Komatsu Avance Plus WA500-3LK WHEEL LOADER Shop Manual CEBM005403 PDF

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Komatsu Avance Plus WA500-3LK WHEEL LOADER Shop Manual CEBM005403  – PDF DOWNLOAD

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Komatsu Avance Plus WA500-3LK WHEEL LOADER Shop Manual CEBM005403  – PDF DOWNLOAD

Language : English
Pages : 1100
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Avance Plus WA500-3LK WHEEL LOADER Shop Manual CEBM005403  – PDF DOWNLOAD

• SERIAL NUMBERS WA500-3LK A71001 and 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

DESCRIPTION:

Komatsu Avance Plus WA500-3LK WHEEL LOADER Shop Manual CEBM005403  – PDF DOWNLOAD

• SERIAL NUMBERS WA500-3LK A71001 and UP

G.B 22/ 12/24