Komatsu Avance WA700-3L Wheel Loader Shop Manual CEBM004402 – PDF

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Komatsu Avance WA700-3L Wheel Loader Shop Manual CEBM004402 – PDF DOWNLOAD

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Komatsu Avance WA700-3L Wheel Loader Shop Manual CEBM004402 – PDF DOWNLOAD

Language : English
Pages : 1052
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Avance WA700-3L Wheel Loader Shop Manual CEBM004402 – PDF DOWNLOAD

• SERIAL NUMBERS 
• WA700-3L A50001 and UP

MAIN MENU 0
COVER 1
CONTENTS 2
01 GENERAL 31
GENERAL ASSEMBLY DRAWING 32
SPECIFICATIONS 33
WEIGHT TABLE 36
LIST OF LUBRICANT AND WATER 38
REMARKS 39
10 STRUCTURE AND FUNCTION 41
POWER TRAIN SYSTEM 44
DAMPER 46
OPERATION 46
TORQUE CONVERTER AND TRANSMISSION 48
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 48
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 50
TORQUE CONVERTER AND TRANSMISSION PIPING 51
TORQUE CONVERTER AND PTO 52
TRANSMISSION 55
OPERATION OF CLUTCH 58
FORWARD 1ST 59
FORWARD 2ND 60
FORWARD 3RD 61
FORWARD 4TH 62
REVERSE 1ST 63
TRANSMISSION CONTROL VALVE 64
TRANSMISSION SOLENOID VALVE 65
UPPER VALVE 66
MAIN RELIEF VALVE 66
LOWER VALVE 67
MAIN RELIEF VALVE 68
PILOT REDUCING VALVE 69
TRANSMISSION SOLENOID VALVE 70
PRIORITY VALVE 71
MODULATING VALVE AND QUICK RETURN VALVE 72
REDUCING VALVE 75
QUICK FILL VALVE (FOR 2ND CLUTCH) 76
TORQUE CONVERTER RELIEF VALVE 77
LUBRICATING RELIEF VALVE 78
EMERGENCY MANUAL SPOOL 79
LUBRICATION BYPASS VALVE 80
HYDRAULIC CIRCUIT SCHEMATIC 82
FORWARD 1ST 82
TRANSFER 84
AXLE 85
FRONT AXLE 85
REAR AXLE 86
DIFFERENTIAL 87
FRONT DIFFERENTIAL 87
REAR DIFFERENTIAL 88
FINAL DRIVE 89
STEERING 91
STEERING PIPING DIAGRAM 91
STEERING AND SWITCH PUMP 92
STEERING UNIT (ORBIT-ROLL VALVE) 94
STEERING DEMAND VALVE 97
OVERLOAD RELIEF VALVE 98
MAIN RELIEF VALVE 100
OPERATION OF DEMAND VALVE 102
WHEN STEERING SPOOL IS OPERATED 103
OPERATION OF STEERING VALVE 105
TWO-WAY RESTRICTOR 108
STOP VALVE 109
DIVERTER VALVE 110
GROUND DRIVEN STEERING RELIEF VALVE 113
BRAKE 114
BRAKE PIPING 114
BRAKE CIRCUIT DIAGRAM 115
BRAKE VALVE 116
BRAKE VALVE (RIGHT) 116
BRAKE VALVE (LEFT) 117
CHARGE VALVE 122
ACCUMULATOR (FOR BRAKE) 126
SLACK ADJUSTER 127
BRAKE 129
PARKING BRAKE 131
PARKING BRAKE CALIPER 132
SPRING CYLINDER 133
PARKING BRAKE SOLENOID VALVE 134
HYDRAULIC 136
HYDRAULIC PIPING 136
HYDRAULIC CIRCUIT DIAGRAM 138
MAIN PISTON PUMP 141
PISTON PUMP (HPV90 + HPF90) 142
CONTROL PUMP (BAR025) 147
CONTROL PUMP RELIEF VALVE 148
ES VALVE (ENGINE SENSING VALVE) 149
SERVO VALVE 150
PRESSURE DIFFERENTIAL VALVE 151
PPC VALVE (PROPORTIONAL PRESSURE VALVE) 152
PPC RELIEF VALVE 156
ACCUMULATOR (FOR PPC VALVE) 157
MAIN CONTROL VALVE 158
WORK EQUIPMENT 160
WORK EQUIPMENT LUBRICATION 160
WORK EQUIPMENT LINKAGE 162
BUCKET POSITIONER AND BOOM KICK-OUT 164
BUCKET POSITIONER 165
BOOM KICK-OUT 165
PROXIMITY SWITCH – OPERATION 166
BOOM RAISE 166
BUCKET TILT 168
AIR CONDITIONER 170
AIR CONDITIONER PIPING 170
AIR CONDITIONER CONDENSER 171
AIR CONDITIONER COMPRESSOR 172
DRY RESERVOIR 173
MAIN MONITOR SYSTEM 174
MAIN MONITOR 175
MAIN MONITOR DISPLAY FUNCTION TABLE 176
MAIN MONITOR SWITCH FUNCTION 178
TROUBLE DATA DISPLAY MODE 179
MAINTENANCE MONITOR 180
MAINTENANCE MONITOR DISPLAY FUNCTION TABLE 181
AUTOMATIC TRANSMISSION SYSTEM (ATM) 183
SYSTEM STRUCTURE DIAGRAM 184
JOYSTICK 197
JOYSTICK TRANSMISSION SYSTEM 197
TRANSMISSION AND JOYSTICK CONTROLLER 198
ELECTRICAL 201
ENGINE STARTING CIRCUIT 201
ENGINE STOP CIRCUIT 203
AUTO PRIMING SYSTEM (APS) 204
APS CONTROLLER 205
APS ASSISTER 205
ELECTRICAL TRANSMISSION CONTROL 208
COMBINATION SWITCH 210
KICK-DOWN, HOLD SWITCH 212
KICK-DOWN ELECTRICAL CIRCUIT 213
PARKING BRAKE SWITCH 220
PARKING BRAKE VALVE 221
PARKING SAFETY RELAY 221
NEUTRALIZER RELAY 221
EMERGENCY BRAKE SWITCH 221
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (1 0F 6) 229
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (2 OF 6) 231
ELECTRICALCIRCUIT DIAGRAM FOLDOUT (3 OF 6) 233
ELECTRICAL CIRUIT DIAGRAM FOLDOUT (4 OF 6) 235
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (5 OF 6) 237
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (6 OF 6) 239
ELECTRICAL CIRCUIT DIAGRAM (2) (1 OF 4) 241
ELECTRICAL CIRCUIT DIAGRAM (2) (2 OF 4) 243
ELECTRICAL CIRCUIT DIAGRAM (2) (3 OF 4) 245
ELECTRICAL CIRCUIT DIAGRAM (2) (4 OF 4) 247
20 TESTING, ADJUSTING AND TROUBLESHOOTING 249
STANDARD VALUE TABLE 252
ENGINE TABLE – IN CHASSIS 252
CHASSIS TABLE 253
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 258
SERVICE TOOLS 266
ENGINE 268
ADJUSTING ENGINE STOP MOTOR CABLE 268
ADJUSTING ENGINE STOP SOLENOID 268
MEASURING AND ADJUSTING VALVE CLEARANCE 268
MEASURING BLOW-BY PRESSURE 268
MEASURING COMPRESSION PRESSURE 268
MEASURING COOLANT TEMPERATURE 268
MEASURING ENGINE LUBRICATING OIL PRESSURE 268
MEASURING ENGINE SPEEDS 268
MEASURING EXHAUST COLOR 268
MEASURING EXHAUST GAS TEMPERATURE 268
MEASURING FUEL FILTER INLET RESTRICTION 268
TEST AND ADJUSTING FAN BELT TENSION 268
TEST AND ADJUSTING FUEL INJECTION TIMING 268
ACCELERATOR PEDAL 269
OPERATING FORCE 269
ADJUSTING PEDAL TRAVEL, POTENTIOMETER 270
ADJUSTING PEDAL MICRO SWITCH 272
TORQUE CONVERTER & TRANSMISSION PRESSURE 273
EMERGENCY MANUAL SPOOL 276
OPERATION 276
STEERING 278
STEERING OIL PRESSURE 278
MEASURING 278
ADJUSTING 278
STEERING STOPPER BOLT 279
ADJUSTING 279
JOYSTICK STEERING 280
ADJUSTING 280
JOYSTICK LEVER NEUTRAL DETECTION SWITCH 281
ADJUSTING 281
BRAKE 282
BRAKE OIL PRESSURE 282
TESTING 282
BRAKE DISC 283
MEASURING WEAR 283
BRAKE PERFORMANCE 284
MEASURING 284
PARKING BRAKE 285
TESTING 285
MEASURING PAD 285
MEASURING CLEARANCE 285
ADJUSTING 286
ACCUMULATOR CHARGE PRESSURE 287
TESTING 287
ADJUSTING 287
WORK EQUIPMENT 288
PPC RELIEF VALVE 288
MEASURING HYDRUALIC PRESSURE 288
ADJUSTING HYDRAULIC PRESSURE 289
HYDRAULIC PRESSURE 290
TESTING 290
ADJUSTING 291
PISTON PUMP 292
BLEEDING AIR 292
LEVER LINKAGE 293
ADJUSTING 293
BUCKET POSITIONER 295
TESTING 295
ADJUSTING 295
BOOM KICK-OUT 296
TESTING 296
ADJUSTING 296
PROXIMITY SWITCH ACTUATION PILOT LAMP 297
LAMP (RED) 297
MAIN MONITOR (SPEEDOMETER MODULE) 298
ADJUSTMENT PROCEDURE 298
BLEEDING AIR 299
BLEEDING AIR FROM BRAKE SYSTEM 299
BLEEDING AIR FROM HYDRAULIC CYLINDERS 299
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 300
BLEEDING AIR FROM HYDRAULIC TANK 300
BLEEDING AIR FROM THE PISTON PUMP 301
BLEEDING AIR FROM THE HYDRAULIC CIRCUIT 302
TROUBLESHOOTING GENERAL 303
POINTS TO REMEMBER WHEN TROUBLESHOOTING 1026
SEQUENCE OF EVENTS IN TROUBLESHOOTING 0
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 49
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 49
HANDLING CONTROL BOX 0
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 22
CHECKS BEFORE TROUBLESHOOTING 317
JUDGEMENT OF POWER TRAIN 54
PRECAUTIONS WHEN TROUBLESHOOTING 24
SAFETY 0
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 24
PREVENTING RECURRENCE OF TROUBLE 0
HYDRAULIC EQUIPMENT 24
OIL CHECKS 320
CLEANING FRAGMENTS OF DAMAGED PARTS 25
METHOD OF USING TROUBLESHOOTING CHARTS 25
CATEGORY OF TROUBLESHOOTING CODE NUMBER 25
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 25
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 26
METHOD OF USING ENGINE RELATED CHARTS 325
TROUBLESHOOTING ELECTRICAL CONNECTORS 331
CONNECTOR TYPES 333
CONNECTOR PIN ARRANGEMENT 30
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 30
ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM 113
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 349
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ACTION 351
TRANSMISSION CONTROLLER LED DISPLAY 229
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 355
E-1 ENGINE DOES NOT START 24
A STARTING MOTOR DOES NOT TURN 358
B STARTING MOTOR TURNS 364
E-2 ABNORMALITY IN APS SYSTEM 367
A WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOT LIGHT UP, BUT NO PILOT LED ON 369
B WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 2O° C, PREHEATING 370
C AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START, B 371
D LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 372
E LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 372
F LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 373
G LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 373
H LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 374
I LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 374
J WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP 375
E-3 PARKING BRAKE DOES NOT HAVE EFFECT 376
A PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON 376
B PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE D 376
E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 378
E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 380
E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORK 380
E-7 TRANSMISSION DOES NOT WORK PROPERLY 382
A ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY 384
B NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT 388
C NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT 390
D SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT 392
E ABNORMALITY IN SHIFT SOLENOID CIRCUIT 398
F SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT 401
E-8 KICK-DOWN SWITCH DOES NOT WORK 406
E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON 409
E-10 KICK-DOWN ALWAYS WORKS 410
E-11 KICK-DOWN SWICTH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND 412
E-12 BOOM KICK-OUT DOES NOT WORK 414
E-13 DEFECTIVE BUCKET POSITIONER 416
E-14 POWER WINDOW DOES NOT WORK 418
A WINDOW DOES NOT GO UP 418
B WINDOW DOES NOT GO DOWN 419
E-15 ABNORMALITY IN FRONT WORKING LAMP 421
E-16 ABNORMALITY IN REAR WORKING LAMP 421
E-17 ABNORMALITY IN TRANSMISSION CUT-OFF 421
E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 421
E-19 ABNORMALITY IN BUZZER 421
TROUBLESHOOTING OF ELECTRIC ENGINE THROTTLE & APS CONTROLLERS (G MODE) 423
JUDGEMENT TABLE 27
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS 427
ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS 433
POINTS TO REMEMBER WHEN TROUBLESHOOTING 154
JUDGEMENT TABLE FOR ENGINE CONTROLLER 436
G-1 [90] [OFF or 101] ABNORMALITY IN POWER SOURCE SYSTEM 437
G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM 437
G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR 438
G-4 G-4 [90] [56] ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM 438
G-5 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM 439
G-6 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM 440
G-7 [91] [14] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM 441
G-8 [91] [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM 442
G-9 [91] [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM 443
G-10 [91] [1d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM 444
G-11 [92] [12] ABNORMALITY IN RACK SENSOR SYSTEM 445
G-12 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM 446
G-13 [93] [1b] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM 447
G-14 [94] [1c] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM 448
G-15 [93, 94] [1b, 1c] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM 449
G-16 [95] [40] ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM 449
G-17 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM 450
G-18 [99] [22] ENGINE OVERRUN 452
G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY) 452
G-20 ENGINE DOES NOT START 454
G-21 ENGINE DOES NOT STOP 457
G-22 DEFECTIVE ACTUATION OF APS 458
A PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE AL 458
B 1 PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20C WHEN APS SWITCH IS ON (C 460
B 2 PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20C WHEN APS SWITCH IS ON 460
C NOZZLE DOES NOT INJECT FUEL WHEN STARTING SWITCH IS TURNED TO START AFTER COMPLETION OF PREHEA 460
D APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY 20
E APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY 20
F APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY 462
G APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY 462
H APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) GIVES ABNORMAL DISPLAY 463
I APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY 20
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 465
POWER TRAIN 467
H-1 MACHINE DOES NOT START 467
H-2 MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES) 468
H-3 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 469
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 470
STEERING 471
H-5 STEERING DOES NOT TURN 471
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK] 472
H-7 TURNING, RESPONSE OF STEERING IS POOR 473
H-8 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK] 474
H-9 STEERING IS HEAVY 476
H-10 STEERING WHEEL SHAKES OR JERKS 477
H-11 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK] 478
H-12 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING 478
BRAKES 479
H-13 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 479
H-14 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 481
H-15 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR 482
H-16 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 483
WORK EQUIPMENT 484
H-17 NEITHER BOOM NOR BUCKET MOVE 484
H-18 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER 485
H-19 BOOM DOES NOT MOVE 486
H-20 BOOM IS SLOW OR BOOM LACKS POWER 487
H-21 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT 488
H-22 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 488
H-23 EXCESSIVE HYDRAULIC DRIFT OF BOOM 489
H-24 BUCKET DOES NOT MOVE 490
H-25 BUCKET IS SLOW OR LACKS POWER 491
H-26 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 492
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE) 493
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS 495
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 496
ELECTRICAL CIRCUIT DIAGRAM 500
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED 501
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED 502
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED 503
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED 504
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED 505
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DIS 506
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPL 507
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYST 508
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE 509
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM 510
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 511
J-12 DISCONNECTION IN STEERING LEFT SOLENOID 512
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 513
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC 515
A NO LAMPS ON MAINTENANCE MONITOR LIGHT UP 515
B SOME LAMPS DO NOT LIGHT UP 515
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OU 516
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO 517
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 518
A ENGINE OIL LEVEL DISPLAY FLASHES 518
B ENGINE WATER LEVEL DISPLAY FLASHES 519
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 520
A ENGINE OIL PRESSURE DISPLAY FLASHES 520
B BATTERY CHARGE LEVEL DISPLAY FLASHES 521
C BRAKE OIL PRESSURE DISPLAY FLASHES 522
D AIR CLEANER (L H ) DISPLAY FLASHES 523
E AIR CLEANER (R H ) DISPLAY FLASHES 524
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND 525
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS 526
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH 527
A CHECK LAMP 527
B CAUTION LAMP 527
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION 528
A CHECK LAMP 528
B CAUTION LAMP 528
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE 529
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP 530
K-12 SERVICE METER DOES NOT WORK 531
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 531
K-14 ABNORMALITY IN GAUGE ITEMS 533
A ABNORMALITY IN FUEL GAUGE 533
B ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 534
C ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 535
TROUBLESHOOTING OF MAIN MONITOR (M MODE) 537
M-1 MAIN MONITOR DOES NOT WORK 539
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP 540
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 541
M-4 ABNORMALITY IN SHIFT INDICATOR 542
A DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F 542
B DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R 542
C DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER 542
D DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER 543
E DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R) 543
F DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R) 543
G DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R) 544
H DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R) 544
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 546
A L H TURN SIGNAL DISPLAY DOES NOT LIGHT UP 546
B R H TURN SIGNAL DISPLAY DOES NOT LIGHT UP 546
M-6 ABNORMALITY IN PARKING DISPLAY 547
A PARKING LAMP DISPLAY DOES NOT LIGHT UP 547
B PARKING LAMP DISPLAY STAYS LIGHTED UP 547
M-7 NIGHT LIGHTING DOES NOT LIGHT UP 548
M-8 ABNORMALITY IN FRONT WORKING LAMP 549
A NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 549
B WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 549
C MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 549
M-9 ABNORMALITY IN REAR WORKING LAMP 551
A NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 551
B WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 551
C MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 551
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF 553
STANDARD SPECIFICATION 553
A WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES 553
B WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED 553
C TRANSMISSION CUT-OFF SWITCH TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED 554
AUTO-SHIFT SPECIFICATION 555
A WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED 555
B WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF 555
C WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION 555
D CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH 555
E MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT 556
M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 557
A WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WH 557
B WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W 557
M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU 559
A ACTUATED CONTINUOUSLY 559
B NOT ACTUATED 559
M-13 ABNORMALITY IN BUZZER 560
A BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK) 560
B BUZZER ALWAYS SOUNDS 560
M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 561
M-15 ABNORMALITY IN FAILURE DISPLAY MODE 562
A DOES NOT ENTER FAILURE DISPLAY MODE 562
B COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE 562
M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY 563
A THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED 563
B THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED 563
C PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED 563
D PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED 564
M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY 565
A EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP 565
B EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP 565
M-18 ABNORMALITY IN AUTO-GREASING SYSTEM 566
A FORCED GREASING CANNOT BE CARRIED OUT 566
B MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SET) 566
C WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 566
D MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) 567
E MONITOR DISPLAY GOES OUT 567
M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM 568
A DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED 568
B MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK 568
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 569
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 571
S-2 ENGINE DOES NOT START 576
A ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 576
B EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 578
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 579
S-4 ENGINE STOPS DURING OPERATIONS 580
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 582
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 583
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 584
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 585
S-9 OIL BECOMES CONTAMINATED QUICKLY 586
S-10 FUEL CONSUMPTION IS EXCESSIVE 587
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 588
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 589
S-13 OIL LEVEL RISES 590
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 591
S-15 ABNORMAL NOISE IS MADE 592
S-16 VIBRATION IS EXCESSIVE 594
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE) 595
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS 596
CONTROLLER ACTIONS DURING ABNORMALITY 598
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LA 604
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI 605
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI 606
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN 607
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLEN 608
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN 609
T-7 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN 610
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS 612
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 614
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED 616
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED 618
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 619
A TRANSMISSION CONTROLLER SYSTEM 619
B ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM 619
T-13 HOLD SWITCH SYSTEM 622
T-14 KICK-DOWN SWITCH SYSTEM 622
T-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM 623
T-16 NEUTRALIZER RELAY SIGNAL SYSTEM 624
T-17 BUZZER SIGNAL SYSTEM 625
T-18 NETWORK SYSTEM 626
T-19 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM 627
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 628
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER 629
SERVICE TOOLS 25
GAUGE MANIFOLD 961
STRUCTURE AND HANDLING OF GAUGE MANIFOLD 632
CHARGING HOSES 63
GAS LEAK DETECTOR 635
HALIDE TORCH LEAK DETECTOR 26
ELECTRIC LEAK TESTER 68
VALVE FOR SERVICE CANS 639
MAINTENANCE PROCEDURE 640
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING 79
PROHIBITED WORK 79
OTHER PRECAUTIONS 640
BLEEDING AIR FROM REFRIGERATION CIRCUIT 91
PURPOSE 91
CONNECTING GAUGE MANIFOLD 98
EVACUATION 963
AIR-TIGHTNESS CHECK 29
GAS-LEAK CHECK 29
EVACUATION (REPEATING) 29
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT 29
CHARGING FROM THE HIGH-PRESSURE SIDE 92
CHARGING FROM THE LOW PRESSURE SIDE 646
WHEN THE AMBIENT TEMPERATURE IS LOW 647
WHEN THE AMBIENT TEMPERATURE IS HIGH 29
REPLACING SERVICE CANS 30
CHECKING THE AMOUNT OF REFRIGERANT 30
REMOVAL OF GAUGE MANIFOLD 30
DISCHARGING THE REFRIGERANT 650
DAILY CHECKS 30
CHECK REFRIGERANT LEVEL 651
CLEANING THE CONDENSER 651
CHECKING THE V-BELT 651
CHECKING OIL LEVEL 652
PROCEDURE FOR CHECKING 30
PROCEDURE FOR CHECKING OIL LEVEL 30
ADDING AND REMOVING OIL 653
ADDING OIL BY EVACUATION 30
TROUBLESHOOTING 121
VISUAL AND ACOUSTICAL CHECKS 123
DEFECTIVE COOLING 0
TROUBLESHOOTING TABLE 25
DEFECTIVE HEATING 25
TROUBLESHOOTING USING GAUGE MANIFOLD 660
PREPARATIONS BEFORE MEASURING 199
INSUFFICIENT REFRIGERANT 199
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER 661
AIR INSIDE REFRIGERATION SYSTEM 662
MOISTURE IN REFRIGERATING SYSTEM 663
REFRIGERANT DOES NOT CIRCULATE 664
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE 665
DEFECTIVE COMPRESSION BY COMPRESSOR 666
30 DISASSEMBLY AND ASSEMBLY 667
METHOD OF USING MANUAL 671
PRECAUTIONS DURING OPERATION 672
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 672
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 673
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 674
OTHER PRECAUTIONS 26
SPECIAL TOOL LIST 675
SKETCHES OF SPECIAL TOOLS 679
ENGINE 683
ALTERNATOR 683
CYLINDER HEAD 683
ENGINE FRONT SEAL 683
ENGINE OIL COOLER 683
ENGINE REAR SEAL 683
FUEL INJECTION PUMP 683
NOZZLE HOLDER 30
STARTING MOTOR 683
THERMOSTAT 683
TURBOCHARGER 30
WATER PUMP 30
HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER 684
REMOVAL 684
INSTALLATION 685
DAMPER, ENGINE 686
REMOVAL 686
INSTALLATION 688
DAMPER 689
REMOVAL 689
INSTALLATION 690
DISASSEMBLY 691
ASSEMBLY 693
PTO 697
DISASSEMBLY 697
ASSEMBLY 699
TORQUE CONVERTER, TRANSMISSION 702
REMOVAL 702
INSTALLATION 706
TORQUE CONVERTER 707
DISASSEMBLY 707
ASSEMBLY 711
TRANSMISSION 716
DISASSEMBLY 716
ASSEMBLY 730
TRANSMISSION VALVE 745
REMOVAL 745
INSTALLATION 745
TRANSMISSION CONTROL VALVE 746
LOWER VALVE 746
DISASSEMBLY 747
ASSEMBLY 747
UPPER VALVE 748
DISASSEMBLY 749
ASSEMBLY 751
MAIN RELIEF VALVE 752
DISASSEMBLY 753
ASSEMBLY 753
TRANSFER 754
DISASSEMBLY 754
ASSEMBLY 761
CENTER SUPPORT 771
REMOVAL 771
INSTALLATION 772
DISASSEMBLY 773
ASSEMBLY 775
DRIVE SHAFT 778
DISASSEMBLY 778
ASSEMBLY 780
FRONT AXLE 782
REMOVAL 782
INSTALLATION 783
FRONT DIFFERENTIAL 784
REMOVAL 784
INSTALLATION 786
REAR AXLE 787
REMOVAL 787
INSTALLATION 792
REAR DIFFERENTIAL 793
REMOVAL 793
INSTALLATION 794
DIFFERENTIAL 795
DISASSEMBLY 795
ASSEMBLY 799
FINAL DRIVE 808
DISASSEMBLY 808
ASSEMBLY 812
ORBITROL STEERING VALVE 816
REMOVAL 816
INSTALLATION 817
STEERING CYLINDER 818
REMOVAL 818
INSTALLATION 820
STEERING DEMAND VALVE 821
REMOVAL 821
INSTALLATION 822
BRAKE VALVE 823
REMOVAL 823
INSTALLATION 824
BRAKE VALVE (RIGHT) 825
DISASSEMBLY 825
ASSEMBLY 827
BRAKE VALVE (LEFT) 829
DISASSEMBLY 829
ASSEMBLY 831
SLACK ADJUSTER 833
REMOVAL 833
INSTALLATION 833
DISASSEMBLY 834
ASSEMBLY 835
BRAKE 836
REMOVAL 836
INSTALLATION 837
DISASSEMBLY 838
ASSEMBLY 842
HYDRAULIC PUMP 848
REMOVAL 848
INSTALLATION 849
PISTON PUMP 850
DISASSEMBLY 850
ASSEMBLY 856
HYDRAULIC TANK 872
REMOVAL 872
INSTALLATION 873
PPC VALVE 874
REMOVAL 874
INSTALLATION 875
DISASSEMBLY 876
ASSEMBLY 876
WORK EQUIPMENT CONTROL VALVE 877
REMOVAL 877
INSTALLATION 878
DISASSEMBLY 879
ASSEMBLY 881
DUMP CYLINDER 883
REMOVAL 883
INSTALLATION 883
LIFT CYLINDER 884
REMOVAL 884
INSTALLATION 885
STEERING, LIFT, DUMP CYLINDER 886
DISASSEMBLY 886
ASSEMBLY 888
CENTER HINGE PIN 890
REMOVAL 890
INSTALLATION 896
WORK EQUIPMENT 900
REMOVAL 900
INSTALLATION 903
BULKHEAD 905
REMOVAL 905
INSTALLATION 906
FLOOR FRAME 907
REMOVAL 907
INSTALLATION 909
COUNTERWEIGHT 910
REMOVAL 910
INSTALLATION 911
FUEL TANK 912
REMOVAL 912
INSTALLATION 913
CAB 914
REMOVAL 914
INSTALLATION 916
STOP VALVE 917
REMOVAL 917
INSTALLATION 917
ACCUMULATOR CHARGE VALVE 918
REMOVAL 918
INSTALLATION 918
DISASSEMBLY 919
ASSEMBLY 920
PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH 922
REMOVAL 922
INSTALLATION 922
DIVERTER VALVE 923
REMOVAL 923
INSTALLATION 923
DISASSEMBLY 924
ASSEMBLY 925
EMERGENCY STEERING PUMP 927
REMOVAL 927
INSTALLATION 927
PARKING BRAKE 928
REMOVAL 928
INSTALLATION 929
PARKING BRAKE CALIPERS 930
DISASSEMBLY 930
ASSEMBLY 932
PARKING BRAKE PAD 934
REMOVAL 934
INSTALLATION 934
REAR TIRE 935
REMOVAL 935
INSTALLATION 935
AIR CONDITIONER COMPRESSOR 936
REMOVAL 936
INSTALLATION 936
AIR CONDITIONER CONDENSER 937
REMOVAL 937
INSTALLATION 938
AIR CONDITIONER RECEIVER TANK 939
REMOVAL 939
INSTALLATION 939
AIR CONDITIONER UNIT 940
REMOVAL 940
INSTALLATION 941
MAIN MONITOR 942
REMOVAL 942
INSTALLATION 943
MAINTENANCE MONITOR 944
REMOVAL 944
INSTALLATION 944
ENGINE, APS CONTROLLER 945
REMOVAL 945
INSTALLATION 945
40 MAINTENANCE STANDARD 949
ENGINE AND TRANSMISSION MOUNT 950
DAMPER 952
TORQUE CONVERTER AND PTO 954
TRANSMISSION CLUTCH 956
TRANSMISSION GEAR 958
TRANSMISSION CONTROL VALVE 960
UPPER VALVE 960
RELIEF VALVE 960
LOWER VALVE 962
SOLENOID VALVE 964
TRANSFER 966
DRIVE SHAFT 968
CENTER SUPPORT 969
DIFFERENTIAL 970
FINAL DRIVE 974
AXLE MOUNT 976
CENTER HINGE PIN 978
STEERING COLUMN 981
STEERING DEMAND VALVE 982
DIVERTER VALVE 985
STEERING CYLINDER MOUNT 986
GROUND DRIVEN STEERING PUMP 988
BRAKE VALVE 990
LEFT 990
RIGHT 992
SLACK ADJUSTER 994
CONTROL PUMP 995
BRAKE 996
PARKING BRAKE 998
MAIN CONTROL VALVE 1000
PPC VALVE 1002
PPC RELIEF VALVE 1004
HYDRAULIC CYLINDER 1006
WORK EQUIPMENT LINKAGE 1008
BUCKET POSITIONER 1010
BOOM KICK-OUT 1010
90 OTHERS 1013
SHOP MANUAL FOLDOUTS 1015
ELECTRICAL CIRCUIT DIAGRAM 1015
DIAGRAM ONE (1/6) 1015
DIAGRAM ONE (2/6) 1017
DIAGRAM ONE (3/6) 1019
DIAGRAM ONE (4/6) 1021
DIAGRAM ONE (5/6) 1023
DIAGRAM ONE (6/6) 1025
DIAGRAM TWO (1/4) 1027
DIAGRAM TWO (2/4) 1029
DIAGRAM TWO (3/4) 1031
DIAGRAM TWO (4/4) 1033
CONNECTOR PIN ARRANGMENT 1035
CONNECTOR PIN DIGRAM (1/6) 1035
CONNECTOR PIN DIAGRAM (2/6) 1037
CONNECTOR PIN DIAGRAM (3/6) 1039
CONNECTOR PIN DIAGRAM (4/6) 1041
CONNECTOR PIN DIAGRAM (5/6) 1043
CONNECTOR PIN DIAGRAM (6/6) 1045
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM 1047

DESCRIPTION:

Komatsu Avance WA700-3L Wheel Loader Shop Manual CEBM004402 – PDF DOWNLOAD

• SERIAL NUMBERS 
• WA700-3L A50001 and UP

GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding
of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand
the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following 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

G.B  16/12/24