Komatsu Avance Loader WA900L-3 Shop Manual SEBM035704 – PDF DOWNLOAD

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Komatsu Avance Loader WA900L-3 Shop Manual SEBM035704 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Avance Loader WA900L-3 Shop Manual SEBM035704 – PDF DOWNLOAD

Language : English
Pages :831
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Avance Loader WA900L-3 Shop Manual SEBM035704 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
WA900L-3 52001 and up

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.

TABLE OF CONTENTS:

Komatsu Avance Loader WA900L-3 Shop Manual SEBM035704 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
WA900L-3 52001 and up

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 44
POWER TRAIN 45
POWER TRAIN SYSTEM 46
ENGINE CONTROL 47
RADIATOR AND COOLER 48
DAMPER 50
TORQUE CONVERTER AND TRANSMISSION PIPING 51
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 53
TORQUE CONVERTER 54
TRANSMISSION 59
TRANSFER 67
TRANSMISSION CONTROL VALVE 68
TORQUE CONVERTER OIL COOLER 84
DRIVE SHAFT 85
CENTER SUPPORT 86
AXLE 87
DIFFERENTIAL 89
FINAL DRIVE 92
CENTER HINGE PIN 93
AXLE MOUNT 94
TIRE AND WHEEL 96
STEERING PIPING 97
JOYSTICK STEERING LINKAGE 98
STEERING PUMP 99
SWITCH PUMP101
STEERING DEMAND VALVE109
EPC VALVE120
ROTARY VALVE121
TWO-WAY RESTRICTOR VALVE123
DIVERTER VALVE124
BRAKE PIPING128
BRAKE CIRCUIT DIAGRAM129
BRAKE VALVE131
CHARGE VALVE136
ACCUMULATOR (FOR BRAKE)140
SLACK ADJUSTER141
BRAKE144
PARKING BRAKE145
SPRING CYLINDER147
PARKING BRAKE SOLENOID VALVE148
HYDRAULIC PIPING149
WORK EQUIPMENT LEVER LINKAGE152
HYDRAULIC TANK153
MAIN PISTON PUMP156
ES VALVE (ENGINE SENSING VALVE)164
SERVO VALVE166
PPC VALVE (PROPORTIONAL PRESSURE VALVE)169
PPC RELIEF VALVE173
ACCUMULATOR (FOR PPC VALVE)174
MAIN CONTROL VALVE175
LUBRICATION OF WORK EQUIPMENT188
WORK EQUIPMENT LINKAGE191
BUCKET POSITIONER AND BOOM KICK-OUT193
OPERATION OF PROXIMITY SWITCH195
CRB AND ROPS CANOPY199
AIR CONDITIONER200
MACHINE MONITOR SYSTEM204
MAIN MONITOR205
MAINTENANCE MONITOR209
ENGINE STARTING CIRCUIT212
ENGINE STOP CIRCUIT215
PREHEATING CIRCUIT216
ELECTRICAL TRANSMISSION CONTROL217
KICK-DOWN, HOLD SWITCH218
AUTOMATIC TRANSMISSION (ATM) SYSTEM219
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)229
ELECTRIC PARKING BRAKE CONTROL234
20 TESTING AND ADJUSTING243
STANDARD VALVE TABLE FOR ENGINE244
STANDARD VALVE TABLE FOR CHASSIS245
STANDARD VALVE TABLE FOR ELECTRICAL PARTS249
TESTING AND ADJUSTING259
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING260
MEASURING ENGINE SPEED262
MEASURING EXHAUST GAS COLOR263
ADJUSTING VALVE CLEARANCE264
MEASURING COMPRESSION PRESSURE264
MEASURING BLOW-BY PRESSURE264
TESTING AND ADJUSTING FUEL INJECTION TIMING264
MEASURING ENGINE OIL PRESSURE264
MEASURING EXHAUST TEMPERATURE264
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)264
TESTING AND ADJUSTING ALTERNATOR BELT TENSION265
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR266
MEASURING ACCELERATOR PEDAL267
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE268
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS270
TESTING AND ADJUSTING STEERING OIL PRESSURE272
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE273
BLEEDING AIR FROM STEERING CIRCUIT275
TESTING AND ADJUSTING STEERING STOPPER BOLT276
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR277
TESTING WHEEL BRAKE PERFORMANCE278
TESTING WHEEL BRAKE OIL PRESSURE DROP279
MEASURING WEAR OF WHEEL BRAKE DISC281
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE282
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT284
TESTING PARKING BRAKE PERFORMANCE285
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE286
CHECKING AND ADJUSTING PARKING BRAKE PAD287
TESTING AND ADJUSTING PPC PRESSURE289
ADJUSTING PPC VALVE LINKAGE290
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE291
BLEEDING AIR FROM PISTON PUMP293
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT294
ADJUSTING WORK EQUIPMENT LEVER LINKAGE295
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 296
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH297
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH297
TESTING PROXIMITY ACTUATION PILOT LAMP298
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR299
TROUBLESHOOTING300
POINTS TO REMEMBER WHEN TROUBLESHOOTING301
SEQUENCE OF EVENTS IN TROUBLESHOOTING302
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE303
CHECKS BEFORE TROUBLESHOOTING311
TYPES AND LOCATIONS OF CONNECTORS312
CONNECTOR LOCATION STEREOGRAM318
WIRING TABLE FOR CONNECTOR PIN NUMBERS324
T-ADAPTER BOX AND T-ADAPTER TABLE357
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM360
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE364
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION366
TRANSMISSION CONTROLLER LED DISPLAY368
METHOD OF USING JUDGEMENT TABLE369
METHOD OF USING TROUBLESHOOTING CHARTS370
METHOD OF USING MATRIX TROUBLESHOOTING TABLES372
TROUBLESHOOTING OF ENGINE (S MODE)374
METHOD OF USING TROUBLESHOOTING CHARTS375
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)379
S-2 ENGINE DOES NOT START380
(1) ENGINE DOES NOT TURN380
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES UOT (FUEL IS NOT BEING INJECTED) (INCLUDING CASES WITH V-TYPE ENGINE WHERE THERE IS NO FUEL INJECTION FOR THE BANK ON ONE SIDE)381
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)382
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)383
S-4 ENGINE STOPS DURING OPERATIONS (FOR V TYPE ENGINE, INCLUDING CASES WHERE ONE BANK STOPS)384
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)385
S-6 ENGINE LACKS UOTPUT (NO POWER) (WITH V-TYPE ENGINE, FOR CASES WHERE THERE IS INJECTION FOR ONLY BANK,GO TO TROUBLESHOOTING S-2-(2)OR S-4)386
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)387
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)388
S-9 OIL BECOMES CONTAMINATED QUICKLY389
S-10 FUEL CONSUMPTION IS EXCESSIVE390
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN391
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)392
S-13 OIL LEVEL RISES393
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)394
S-15 ABNORMAL NOISE IS MADE395
S-16 VIBRATION IS EXCESSIVE396
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)397
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS398
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE399
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM403
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED405
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED406
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED407
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED408
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED409
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED410
T-7 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVEL SWITCH SYSTEM) IS DISPLAYED411
T-8 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED412
T-9 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED413
T-10 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED414
T-11 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM 415
T-12 TRANSMISSION CUT-OFF SIGNAL SYSTEM416
T-13 NEUTRALIZER SIGNAL SYSTEM417
T-14 BUZZER SIGNAL SYSTEM418
T-15 NETWORK SYSTEM419
T-16 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM420
T-17 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 421
T-18 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS422
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)423
TROUBLE DATA DISPLAY425
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM427
M-1 MAIN MONITOR DOES NOT WORK429
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP430
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY431
M-4 ABNORMALITY IN SHIFT INDICATOR432
a) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT F432
b) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT R432
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL SWITCH IS AT N (DISPLAY 1ST-3RD)432
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP434
a) LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP434
b) RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP434
M-6 ABNORMALITY IN PARKING DISPLAY436
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP436
b) PARKING LAMP DISPLAY STAYS LIGHT UP436
M-7 NIGHT LIGHTING DOES NOT LIGHT UP437
M-8 ABNORMALITY IN FRONT WORKING LAMP439
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP439
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP439
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP 439
M-9 ABNORMALITY IN REAR WORKING LAMP441
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 441
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 441
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP441
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF443
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE443
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED443
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED443
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)443
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED444
M-11 ABNORMALITY IN LOW IDLE SELECTION445
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLE SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE 445
b) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLE SPEED DOES NOT RISE445
c) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLE SPEED DOES NOT LOWER446
M-12 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY447
M-13 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY448
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP448
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP448
M-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING449
a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL SWITCH IS AT N449
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 N449
M-15 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED450
a) ACTUATED CONTINUOUSLY450
b) NOT ACTUATED450
M-16 ABNORMALITY IN BUZZER451
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)451
b) BUZZER ALWAYS SOUNDS451
M-17 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY452
M-18 ABNORMALITY IN FAILURE DISPLAY MODE453
a) DOES NOT ENTER FAILURE DISPLAY MODE453
b) COUNT FOR TIME ELAPSED SINCE FAILURE DISPLAY MODE DOES NOT ADVANCE453
M-19 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER454
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM455
a) FORCED GREASING CANNOT BE CARRIED OUT455
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)455
c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)455
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY456
e) MONITOR DISPLAY GOES OUT456
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)457
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)458
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM459
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK461
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP461
b) SOME LAMPS DO NOT LIGHT UP461
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)462
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT463
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH465
a) ENGINE OIL LEVEL DISPLAY FLASHES465
b) ENGINE WATER LEVEL DISPLAY FLASHES466
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH467
a) ENGINE OIL PRESSURE DISPLAY FLASHES467
b) BATTERY CHARGE LEVEL DISPLAY FLASHES468
c) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE BRAKE OIL PRESSURE IS CORRECT)469
d) AIR CLEANER (RH) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (RH) IS NOT CLOGGED)471
e) AIR CLEANER (LH) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (LH) IS NOT CLOGGED)472
f) TRANSMISSION OIL FILTER DISPLAY FLASHES (THE TRANSMISSION OIL FILTER MUST NOT BE CLOGGED)473
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND474
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS475
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES476
a) CHECK LAMP476
b) CAUTION LAMP476
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP 477
a) CHECK LAMP477
b) CAUTION LAMP477
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON478
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF479
K-12 SERVICE METER DOES NOT WORK480
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED480
K-14 ABNORMALITY IN GAUGE DISPLAY482
a) ABNORMALITY IN FUEL GAUGE482
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE483
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE484
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)485
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING486
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE488
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER489
E-1 ENGINE DOES NOT START490
a) STARTING MOTOR DOES NOT TURN490
b) STARTING MOTOR TURNS494
E-2 ENGINE DOES NOT STOP495
E-3 ABNORMALITY IN PREHEATING SYSTEM498
a) DOES NOT CARRY OUT PREHEATING498
b) ONLY MONITOR DISPLAY LIGHTS UP 498
c) MONITOR DISPLAY DOES NOT LIGHT UP WHEN PREHEATING IS COMPLETED499
d) MONITOR DISPLAY KEEPS LIGHTING UP WHEN PREHEATING IS NOT COMPLETED499
E-4 PARKING BRAKE DOES NOT HAVE EFFECT501
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON501
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)501
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING502
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNDED ON504
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)504
E-8 KICK-DOWN SWITCH DOES NOT WORK506
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY506
b) KICK-DOWN CANNOT BE CANCELED507
E-9 BOOM KICK-OUT DOES NOT WORK508
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION511
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP514
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP 514
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF514
E-14 ABNORMALITY IN LOW IDLING SELECTION514
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 514
E-16 ABNORMALITY IN BUZZER 514
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)515
H-1 MACHINE DOES NOT MOVE516
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)517
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR518
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 519
H-5 STEERING DOES NOT TURN520
H-6 TURNING,RESPONSE OF STEERING IS POOR521
H-7 JOYSTICK LEVEL IS HEAVY522
H-8 STEERING WHEEL SHAKES OR JERKS523
H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT524
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR525
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG526
H-12 BOOM DOES NOT RISE527
H-13 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER528
H-14 WHEN RAISING BOOM,BECOMES SLOW AT CERTAIN HEIGHT529
H-15 BOOM CYLINDER CANNOT HOLD DOWN BUCKET529
H-16 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT529
H-17 BOOM FLUCTUATES WHILE WORKING 530
H-18 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE530
H-19 BUCKET DOES NOT TILT BACK531
H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER532
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK533
H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET533
H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT533
H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE “HOLD”)534
H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT534
H-26 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY535
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)536
JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM537
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY 538
ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL542
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED544
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED545
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGEL SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED546
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED547
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED548
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED549
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 DISPLAYED550
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT551
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)552
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE553
30 DISASSEMBLY AND ASSEMBLY554
METHOD OF USING MANUAL556
STANDARD TIGHTENING TORQUE TABLE558
PRECAUTIONS WHEN CARRYING OUT OPERATION562
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER565
COATING MATERIALS LIST568
SPECIAL TOOL LIST572
SKETCHES OF SPECIAL TOOLS578
ENGINE RELATED PARTS586
STARTING MOTOR586
ALTERNATOR586
ENGINE OIL COOLER586
FUEL INJECTION PUMP FOR LEFT BANK586
FUEL INJECTION PUMP FOR RIGHT BANK586
WATER PUMP586
NOZZELE HODLER586
TURBOCHARGER586
ENGINE FRONT SEAL586
ENGINE REAR SEAL586
CYLINDER HEAD586
REMOVAL AND INSTALLATION OF RADIATOR587
REMOVAL AND INSTALLATION OF ENGINE590
REMOVAL AND INSTALLATION OF DAMPER595
DISASSEMBLY AND ASSEMBLY OF DAMPER596
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY600
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER607
DISASSEMBLY AN ASSEMBLY OF TORQUE CONVERTER VALVE614
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION615
REMOVAL AND INSTALLATION OF TRANSMISSION VALVE639
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE640
DISASSEMBLY AND ASSEMBLY OF TRANSFER644
DISASSEMBLY AND ASSEMBLY OF PTO656
REMOVAL AND INSTALLATION OF CENTER SUPPORT661
DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT663
DISASSEMBLY AND ASSEMBLY OF DRIVE SHAFT667
REMOVAL AND INSTALLATION OF FRONT AXLE670
REMOVAL AND INSTALLATION OF REAR AXLE672
REMOVAL AND INSTALLATION OF DIFFERENTIAL677
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL679
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE687
REMOVAL AND INSTALLATION OF ROTARY VALVE692
REMOVAL AND INSTALLATION OF EMERGENCY STEERING PUMP693
REMOVAL AND INSTALLATION OF DIVERTER VALVE694
DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE695
REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE697
DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE698
REMOVAL AND INSTALLATION OF STEERING CYLINDER700
REMOVAL AND INSTALLATION OF STEERING VALVE702
REMOVAL AND INSTALLATION OF BRAKE VALVE704
REMOVAL AND INSTALLATION OF SLACK ADJUSTER705
DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER706
REMOVAL AND INSTALLATION OF BRAKE708
DISASSEMBLY AND ASSEMBLY OF BRAKE709
REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS713
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS714
REMOVAL AND INSTALLATION OF PARKING BRAKE PAD716
REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER717
REMOVAL AND INSTALLATION OF BRAKE OIL TANK718
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP719
REMOVAL AND INSTALLATOIN OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY721
REMOVAL AND INSTALLATION OF PPC VALVE723
DISASSEMBLY AND ASSEMBLY OF PPC VALVE725
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY726
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE728
REMOVAL AND INSTALLATION OF CAB731
REMOVAL AND INSTALLATION OF FLOOR FRAME733
REMOVAL AND INSTALLATION OF CENTER HINGE PIN736
REMOVAL AND INSTALLATION OF WORK EQUIPMENT743
REPLACEMENT OF BOOM FRONT END BUSH748
REMOVAL AND INSTALLATION OF BUCKET CYLINDER749
REMOVAL AND INSTALLATION OF LIFT CYLINDER750
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER752
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT756
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR758
REMOVAL AND INSTALLATION OF RECEIVER TANK759
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER760
REMOVAL AND INSTALLATION OF TRANSMISSION AND JOYSTICK STEERING CONTROLLER761
REMOVAL AND INSTALLATION OF MAIN MONITOR762
REMOVAL AND INSTALLATION OF FUEL TANK764
REMOVAL AND INSTALLATION OF COUNTERWEIGHT766
40 MAINTENANCE STANDARD767
ENGINE MOUNT768
TRANSMISSION MOUNT769
DAMPER770
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP772
TORQUE CONVERTER 774
TORQUE CONVERTER REGULATOR VALVE775
TRANSMISSION (1/2)776
TRANSMISSION (2/2)778
TRANSFER779
TRANSMISSION CONTROL VALVE780
DRIVE SHAFT785
CENTER SUPPORT786
DIFFERENTIAL (1/2)787
DIFFERENTIAL (2/2)788
FINAL DRIVE790
AXLE MOUNT792
CENTER HINGE PIN794
STEERING DEMAND VALVE796
DIVERTER VALVE798
STEERING CYLINDER MOUNT799
EMERGENCY STEERING PUMP800
BRAKE VALVE801
SLACK ADJUSTER804
BRAKE805
PARKING BRAKE807
PPC VALVE809
PPC RELIEF VALVE811
CONTROL PUMP812
STEERING PUMP813
SWITCH PUMP814
MAIN PISTON PUMP815
MAIN CONTROL VALVE816
HYDRAULIC CYLINDER818
WORK EQUIPMENT LINKAGE819
BUCKET POSITIONER AND BOOM KICK-OUT821
ROPS CANOPY822
90 OTHERS823
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM824
ELECTRIC CIRCUIT DIAGRAM (1/5)825
ELECTRIC CIRCUIT DIAGRAM (2/5)826
ELECTRIC CIRCUIT DIAGRAM (3/5)827
ELECTRIC CIRCUIT DIAGRAM (4/5)828
ELECTRIC CIRCUIT DIAGRAM (5/5)829
ELECTRIC CIRCUIT DIAGRAM (ENGINE SHUT-DOWN)830
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING)831

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24