 ABNORMALITY IN AUTO-GREASING SYSTEM...........................................................................................................................................464 a) CHECK POWER SUPPLY SYSTEM 1 (RELAY G1)......................................................................................................................................464 b) CHECK POWER SUPPLY SYSTEM 2 (RELAY G2)......................................................................................................................................464 c) FORCED GREASING DOES NOT START..............................................................................................................................................465 d) MONITOR DOES NOT FLASH WHILE GREASE IS BEING SUPPLIED.......................................................................................................................465 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.................................466 M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK).............................................................................................................468 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).................................................................................................................................469 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM..........................................................................................................................470 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOSE NOT WORK...........................................472 a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP....................................................................................................................................472 b) SOME LAMPS DO NOT LIGHT UP..................................................................................................................................................472 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)..........................................................473 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT...............................................474 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH..........................................................................................................476 a) ENGINE OIL LEVEL DISPLAY FLASHES............................................................................................................................................476 b) ENGINE WATER LEVEL DISPLAY FLASHES..........................................................................................................................................477 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH........................................................................................................478 a) ENGINE OIL PRESSURE DISPLAY FLASHES.........................................................................................................................................478 b) BATTERY CHARGE LEVEL DISPLAY FLASHES........................................................................................................................................479 c) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE BRAKE OIL PRESSURE IS CORRECT.)..........................................................................................480 d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (R.H.) IS NOT CLOGGED.).............................................................................482 e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (L.H.) IS NOT CLOGGED.).............................................................................483 f) TRANSMISSION OIL FILTER DISPLAY FLASHES (THE TRANSMISSION OIL FILTER MUST NOT BE CLOGGED.)..................................................................................484 K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND...........................................................................................................................485 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS...........................................................................................................486 K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES.....................................................................................................487 a) CHECK LAMP..................................................................................................................................................................487 b) CAUTION LAMP................................................................................................................................................................487 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP................................................................................488 a) CHECK LAMP..................................................................................................................................................................488 b) CAUTION LAMP................................................................................................................................................................488 K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON................................................................................489 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF..............................................................................................................490 K-12 SERVICE METER DOES NOT WORK...................................................................................................................................................491 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED..........................................................................................................................491 K-14 ABNORMALITY IN GAUGE DISPLAY..................................................................................................................................................493 a) ABNORMALITY IN FUEL GAUGE...................................................................................................................................................493 b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...............................................................................................................................494 c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.......................................................................................................................495 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..........................................................................................................................................497 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING.......................................................................................498 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE.......................................................................................................................................500 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER.................................................................................................................501 E-1 ENGINE DOES NOT START..........................................................................................................................................................502 a) STARTING MOTOR DOES NOT TURN................................................................................................................................................502 b) STARTING MOTOR TURNS........................................................................................................................................................506 E-2 ENGINE DOES NOT................................................................................................................................................................507 E-3 ABNORMALITY IN PREHEATING SYSTEM...............................................................................................................................................510 a) DOES NOT CARRY OUT PREHEATING...............................................................................................................................................510 b) ONLY MONITOR DISPLAY LIGHTS UP..............................................................................................................................................510 c) MONITOR DISPLAY DOES NOT LIGHT UP WHEN PREHEATING IS COMPLETED..............................................................................................................511 d) MONITOR DISPLAY KEEPS LIGHTING UP WHEN PREHEATING IS NOT COMPLETED..........................................................................................................511 E-4 PARKING BRAKE DOES NOT HAVE EFFECT.............................................................................................................................................513 a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON..........................................................................................................513 b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE).............................................................513 E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.............................................................................................................................514 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON....................................................................................................................516 E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY).......................................................................516 E-8 KICK-DOWN SWITCH DOES NOT WORK.................................................................................................................................................518 a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY........................................................................................................518 b) KICK-DOWN CANNOT BE CANCELED................................................................................................................................................519 E-9 BOOM KICK-OUT DOES NOT WORK....................................................................................................................................................520 E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION.....................................................................................................................................524 E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP..............................................................................................................................527 E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP...............................................................................................................................527 E-13 ABNORMALITY IN TRANSMISSION CUT-OFF...........................................................................................................................................527 E-14 ABNORMALITY IN LOW IDLING SELECTION...........................................................................................................................................527 E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.................................................................................................................................527 E-16 ABNORMALITY IN BUZZER.........................................................................................................................................................527 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)............................................................................................................................529 H-1 MACHINE DOES NOT MOVE..........................................................................................................................................................530 H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)...............................................................................................................................531 H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR......................................................................................................................532 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.......................................................................................................................................533 H-5 STEERING DOES NOT TURN.........................................................................................................................................................534 H-6 TURNING, RESPONSE OF STEERING IS POOR..........................................................................................................................................535 H-7 JOYSTICK LEVER IS HEAVY........................................................................................................................................................536 H-8 STEERING WHEEL SHAKES OR JERKS.................................................................................................................................................537 H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT..........................................................................................................................538 H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR............................................................................................................................539 H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG..................................................................................................................................540 H-12 BOOM DOES NOT RISE............................................................................................................................................................541 H-13 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...................................................................................................................542 H-14 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT.............................................................................................................................543 H-15 BOOM CYLINDER CANNOT HOLD DOWN BUCKET.........................................................................................................................................543 H-16 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT......................................................................................................................................543 H-17 BOOM FLUCTUATES WHILE WORKING.................................................................................................................................................544 H-18 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE..............................................................................................................544 H-19 BUCKET DOES NOT TILT BACK.....................................................................................................................................................545 H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER.......................................................................................................................546 H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK.................................................................................................................................547 H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET.......................................................................................................................................547 H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT....................................................................................................................................547 H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE "HOLD")....................................................................................................548 H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT.............................................................................................................548 H-26 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY...................................................................................................................................549 TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)....................................................................................................551 JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM............................................................................................................................................552 OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY.......................................................................................554 ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL..........................................................................................................................................558 A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED.............................................................560 A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED......................................................561 A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED.......................................................................562 A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED...............................................................563 A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED..............................................564 A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED.................................................565 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....566 A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT...............................................................................................................................567 A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE).................................................................568 A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE.......................................................................................................................................569 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................571 METHOD OF USING MANUAL.....................................................................................................................................................................573 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................................................................575 SPECIAL TOOL LIST..........................................................................................................................................................................577 SKETCHES OF SPECIAL TOOLS..................................................................................................................................................................583 ENGINE RELATED PARTS.......................................................................................................................................................................591 STARTING MOTOR.........................................................................................................................................................................591 ALTERNATOR.............................................................................................................................................................................591 ENGINE OIL COOLER......................................................................................................................................................................591 FUEL INJECTION PUMP FOR LEFT BANK......................................................................................................................................................591 FUEL INJECTION PUMP FOR RIGHT BANK.....................................................................................................................................................591 WATER PUMP.............................................................................................................................................................................591 NOZZELE HODLER.........................................................................................................................................................................591 TURBOCHARGER...........................................................................................................................................................................591 ENGINE FRONT SEAL......................................................................................................................................................................591 ENGINE REAR SEAL.......................................................................................................................................................................591 CYLINDER HEAD..........................................................................................................................................................................591 REMOVAL AND INSTALLATION OF RADIATOR.......................................................................................................................................................592 REMOVAL AND INSTALLATION OF ENGINE.........................................................................................................................................................595 REMOVAL AND INSTALLATION OF DAMPER ........................................................................................................................................................600 DISASSEMBLY AND ASSEMBLY OF DAMPER.........................................................................................................................................................601 REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY.....................................................................................................................605 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER...............................................................................................................................................612 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE.........................................................................................................................................619 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION...................................................................................................................................................620 REMOVAL AND INSTALLATION OF TRANSMISSION VALVE.............................................................................................................................................644 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE.............................................................................................................................................645 DISASSEMBLY AND ASSEMBLY OF TRANSFER.......................................................................................................................................................649 DISASSEMBLY AND ASSEMBLY OF PTO............................................................................................................................................................663 REMOVAL AND INSTALLATION OF CENTER SUPPORT.................................................................................................................................................668 DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT.................................................................................................................................................670 DISASSEMBLY AND ASSEMBLY OF DRIVE SHAFT....................................................................................................................................................674 REMOVAL AND INSTALLATION OF FRONT AXLE.....................................................................................................................................................677 REMOVAL AND INSTALLATION OF REAR AXLE......................................................................................................................................................679 REMOVAL AND INSTALLATION OF DIFFERENTIAL...................................................................................................................................................684 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL...................................................................................................................................................686 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE....................................................................................................................................................694 REMOVAL AND INSTALLATION OF ROTARY VALVE...................................................................................................................................................699 REMOVAL AND INSTALLATION OF EMERGENCY STEERING PUMP........................................................................................................................................700 REMOVAL AND INSTALLATION OF DIVERTER VALVE.................................................................................................................................................701 DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE.................................................................................................................................................702 REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE.......................................................................................................................................704 DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE.......................................................................................................................................705 REMOVAL AND INSTALLATION OF STEERING CYLINDER..............................................................................................................................................707 REMOVAL AND INSTALLATION OF STEERING VALVE.................................................................................................................................................709 REMOVAL AND INSTALLATION OF BRAKE VALVE....................................................................................................................................................711 REMOVAL AND INSTALLATION OF SLACK ADJUSTER.................................................................................................................................................712 DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER.................................................................................................................................................713 REMOVAL AND INSTALLATION OF BRAKE..........................................................................................................................................................715 DISASSEMBLY AND ASSEMBLY OF BRAKE..........................................................................................................................................................716 REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS.........................................................................................................................................722 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS.........................................................................................................................................723 REMOVAL AND INSTALLATION OF PARKING BRAKE PAD..............................................................................................................................................725 REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER..................................................................................................................................726 REMOVAL AND INSTALLATION OF BRAKE OIL TANK.................................................................................................................................................727 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP.................................................................................................................................................728 REMOVAL AND INSTALLATION OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY........................................................................................................................730 REMOVAL AND INSTALLATION OF PPC VALVE......................................................................................................................................................732 DISASSEMBLY AND ASSEMBLY OF PPC VALVE......................................................................................................................................................734 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY..........................................................................................................................735 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE...................................................................................................................................737 REMOVAL AND INSTALLATION OF CAB............................................................................................................................................................740 REMOVAL AND INSTALLATION OF FLOOR FRAME....................................................................................................................................................742 REMOVAL AND INSTALLATION OF CENTER HINGE PIN...............................................................................................................................................745 REMOVAL AND INSTALLATION OF WORK EQUIPMENT.................................................................................................................................................752 REPLACEMENT OF BOOM FRONT END BUSH.........................................................................................................................................................757 REMOVAL AND INSTALLATION OF BUCKET CYLINDER................................................................................................................................................758 REMOVAL AND INSTALLATION OF LIFT CYLINDER..................................................................................................................................................759 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER.............................................................................................................................................761 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT...........................................................................................................................................765 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR.....................................................................................................................................767 REMOVAL AND INSTALLATION OF RECEIVER TANK..................................................................................................................................................768 REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER......................................................................................................................................769 REMOVAL AND INSTALLATION OF TRANSMISSION AND JOYSTICK STEERING CONTROLLER..................................................................................................................770 REMOVAL AND INSTALLATION OF MAIN MONITOR...................................................................................................................................................771 REMOVAL AND INSTALLATION OF FUEL TANK......................................................................................................................................................773 REMOVAL AND INSTALLATION OF COUNTERWEIGHT..................................................................................................................................................775 REMOVAL AND INSTALLATION OF AJSS LEVER SWITCH ASSEMBLY.....................................................................................................................................776 40 MAINTENANCE STANDARD........................................................................................................................................................................781 ENGINE MOUNT...............................................................................................................................................................................782 TRANSMISSION MOUNT.........................................................................................................................................................................783 DAMPER.....................................................................................................................................................................................784 TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP..............................................................................................................................................786 TORQUE CONVERTER...........................................................................................................................................................................788 TORQUE CONVERTER REGULATOR VALVE...........................................................................................................................................................789 TRANSMISSION (1/2).........................................................................................................................................................................790 TRANSMISSION (2/2).........................................................................................................................................................................792 TRANSFER...................................................................................................................................................................................793 TRANSMISSION CONTROL VALVE.................................................................................................................................................................794 DRIVE SHAFT................................................................................................................................................................................799 CENTER SUPPORT.............................................................................................................................................................................800 DIFFERENTIAL (1/2).........................................................................................................................................................................801 DIFFERENTIAL (2/2).........................................................................................................................................................................802 FINAL DRIVE................................................................................................................................................................................804 AXLE MOUNT.................................................................................................................................................................................806 CENTER HINGE PIN...........................................................................................................................................................................808 STEERING DEMAND VALVE......................................................................................................................................................................810 DIVERTER VALVE.............................................................................................................................................................................812 STEERING CYLINDER MOUNT....................................................................................................................................................................813 EMERGENCY STEERING PUMP....................................................................................................................................................................814 BRAKE VALVE................................................................................................................................................................................816 SLACK ADJUSTER.............................................................................................................................................................................819 BRAKE......................................................................................................................................................................................820 PARKING BRAKE..............................................................................................................................................................................822 PPC VALVE..................................................................................................................................................................................824 PPC RELIEF VALVE...........................................................................................................................................................................826 CONTROL PUMP...............................................................................................................................................................................827 STEERING PUMP..............................................................................................................................................................................828 SWITCH PUMP................................................................................................................................................................................829 MAIN PISTON PUMP...........................................................................................................................................................................830 MAIN CONTROL VALVE.........................................................................................................................................................................832 HYDRAULIC CYLINDER.........................................................................................................................................................................834 WORK EQUIPMENT LINKAGE.....................................................................................................................................................................836 BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................................................................................838 ROPS CANOPY................................................................................................................................................................................839 90 OTHERS......................................................................................................................................................................................841 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................................843 ELECTRICAL CIRCUIT DIAGRAM (1/5)...........................................................................................................................................................845 ELECTRICAL CIRCUIT DIAGRAM (2/5)...........................................................................................................................................................847 ELECTRICAL CIRCUIT DIAGRAM (3/5)...........................................................................................................................................................849 ELECTRICAL CIRCUIT DIAGRAM (4/5)...........................................................................................................................................................851 ELECTRICAL CIRCUIT DIAGRAM (5/5)...........................................................................................................................................................853 ELECTRICAL CIRCUIT DIAGRAM (ENGINE SHUT-DOWN)..............................................................................................................................................855 ELECTRICAL CIRCUIT DIAGRAM (AUTO-GREASING).................................................................................................................................................857
DESCRIPTION:
KOMATSU AVANCE LOADER WA800L-3 SHOP MANUAL SEBM035607 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual 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 22/12/24
