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KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL (SN:A71001 & UP) – PDF DOWNLOAD
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- KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A71001 & UP
- PUBLICATION NUMBER:CEBM005403
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Description
KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL (SN:A71001 & UP)
KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL (SN:A71001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL (SN:A71001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL (SN:A71001 & UP)
MAIN MENU............................................................................................................... 0 COVER................................................................................................................... 1 CONTENTS................................................................................................................ 2 SAFETY.................................................................................................................. 15 SAFETY NOTICE....................................................................................................... 15 IMPORTANT SAFETY NOTICE......................................................................................... 15 GENERAL PRECAUTIONS............................................................................................. 15 PREPARATIONS FOR WORK........................................................................................... 15 PRECAUTIONS DURING WORK......................................................................................... 15 GENERAL................................................................................................................. 17 HOW TO READ THE SHOP MANUAL......................................................................................... 18 VOLUMES......................................................................................................... 18 DISTRIBUTION AND UPDATING....................................................................................... 18 FILING METHOD................................................................................................... 18 REVISED EDITION MARK............................................................................................ 18 REVISIONS....................................................................................................... 18 SYMBOLS......................................................................................................... 18 HOISTING INSTRUCTIONS............................................................................................... 19 HOISTING........................................................................................................ 19 WIRE ROPES...................................................................................................... 19 PUSH-PULL TYPE COUPLER.............................................................................................. 20 COATING MATERIALS................................................................................................... 23 STANDARD TIGHTENING TORQUE.......................................................................................... 25 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.................................................................... 25 TIGHTENING TORQUE OF HOSE NUTS.................................................................................. 26 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS......................................................................... 26 TIGHTENING TORQUE FOR FLARED NUTS............................................................................... 26 ELECTRIC WIRE CODE.................................................................................................. 27 CLASSIFICATION BY THICKNESS..................................................................................... 27 CLASSIFICATION BY COLOR AND CODE................................................................................ 27 CONVERSION TABLES................................................................................................... 28 METHOD OF USING THE CONVERSION TABLE............................................................................ 28 01 GENERAL.............................................................................................................. 35 DIMENSIONS.......................................................................................................... 36 SPECIFICATIONS...................................................................................................... 38 WEIGHT TABLE........................................................................................................ 41 FUEL, COOLANT AND LUBRICATNTS....................................................................................... 42 ENGINE OIL...................................................................................................... 43 NORMAL OPERATION............................................................................................ 43 ARCTIC OPERATION............................................................................................ 45 TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL................................................................ 45 AXLE OIL........................................................................................................ 45 GREASE.......................................................................................................... 46 DIESEL FUEL..................................................................................................... 46 COOLANT SPECIFICATIONS.......................................................................................... 47 GENERAL..................................................................................................... 47 WATER....................................................................................................... 47 ANTIFREEZE.................................................................................................. 47 SUPPLEMENTAL COOLANT ADDITIVES.............................................................................. 49 10 STRUCTURE AND FUNCTION............................................................................................... 51 GENERAL............................................................................................................. 55 RADIATOR AND OIL COOLER............................................................................................. 58 DAMPER.............................................................................................................. 60 TORQUE CONVERTER AND TRANSMISSION PIPING............................................................................ 62 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................... 64 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN........................................................................... 65 TORQUE CONVERTER AND PTO............................................................................................ 66 TRANSMISSION........................................................................................................ 68 TRANSMISSION CUTAWAY............................................................................................ 70 OPERATION OF CLUTCH............................................................................................. 72 FORWARD 1ST..................................................................................................... 73 FORWARD 2ND..................................................................................................... 74 FORWARD 3RD..................................................................................................... 75 FORWARD 4TH..................................................................................................... 76 REVERSE 1ST..................................................................................................... 77 TRANMISSION CONTROL VALVE........................................................................................... 78 ECMV (ELECTRONIC CONTROL MODULATION VALVE).......................................................................... 80 OUTLINE OF ECMV................................................................................................. 82 ECMV AND PROPORTIONAL SOLENOID.................................................................................. 82 ECMV AND FILL SWITCH............................................................................................ 82 ACTUATION OF ECMV............................................................................................... 83 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE.......................................................................... 86 MAIN RELIEF VALVE............................................................................................... 87 TORQUE CONVERTER RELIEF VALVE................................................................................... 87 LUBRICATING RELIEF VALVE............................................................................................ 88 TORQUE CONVERTER OIL FILTER......................................................................................... 89 PILOT FILTER........................................................................................................ 90 TRANSFER............................................................................................................ 91 DRIVE SHAFT......................................................................................................... 92 CENTER SUPPORT...................................................................................................... 93 AXLE................................................................................................................ 94 FRONT........................................................................................................... 94 REAR............................................................................................................ 95 DIFFERENTIAL........................................................................................................ 96 NORMAL - (STANDARD)............................................................................................. 96 FRONT........................................................................................................... 96 REAR............................................................................................................ 97 LIMITED SLIP (OPTION)........................................................................................... 99 FRONT....................................................................................................... 99 REAR........................................................................................................ 99 FINAL DRIVE......................................................................................................... 104 AXLE MOUNT.......................................................................................................... 106 CENTER HINGE PIN.................................................................................................... 108 TIRE AND WHEEL...................................................................................................... 109 STEERING PIPING..................................................................................................... 110 STEERING COLUMN..................................................................................................... 111 STEERING VALVE...................................................................................................... 112 DEMAND VALVE OPERATION.......................................................................................... 113 STEERING SPOOL AT NEUTRAL................................................................................... 113 STEERING SPOOL OPERATED - ENGINE AT LOW SPEED............................................................... 114 STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED.............................................................. 115 FLOW AMP........................................................................................................ 116 FLOW AMP OPERATION.......................................................................................... 116 STEERING VALVE OPERATION........................................................................................ 119 STEERING RELIEF VALVE........................................................................................... 122 RELIEF VALVE OPERATION...................................................................................... 123 SAFETY VALVE (WITH SUCTION)..................................................................................... 124 ORBIT-ROLL VALVE................................................................................................ 126 STOP VALVE.......................................................................................................... 130 DIVERTER VALVE...................................................................................................... 131 BRAKE............................................................................................................... 134 BRAKE PIPING.................................................................................................... 134 BRAKE CIRCUIT DIAGRAM........................................................................................... 136 BRAKE VALVE..................................................................................................... 138 RIGHT BRAKE VALVE........................................................................................... 138 LEFT BRAKE VALVE............................................................................................ 139 CHARGE VALVE.................................................................................................... 144 ACCUMULATOR (FOR BRAKE)......................................................................................... 148 SLACK ADJUSTER.................................................................................................. 149 BRAKE........................................................................................................... 151 PARKING BRAKE....................................................................................................... 153 PARKING BRAKE CONTROL........................................................................................... 153 PARKING BRAKE................................................................................................... 154 PARKING BRAKE SOLENOID VALVE.................................................................................... 155 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.................................................................. 156 HYDRAULIC........................................................................................................... 157 HYDRAULIC PIPING................................................................................................ 157 HYDRAULIC CIRCUIT DIAGRAM....................................................................................... 159 MACHINES WITH STANDARD SPECIFICATIONS....................................................................... 159 WORK EQUIPMENT LEVER LINKAGE.................................................................................... 162 HYDRAULIC TANK.................................................................................................. 163 OIL FILTER BY-PASS VALVE.................................................................................... 164 BREATHER.................................................................................................... 164 ACCUMULATOR (FOR PPC VALVE)..................................................................................... 165 PPC VALVE....................................................................................................... 166 FOR BUCKET / BOOM........................................................................................... 166 FOR OPTIONAL ATTACHMENT..................................................................................... 168 PPC VALVE NEUTRAL POSITION.................................................................................. 170 PPC VALVE POSITIONS FUNCTIONS............................................................................... 171 PPC RELIEF VALVE................................................................................................ 173 CUT-OFF VALVE................................................................................................... 174 ECSS CONTROL VALVE.............................................................................................. 176 MAIN CONTROL VALVE.............................................................................................. 178 2-SPOOL..................................................................................................... 178 3-SPOOL..................................................................................................... 180 RELIEF VALVE................................................................................................ 183 SAFETY VALVE (WITH SUCTION)................................................................................. 184 FLOAT SELECTOR VALVE AND UNLOAD VALVE....................................................................... 186 BOOM AND DUMP SPOOLS AT HOLD POSITION....................................................................... 187 BOOM SPOOL AT RAISE POSITION................................................................................ 188 BOOM SPOOL AT LOWER POSITION................................................................................ 189 BOOM SPOOL AT FLOAT POSITION................................................................................ 190 BUCKET SPOOL AT DUMP POSITION............................................................................... 191 BUCKET SPOOL AT TILT POSITION............................................................................... 192 WORK EQUIPMENT...................................................................................................... 194 WORK EQUIPMENT LINKAGE.......................................................................................... 194 BUCKET.......................................................................................................... 196 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................. 198 BUCKET POSITIONER........................................................................................... 199 BOOM KICK-OUT............................................................................................... 199 PROXIMITY SWITCH............................................................................................ 200 CAB................................................................................................................. 205 ROPS CANOPY......................................................................................................... 206 AIR CONDITIONER..................................................................................................... 207 AIR CONDITIONER PIPING.......................................................................................... 207 AIR CONDITIONING (GENERAL)...................................................................................... 208 BASIC INFORMATION ON AIR CONDITIONERS........................................................................... 208 HEAT........................................................................................................ 208 TEMPERATURE................................................................................................. 209 PRESSURE.................................................................................................... 210 HUMIDITY.................................................................................................... 211 PRINCIPLE OF COOLING........................................................................................ 211 REFRIGERANTS................................................................................................ 216 FREON-TYPE GASES............................................................................................ 216 SAFETY PRECAUTIONS.......................................................................................... 216 REFRIGERATOR OIL (LUBE OIL)................................................................................. 217 AIR CONDITONING CONDENSER....................................................................................... 218 AIR CONDITIONER COMPRESSOR...................................................................................... 221 RECEIVER WITH SIGHT GLASS (LIQUID TANK)......................................................................... 222 AIR CONDITIONER UNIT............................................................................................ 224 MONITOR SYSTEMS..................................................................................................... 225 MACHINE MONITOR SYSTEM.......................................................................................... 225 MAIN MONITOR.................................................................................................... 226 MAIN MONITOR DISPLAY FUCTION................................................................................ 227 MAIN MONITOR SWITCH FUNCTION................................................................................ 228 TROUBLE DATA DISPLAY MODE................................................................................... 229 MAINTENANCE MONITOR............................................................................................. 230 MAINTENANCE MONITOR DISPLAY FUNCTION........................................................................ 231 MAINTENANCE MONITOR SWITCH FUNCTION......................................................................... 232 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM.......................................................... 233 SYSTEM STRUCTURE DIAGRAM........................................................................................ 234 FUNCTION........................................................................................................ 235 TRANSMISSION CONTROLLER POWER SOURCE............................................................................ 240 INPUT SIGNALS................................................................................................... 240 OUTPUT SIGNALS.................................................................................................. 242 LED DISPLAY..................................................................................................... 243 JOYSTICK TRANSMISSION SYSTEM........................................................................................ 245 REMOTE POSITION, JOYSTICK STEERING CONTROLLER....................................................................... 246 ECSS SYSTEM......................................................................................................... 247 TRANSMISSION CONTROLLER............................................................................................. 252 CONNECTOR SIGNALS............................................................................................... 253 SENSORS............................................................................................................. 254 SPEEDOMETER SENSOR.............................................................................................. 254 ENGINE SPEED SENSOR............................................................................................. 255 ENGINE OIL PRESSURE SENSOR...................................................................................... 255 RADIATOR WATER LEVEL SENSOR..................................................................................... 256 ENGINE OIL LEVEL SENSOR......................................................................................... 256 FUEL LEVEL SENSOR............................................................................................... 257 ENGINE WATER TEMPERATURE SENSOR................................................................................. 258 TORQUE CONVERTER OIL TEMPERATURE SENSOR......................................................................... 258 ELECTRICAL.......................................................................................................... 259 ENGINE STARTING CIRCUIT......................................................................................... 259 ENGINE STOP CIRCUIT............................................................................................. 260 PREHEATING CIRCUIT.............................................................................................. 261 ELECTRICAL TRANSMISSION CONTROL................................................................................. 263 COMBINATION SWITCH.............................................................................................. 264 KICK-DOWN / HOLD SWITCH......................................................................................... 266 KICK-DOWN SWITCH............................................................................................ 266 HOLD SWITCH................................................................................................. 266 KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS........................................................................... 267 NORMAL OPERATION............................................................................................ 267 WHEN KICK-DOWN SWITCH IS OPERATED........................................................................... 268 KICK-DOWN SWITCH OPERATION CANCELED......................................................................... 269 ELECTRIC PARKING BRAKE CONTROL.................................................................................. 271 PARKING BRAKE EMERGENCY RELEASE SWITCH...................................................................... 273 EMERGENCY BRAKE SWITCH...................................................................................... 273 PARKING SAFETY RELAY........................................................................................ 274 NEUTRALIZER RELAY........................................................................................... 274 ELECTRICAL DIAGRAM.............................................................................................. 283 ECSS WIRING DIAGRAM - FOLDOUT 10-225-1...................................................................... 283 JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2......................................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-4, (Sheet 1) (Part 2 of 5)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-5, (Sheet 1) (Part 3 of 5)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-6, (Sheet 1) (Part 4 of 5)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-7, (Sheet 1) (Part 5 of 5)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-8, (Sheet 2) (Part 1 of 4)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-9, (Sheet 2) (Part 2 of 4)...................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-10, (Sheet 2) (Part 3 of 4)..................................... 283 ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-11, (Sheet 2) (Part 4 of 4)..................................... 283 ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12............................................................ 283 CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13.................................................................. 283 ENGINE HARNESS DIAGRAM.......................................................................................... 284 ENGINE - FRAME - FLOOR HARNESS DIAGRAM.......................................................................... 285 A. The standard values in tables are those established for a new machine and are given as referen........... 289 B. Permissible values shown in the tables are estimations based on the results of test performed ........... 289 C. These standard values do not form a basis for judging claims............................................. 289 20 TESTING, ADJUSTING AND TROUBLESHOOTING............................................................................... 287 STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS........................................................................ 291 STANDARD VALUE TABLE FOR CHASSIS.................................................................................... 292 SKETCHES OF SPECIAL TOOLS........................................................................................... 313 ENGINE.............................................................................................................. 314 COMPONETS....................................................................................................... 314 BLEEDING AIR FROM FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)................................................. 314 BLOW-BY PRESSURE (REFER TO ENGINE SHOP MANUAL).............................................................. 314 COMPRESSION PRESSURE (REFER TO ENGINE SHOP MANUAL).......................................................... 314 EXHAUST TEMPERATURE (REFER TO ENGINE SHOP MANUAL)........................................................... 314 FUEL PRESSURE (REFER TO ENGINE SHOP MANUAL)................................................................. 314 HANDLING EQUIPMENT IN FUEL CIRCUIT (REFER TO ENGINE SHOP MANUAL)............................................ 314 INTAKE AIR PRESSURE (BOOST PRESSURE) (REFER TO ENGINE SHOP MANUAL).......................................... 314 LEAKAGE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)........................................................ 314 OIL PRESSURE (REFER TO ENGINE SHOP MANUAL).................................................................. 314 PERFORMANCE TEST STANDARDS (REFER TO ENGINE SHOP MANUAL).................................................... 314 RELEASING REMAINING PRESSURE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)................................... 314 RUN-IN STANDARD (REFER TO ENGINE SHOP MANUAL)............................................................... 314 SPEED SENSOR (REFER TO ENGINE SHOP MANUAL).................................................................. 314 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (REFER TO ENGINE SHOP MANUAL)............................. 314 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (REFER TO ENGINE SHOP MANUAL)................................. 314 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (REFER TO ENGINE SHOP MANUAL)..................................... 314 VALVE CLEARANCE (REFER TO ENGINE SHOP MANUAL)............................................................... 314 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT................................................................. 315 REDUCED CYLINDER MODE........................................................................................... 316 ALTERNATOR BELT TENSION......................................................................................... 319 FAN BELT TENSION................................................................................................ 320 AIR CONDITIONER BELT............................................................................................ 321 TORQUE CONVERTER STALL SPEEDS....................................................................................... 322 SHIFT LEVERS........................................................................................................ 323 OPERATING FORCE OF SPEED LEVER.................................................................................. 323 TRAVEL OF SPEED LEVER........................................................................................... 323 ACCELERATOR PEDAL................................................................................................... 324 OPERATING FORCE................................................................................................. 324 OPERATING ANGLE................................................................................................. 325 TORQUE CONVERTER AND TRANSMISSION................................................................................... 326 OIL PRESSURE.................................................................................................... 326 HYDRAULIC CIRCUIT FLUSHING...................................................................................... 329 TRANSMISSION VALVE FAILS - MOVING MACHINE....................................................................... 331 STEERING WHEEL...................................................................................................... 333 MEASURING PLAY.................................................................................................. 333 MEASURING OPERATING FORCE....................................................................................... 333 MEASURING OPERATING TIME........................................................................................ 334 STEERING OIL PRESSURE............................................................................................... 335 MEASURING....................................................................................................... 335 ADJUSTING....................................................................................................... 336 STEERING STOP VALVE................................................................................................. 337 TESTING......................................................................................................... 337 ADJUSTING....................................................................................................... 337 BRAKE PEDAL......................................................................................................... 338 OPERATING FORCE................................................................................................. 338 TRAVEL.......................................................................................................... 338 PEDAL PLAY...................................................................................................... 338 BRAKE PERFORMANCE................................................................................................... 339 TESTING BRAKE OIL PRESSURE.......................................................................................... 340 BRAKE DISC WEAR..................................................................................................... 341 PARKING BRAKE....................................................................................................... 342 OIL PRESSURE.................................................................................................... 343 DISC WEAR....................................................................................................... 345 MANUAL RELEASE METHOD........................................................................................... 346 PPC VALVE........................................................................................................... 347 OIL PRESSURE.................................................................................................... 347 MEASURING................................................................................................... 347 ADJUSTING................................................................................................... 348 ADJUSTING LINKAGE............................................................................................... 349 ACCUMULATOR......................................................................................................... 350 CHARGE PRESSURE................................................................................................. 350 MEASURING................................................................................................... 350 ADJUSTING................................................................................................... 350 WORK EQUIPMENT...................................................................................................... 351 HYDRAULIC PRESSURE.............................................................................................. 351 ADJUSTING....................................................................................................... 352 CUT-OFF VALVE................................................................................................... 353 TESTING FUNCTION............................................................................................ 353 PROCEDURE................................................................................................... 353 LEVER LINKAGE................................................................................................... 355 ADJUSTING................................................................................................... 355 BUCKET POSITIONER................................................................................................... 356 TESTING......................................................................................................... 356 ADJUSTING....................................................................................................... 356 BOOM KICK-OUT POSITIONER............................................................................................ 357 TESTING......................................................................................................... 357 ADJUSTING....................................................................................................... 357 TRANSMISSION CONTROLLER............................................................................................. 359 INITIAL TEACHING METHOD......................................................................................... 359 MAIN MONITOR........................................................................................................ 361 ADJUSTMENT PROCEDURE............................................................................................ 361 BLEEDING AIR........................................................................................................ 363 RELEASING REMAINING HYDRAULIC OIL PRESSURE.......................................................................... 364 ADJUSTING JOYSTICK LEVER POTENTIOMETER.............................................................................. 365 ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH................................................................... 367 TROUBLESHOOTING GENERAL............................................................................................. 369 POINTS TO REMEMBER WHEN TROUBLEHSOOTING......................................................................... 371 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................... 373 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....................................................................... 374 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT................................................................ 374 HANDLING CONTROL BOX........................................................................................ 379 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT........................................................ 380 CHECKS BEFORE TROUBLESHOOTING................................................................................... 382 JUDGEMENT OF POWER TRAIN........................................................................................ 383 PRECAUTIONS WHEN TROUBLESHOOTING................................................................................ 384 SAFETY...................................................................................................... 384 METHODS FOR TROUBLESHOOTING................................................................................. 384 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING............. 386 PREVENTING RECURRENCE OF TROUBLE................................................................................ 387 HYDRAULIC EQUIPMENT......................................................................................... 387 OIL CHECKS.............................................................................................. 387 CLEANING FRAGMENTS OF DAMAGED PARTS..................................................................... 387 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................... 388 CATEGORY OF TROUBLESHOOTING CODE NUMBER..................................................................... 388 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE......................................... 388 METHOD OF USING MATRIX TROUBLESHOOTING TABLES................................................................... 390 METHOD OF USING ENGINE RELATED CHARTS........................................................................... 392 TROUBLESHOOTING CONNECTORS.......................................................................................... 397 CONNECTOR ARRANGEMENT DIAGRAM................................................................................... 399 CONNECTOR NUMBERS, TYPES AND PINS............................................................................... 400 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................... 409 TROUBLESHOOTING EXPLANATION OF FUNCTION OF ECM (ELECTRIC CONTROL MECHANISM)......................................... 421 EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL MECHANISM).................................................... 422 TRANSMISSION CONTROL SYSTEM................................................................................. 422 MAIN MONITOR SYSTEM......................................................................................... 426 MAINTENANCE MONITOR SYSTEM.................................................................................. 430 ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) CONTROL SYSTEM........................................... 434 JOYSTICK STEERING CONTROL SYSTEM............................................................................ 438 METHOD OF DISPLAYING ACTION AND FAILURE CODE.................................................................... 441 CONTROLLERS AND FAILURE CODES................................................................................... 443 RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM....................................................................... 446 MAIN MONITOR FAILURE DISPLAY................................................................................ 446 TRANSMISSION CONTROLLER LED DISPLAY............................................................................. 449 ERROR CODE DISPLAYS............................................................................................. 450 TROUBLESHOOTING OF ECSS (D MODE).................................................................................... 453 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM................................................................ 454 D-1 ECSS DOES NOT WORK.......................................................................................... 456 A. ERROR CODE (D0) IS DISPLAYED............................................................................. 456 B. NO ABNORMALITY DISPLAY IS GIVEN.......................................................................... 458 1. DOES NOT WORK AT ALL................................................................................. 458 D-2 ECSS CANNOT BE CANCELLED.................................................................................... 459 TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE)............................................................... 461 E-1 ENGINE DOES NOT START....................................................................................... 462 A. STARTING MOTOR DOES NOT TURN............................................................................. 462 B. STARTING MOTOR TURNS..................................................................................... 466 E-2 ENGINE DOES NOT STOP........................................................................................ 470 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING...................................................................... 472 E-5 PARKING BRAKE DOES NOT HAVE EFFECT.......................................................................... 474 A. PARKING BRAKE HAS NOT EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (ACTUATED)........................... 474 B. PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE)................. 474 E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.......................................................... 476 E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON................................................. 480 E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY).... 482 E-9 KICK-DOWN SWITCH DOE NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)................... 484 A. KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)............... 484 B. KICK-DOWN IS NOT CANCELLED............................................................................... 484 E-10 BOOM KICK-OUT CANNOT BE USED............................................................................... 486 E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION.................................................................. 490 E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP........................................................... 493 E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP............................................................ 493 E-14 ABNORMALITY IN TRANMISSION CUT-OFF......................................................................... 493 E-15 ABNORMALITY IN PAKING BRAKE DRAGGING WARNING............................................................... 493 E-16 ABNORMALITY IN BUZZER...................................................................................... 493 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)........................................................ 495 POWER TRAIN..................................................................................................... 496 H-1 MACHINE DOES NOT START.................................................................................. 496 H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES, DOES NOT SHIFT GEAR............... 500 H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.................................................. 505 H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR............................................... 508 H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH................................................................ 511 STEERING SYSTEM................................................................................................. 512 H-6 STEERING WHEEL DOES NOT TURN............................................................................ 512 H-7 STEERING DOES NOT TURN (MACHINE WITH JOYSTICK).......................................................... 513 H-8 TURNING, RESPONSE OF STEERING IS POOR................................................................... 514 H-9 TURNING, RESPONSE OF STEERING IS POOR (MACHINE WITH JOYSTICK)........................................... 515 H-10 STEERING IS HEAVY...................................................................................... 516 H-11 JOYSTICK STEERING IS HEAVY (MACHINES EQUIPPED WITH JOYSTICK)........................................... 517 H-12 STEERING WHEEL SHAKES OR JERKS......................................................................... 518 H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK).................................... 519 H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING................................. 520 BRAKE SYSTEM.................................................................................................... 522 H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR..................................................... 522 H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG........................................................... 524 H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR.................................................. 525 H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)...................... 526 WORK EQUIPMENT.................................................................................................. 527 H-19 NEITHER BOOM NOR BUCKET MOVE........................................................................... 527 H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER............................................................ 528 H-21 BOOM DOES NOT MOVE..................................................................................... 529 H-22 NOT USED............................................................................................... 529 H-23 BOOM IS SLOW OR BOOM LACKS POWER....................................................................... 530 H-24 NOT USED............................................................................................... 530 H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT........................................... 531 H-26 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE............................... 532 H-27 NOT USED............................................................................................... 532 H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM...................................................................... 533 H-29 BUCKET DOES NOT MOVE................................................................................... 534 H-30 BUCKET IS SLOW OR LACKS POWER.......................................................................... 535 H-31 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.................................................................... 536 H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]............................ 537 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)..................................................... 539 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS.................................................... 541 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR............................................................... 542 JOYSTICK CONTROLLER SYSTEM.................................................................................. 542 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED....................... 546 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED............ 547 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED............. 548 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END) IS DISPLAYED.......................... 549 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END) IS DISPLAYED........................... 550 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DIS............... 551 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPL............... 552 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYST............... 553 J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE........................................................................ 554 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM...................................................... 555 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID................................................................... 556 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.................................................................... 557 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE).............................................................. 559 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC............... 561 A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP................................................................. 561 B. SOME LAMPS DO NOT LIGHT UP............................................................................... 561 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OU............... 562 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO ............... 563 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH....................................... 564 A. ENGINE OIL LEVEL DISPLAY FLASHES......................................................................... 564 B. ENGINE WATER LEVEL DISPLAY FLASHES....................................................................... 565 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH..................................... 566 A. ENGINE OIL PRESSURE DISPLAY FLASHES...................................................................... 566 B. BATTERY CHARGE LEVEL DISPLAY FLASHES..................................................................... 567 C. BRAKE OIL PRESSURE DISPLAY FLASHES....................................................................... 568 D. AIR CLEANER DISPLAY FLASHES.............................................................................. 569 K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND................................................ 570 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS........................................ 571 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH....................... 572 A. CHECK LAMP............................................................................................... 572 B. CAUTION LAMP............................................................................................. 572 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION ............... 573 A. CHECK LAMP............................................................................................... 573 B. CAUTION LAMP............................................................................................. 573 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON............................................. 574 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF...................................................... 575 K-12 SERVICE METER DOES NOT WORK................................................................................ 576 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED....................................................... 577 K-14 ABNORMALITY IN GAUGE ITEMS................................................................................. 578 A. ABNORMALITY IN FUEL GAUGE................................................................................ 578 B) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE.......................................................... 579 C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.................................................... 580 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)..................................................................... 581 M-1 MAIN MONITOR DOES NOT WORK.................................................................................. 583 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.............. 584 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.................................................................. 585 M-4 ABNORMALITY IN SHIFT INDICATOR.............................................................................. 586 A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F........................................................... 586 B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R........................................................... 586 C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R WHEN DIRECTIONAL LEVER ........... 586 D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAY F WHEN DIRECTIONAL LEVER I........... 587 E. DOES NOT DISPLAY 1ST - 4TH............................................................................... 587 M-5 HIGH BEAM DOES NOT LIGHT UP................................................................................. 588 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP....................................................................... 589 A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................. 589 B. RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................. 589 M-7 ABNORMALITY IN PARKING DISPLAY.............................................................................. 590 A. PARKING LAMP DISPLAY DOES NOT LIGHT UP................................................................... 590 B. PARKING LAMP DISPLAY STAYS LIT UP........................................................................ 590 M-8 NOT USED.................................................................................................... 591 M-9 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................ 592 M-10 ABNORMALITY IN FRONT WORKING LAMP.......................................................................... 594 A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP.................................................. 594 B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP............................................ 594 C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP............................................ 594 M-11 ABNORMALITY IN REAR WORKING LAMP........................................................................... 596 A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP................................................... 596 B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP............................................ 596 C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP............................................ 596 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF........................................................................ 598 A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED........... 598 B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT, BUT CUT-OF........... 598 C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION ........... 598 D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH........... 598 E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURN ON), BUT CUT-OFF FUNCTION IS NOT A........... 599 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.............................................................. 600 A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN W........... 600 B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W........... 600 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU............... 602 A. ACTUATED CONTINOUSLY..................................................................................... 602 B. NOT ACTUATED............................................................................................. 602 M-15 ABNORMALITY IN BUZZER...................................................................................... 603 A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK).................. 603 B. BUZZER ALWAYS SOUNDS..................................................................................... 603 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...................................................... 604 M-17 ABNORMALITY IN FAILURE DISPLAY MODE........................................................................ 605 A. DOES NOT ENTER FAILURE DISPLAY MODE...................................................................... 605 B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE............................ 605 M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER..................................................... 606 M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY........................................................... 607 A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP...................................................... 607 B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP........................................................... 607 M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY........................................................ 608 A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP................................................... 608 B. EMERGENCY STEERING DISPLAY STAYS LIT UP.................................................................. 608 M-21 NOT USED................................................................................................... 609 M-22 ABNORMALITY IN ECSS SYSTEM................................................................................. 705 A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED........................................................... 610 B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK............................................... 610 M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK).......................................... 718 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE).......................................................... 613 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS................................................ 616 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...................................... 618 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP L............... 624 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI............... 626 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI............... 628 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN............... 630 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLEN............... 632 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN............... 634 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN............... 636 T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS............... 638 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.................. 640 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED....................... 644 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED............................... 648 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED................ 650 T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED................................... 652 T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED...................... 653 T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................ 654 T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................ 655 T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED.............................. 656 T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED.............................. 657 T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED.............................. 658 T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED.............................. 659 T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED........................... 660 T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED............ 662 T-23 HOLD SWITCH SYSTEM......................................................................................... 665 T-24 KICK-DOWN SWITCH SYSTEM.................................................................................... 666 T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM......................................................................... 667 T-26 NEUTRALIZER RELAY SIGNAL SYSTEM............................................................................ 668 T-27 BUZZER SIGNAL SYSTEM....................................................................................... 669 T-28 NETWORK SYSTEM............................................................................................. 670 T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM................................................................ 671 T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM................................................................ 672 T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM................................................ 673 T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM................................................................. 674 T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM................................................................. 675 T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM............................................................... 676 T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM............................................................... 677 T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM............................................................... 678 T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM............................................................... 679 TROUBLESHOOTING AIR CONDITIONING (DENSO)............................................................................ 681 AIR CONDITIONER / HEATER (DENSO)................................................................................ 682 VISUAL AND AUDIBLE INSPECTION............................................................................... 682 TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)................................................... 683 NORMAL CONDITIONS....................................................................................... 683 INSUFFICIENT REFRIGERANT................................................................................ 683 REFRIGERANT FAILS TO CIRCULATE (SYSTEM CLOGGED)......................................................... 684 MOISTURE IN SYSTEM...................................................................................... 684 COMPRESSOR FAILURE...................................................................................... 684 EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING................................................. 685 AIR IN THE SYSTEM....................................................................................... 685 EXPANSION VALVE OPENS TOO FAR........................................................................... 685 TROUBLESHOOTING THE ELECTRICAL CIRCUIT.......................................................................... 686 BLOWER TROUBLESHOOTING...................................................................................... 686 ELECTRICAL CIRCUIT CHECKS................................................................................... 688 HEATER RELAY............................................................................................ 688 BLOWER SWITCH........................................................................................... 688 COOLER CIRCUIT TROUBLESHOOTING.............................................................................. 690 AIR CONDITIONER SWITCH.................................................................................. 690 MAGNETIC CLUTCH RELAY................................................................................... 690 CONDENSER FAN OPERATION CIRCUIT......................................................................... 691 ERROR MESSAGE TABLES............................................................................................ 694 A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER..................................................... 694 B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER..................................................... 694 C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS.................................................. 695 D. PROBLEM - NO HEAT........................................................................................ 695 E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF, WHEN THE POWER IS TURNED ON...................... 695 F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS DEFROST BUTTON IS PUSHED............................. 696 WIRING DIAGRAM.................................................................................................. 698 WIRE CHART.................................................................................................. 699 INSPECTION AREAS............................................................................................ 700 30 DISASSEMBLY AND ASSEMBLY............................................................................................. 701 METHOD OF USING MANUAL.............................................................................................. 705 PRECAUTIONS DURING OPERATION........................................................................................ 706 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...................................................................... 706 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK................................................................. 707 PRECAUTIONS WHEN COMPLETING THE OPERATIONS...................................................................... 708 OTHER PRECAUTIONS............................................................................................... 708 SPECIAL TOOL LIST................................................................................................... 709 SKETCHES OF SPECIAL TOOLS........................................................................................... 713 ENGINE.............................................................................................................. 716 COMPONENTS...................................................................................................... 716 ALTERNATOR (REFER TO THE ENGINE SHOP MANUAL)................................................................ 716 CYLINDER HEAD (REFER TO THE ENGINE SHOP MANUAL)............................................................. 716 ENGINE FRONT SEAL (REFER TO THE ENGINE SHOP MANUAL)......................................................... 716 ENGINE OIL COOLER (REFER TO THE ENGINE SHOP MANUAL)......................................................... 716 ENGINE REAR SEAL (REFER TO THE ENGINE SHOP MANUAL).......................................................... 716 FUEL INJECTION PUMP (REFER TO THE ENGINE SHOP MANUAL)....................................................... 716 NOZZLE HOLDER (REFER TO THE ENGINE SHOP MANUAL)............................................................. 716 STARTING MOTOR (REFER TO THE ENGINE SHOP MANUAL)............................................................ 716 THERMOSTAT (REFER TO THE ENGINE SHOP MANUAL)................................................................ 716 TURBOCHARGER (REFER TO THE ENGINE SHOP MANUAL).............................................................. 716 WATER PUMP (REFER TO THE ENGINE SHOP MANUAL)................................................................ 716 REMOVAL......................................................................................................... 716 INSTALLATION.................................................................................................... 720 RADIATOR............................................................................................................ 722 REMOVAL......................................................................................................... 722 INSTALLATION.................................................................................................... 723 DAMPER.............................................................................................................. 724 REMOVAL......................................................................................................... 724 INSTALLATION.................................................................................................... 725 DISASSEMBLY..................................................................................................... 726 ASSEMBLY........................................................................................................ 729 TORQUE CONVERTER AND TRANSMISSION................................................................................... 734 REMOVAL......................................................................................................... 734 INSTALLATION.................................................................................................... 737 DISCONNECTION................................................................................................... 738 CONNECTION...................................................................................................... 738 TORQUE CONVERTER.................................................................................................... 739 DISASSEMBLY..................................................................................................... 739 ASSEMBLY........................................................................................................ 743 TRANSMISSION........................................................................................................ 750 DISASSEMBLY..................................................................................................... 750 ASSEMBLY........................................................................................................ 767 TRANSFER............................................................................................................ 784 DISASSEMBLY..................................................................................................... 784 ASSEMBLY........................................................................................................ 788 PARKING BRAKE....................................................................................................... 793 DISASSEMBLY..................................................................................................... 793 ASSEMBLY........................................................................................................ 796 TRANSMISSION CONTROL VALVE (ECMV)................................................................................... 800 REMOVAL......................................................................................................... 800 INSTALLATION.................................................................................................... 800 CENTER SUPPORT...................................................................................................... 801 REMOVAL......................................................................................................... 801 INSTALLATION.................................................................................................... 802 DISASSEMBLY..................................................................................................... 803 ASSEMBLY........................................................................................................ 805 DRIVE SHAFT......................................................................................................... 808 DISASSEMBLY..................................................................................................... 808 ASSEMBLY........................................................................................................ 811 FRONT AXLE.......................................................................................................... 814 REMOVAL......................................................................................................... 814 INSTALLATION.................................................................................................... 815 REAR AXLE........................................................................................................... 816 REMOVAL......................................................................................................... 816 INSTALLATION.................................................................................................... 820 DIFFERENTIAL........................................................................................................ 822 REMOVAL (FRONT)................................................................................................. 822 INSTALLATION (FRONT)............................................................................................ 824 REMOVAL (REAR).................................................................................................. 825 INSTALLATION (REAR)............................................................................................. 826 DISASSEMBLY DIFFERENTIAL GEAR ASSEMBLY.......................................................................... 827 FINE DISASSEMBLY OF PINION ASSEMBLY......................................................................... 829 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY......................................................... 830 FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY............................................................ 831 FINE ASSEMBLY OF PINION ASSEMBLY............................................................................ 832 ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY.......................................................................... 833 DISSASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY.............................................................. 839 FINE DISASSEMBLY OF PINION ASSEMBLY......................................................................... 841 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY......................................................... 842 ASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY.................................................................. 843 FINE ASSEMBLY OF PINION ASSEMBLY............................................................................ 845 ASSEMBLY OF DIFFERENTIAL ASSEMBLY........................................................................... 846 DISASSEMBLY OF FINAL DRIVE ASSEMBLY............................................................................. 853 ASSEMBLY OF FINAL DRIVE ASSEMBLY................................................................................ 856 STEERING ORBITAL VALVE.............................................................................................. 860 REMOVAL......................................................................................................... 860 INSTALLATION.................................................................................................... 860 DISASSEMBLY..................................................................................................... 861 ENSURE A CLEAN WORKING ENVIRONMENT.......................................................................... 861 PREPARATORY WORK............................................................................................ 861 ASSEMBLY........................................................................................................ 866 STEERING CYLINDER................................................................................................... 874 REMOVAL......................................................................................................... 874 INSTALLATION.................................................................................................... 875 DISASSEMBLY..................................................................................................... 876 ASSEMBLY........................................................................................................ 878 STEERING VALVE...................................................................................................... 880 REMOVAL......................................................................................................... 880 INSTALLATION.................................................................................................... 882 BRAKE VALVE......................................................................................................... 884 REMOVAL......................................................................................................... 884 INSTALLATION.................................................................................................... 885 SLACK ADJUSTER...................................................................................................... 886 REMOVAL......................................................................................................... 886 INSTALLATION.................................................................................................... 886 DISASSEMBLY..................................................................................................... 887 ASSEMBLY........................................................................................................ 888 BRAKE ASSEMBLY (FRONT AND REAR)..................................................................................... 889 REMOVAL......................................................................................................... 889 INSTALLATION.................................................................................................... 889 DISASSEMBLY..................................................................................................... 890 ASSEMBLY........................................................................................................ 893 HYDRAULIC PUMP...................................................................................................... 898 REMOVAL......................................................................................................... 898 INSTALLATION.................................................................................................... 899 HYDRAULIC TANK...................................................................................................... 900 REMOVAL......................................................................................................... 900 INSTALLATION.................................................................................................... 901 HYDRAULIC FILTER.................................................................................................... 902 REMOVAL......................................................................................................... 902 INSTALLATION.................................................................................................... 902 PPC VALVE........................................................................................................... 903 REMOVAL......................................................................................................... 903 INSTALLATION.................................................................................................... 903 DISASSEMBLY..................................................................................................... 904 ASSEMBLY........................................................................................................ 904 MAIN CONTROL VALVE.................................................................................................. 905 REMOVAL......................................................................................................... 905 INSTALLATION.................................................................................................... 907 DISASSEMBLY..................................................................................................... 908 ASSEMBLY........................................................................................................ 912 BUCKET CYLINDER..................................................................................................... 915 REMOVAL......................................................................................................... 915 INSTALLATION.................................................................................................... 916 DISASSEMBLY..................................................................................................... 917 ASSEMBLY........................................................................................................ 919 BOOM CYLINDER....................................................................................................... 922 REMOVAL......................................................................................................... 922 INSTALLATION.................................................................................................... 923 DISASSEMBLY..................................................................................................... 924 ASSEMBLY........................................................................................................ 926 CENTER HINGE PIN.................................................................................................... 929 REMOVAL......................................................................................................... 929 INSTALLATION.................................................................................................... 935 WORK EQUIPMENT...................................................................................................... 938 REMOVAL......................................................................................................... 938 INSTALLATION.................................................................................................... 942 BULKHEAD............................................................................................................ 944 REMOVAL......................................................................................................... 944 INSTALLATION.................................................................................................... 945 ENGINE HOOD......................................................................................................... 946 REMOVAL......................................................................................................... 946 INSTALLATION.................................................................................................... 948 CAB................................................................................................................. 950 REMOVAL......................................................................................................... 950 INSTALLATION.................................................................................................... 952 FLOOR FRAME......................................................................................................... 953 REMOVAL......................................................................................................... 953 INSTALLATION.................................................................................................... 955 COUNTERWEIGHT....................................................................................................... 956 REMOVAL......................................................................................................... 956 INSTALLATION.................................................................................................... 956 FUEL TANK........................................................................................................... 958 REMOVAL......................................................................................................... 958 INSTALLATION.................................................................................................... 959 AIR CONDITIONER UNIT................................................................................................ 960 REMOVAL......................................................................................................... 960 INSTALLATION.................................................................................................... 961 CONDENSER........................................................................................................... 962 REMOVAL......................................................................................................... 962 INSTALLATION.................................................................................................... 962 RECEIVER TANK....................................................................................................... 963 REMOVAL......................................................................................................... 963 INSTALLATION.................................................................................................... 963 COMPRESSOR ASSEMBLY................................................................................................. 964 REMOVAL......................................................................................................... 964 INSTALLATION.................................................................................................... 965 MAIN MONITOR........................................................................................................ 966 REMOVAL......................................................................................................... 966 INSTALLING...................................................................................................... 967 40 MAINTENANCE STANDARD................................................................................................. 969 ENGINE MOUNT........................................................................................................ 971 TRANSMISSION MOUNT.................................................................................................. 972 TORQUE CONVERTER CHARGING PUMP...................................................................................... 974 DAMPER.............................................................................................................. 976 TORQUE CONVERTER AND PTO............................................................................................ 978 TRANSMISSION........................................................................................................ 980 TRANSFER............................................................................................................ 984 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE.......................................................................... 986 LUBRICATION RELIEF VALVE............................................................................................ 987 DRIVE SHAFT......................................................................................................... 988 CENTER SUPPORT...................................................................................................... 990 DIFFERENTIAL, NORMAL - (STANDARD)................................................................................... 992 DIFFERENTIAL, LIMITED SLIP.......................................................................................... 996 FINAL DRIVE......................................................................................................... 998 AXLE MOUNT..........................................................................................................1000 CENTER HINGE PIN....................................................................................................1002 STEERING COLUMN.....................................................................................................1006 STEERING PUMP.......................................................................................................1008 STEERING VALVE......................................................................................................1009 STEERING CYLINDER MOUNT.............................................................................................1010 BRAKE VALVE.........................................................................................................1012 RIGHT...........................................................................................................1012 LEFT............................................................................................................1014 SLACK ADJUSTER......................................................................................................1016 BRAKE...............................................................................................................1018 PARKING BRAKE.......................................................................................................1020 HYDRAULIC PUMP......................................................................................................1021 SAR(4)-160......................................................................................................1021 SWITCH, PPC PUMP....................................................................................................1022 SAR(3)-63 + SAR(1)-28...........................................................................................1022 PPC VALVE...........................................................................................................1023 FOR BUCKET AND BOOM.............................................................................................1023 FOR AUXILIARY ATTACHMENT........................................................................................1024 CUT-OFF VALVE.......................................................................................................1025 MAIN CONTROL VALVE..................................................................................................1026 2 SPOOL VALVE...................................................................................................1026 3-SPOOL.........................................................................................................1028 HYDRAULIC CYLINDERS.................................................................................................1030 BUCKET LINKAGE......................................................................................................1032 BUCKET..............................................................................................................1034 BUCKET POSITIONER AND BOOM KICK-OUT.................................................................................1035 ROPS CAB............................................................................................................1036 90 OTHERS...............................................................................................................1037 ELECTRICAL DIAGRAMS.................................................................................................1039 ECSS WIRING DIAGRAM.............................................................................................1039 JOYSTICK STEERING WIRING DIAGRAM................................................................................1041 ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 OF 5)..............................................................1043 ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 2 OF 5)..............................................................1045 ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 3 OF 5)..............................................................1047 ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 4 OF 5)..............................................................1049 ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 5 OF 5)..............................................................1051 ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 1 OF 4)..............................................................1053 ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 2 OF 4)..............................................................1055 ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 3 OF 4)..............................................................1057 ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 4 OF 4)..............................................................1059 ENGINE FLOOR HARNESS DIAGRAM....................................................................................1061 CAB ELECTRICAL DIAGRAM..........................................................................................1063 CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5)...........................................................1065 CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 2 OF 5)...........................................................1067 CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5)...........................................................1069 CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 4 OF 5)...........................................................1071 CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 5 OF 5)...........................................................1073 3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2)........................................................1075 3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2)........................................................1077 PARKING BRAKE CONTROL DIAGRAM...................................................................................1079 HYDRAULIC...........................................................................................................1081 CIRCUIT DIAGRAM.................................................................................................1081 JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)...........................................................1083 JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)...........................................................1085 JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)...........................................................1087 STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)....................................................................1089 STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)....................................................................1091 STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)....................................................................1093 HYDRAULIC LINE ASSEMBLY (PART 1 OF 3)...........................................................................1095 HYDRAULIC LINE ASSEMBLY (PART 2 OF 3)...........................................................................1097 HYDRAULIC LINE ASSEMBLY (PART 3 OF 3)...........................................................................1099
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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2 reviews for KOMATSU AVANCE PLUS WA500-3LK WHEEL LADER SERVICE REPAIR MANUAL (SN:A71001 & UP) – PDF DOWNLOAD
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Kyng Jaxtyn –
Frankie Jovanni –
They sent link on dropbox and it was not a direct download.