Komatsu Avance WA900-3LC Wheel Loader Shop Manual CEBM003702 – PDF

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Komatsu Avance WA900-3LC Wheel Loader Shop Manual CEBM003702 – PDF DOWNLOAD

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Komatsu Avance WA900-3LC Wheel Loader Shop Manual CEBM003702 – PDF DOWNLOAD

Language : English
Pages : 939
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Avance WA900-3LC Wheel Loader Shop Manual CEBM003702 – PDF DOWNLOAD

• SERIAL NUMBERS  WA900-3LC A50001 and UP

MAIN MENU 0
COVER PAGE 1
CONTENTS 2
00 FOREWORD 13
SAFETY 13
SAFETY NOTICE 13
IMPORTANT SAFETY NOTICE 13
GENERAL PRECAUTIONS 13
PREPARATIONS FOR WORK 13
PRECAUTIONS DURING WORK 13
GENERAL 15
HOW TO READ THE SHOP MANUAL 16
VOLUMES 16
DISTRIBUTION AND UPDATING 16
FILING METHOD 16
REVISED EDITION MARK 16
REVISIONS 16
SYMBOLS 16
HOISTING INSTRUCTIONS 17
HOISTING 17
WIRE ROPES 17
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 20
TIGHTENING TORQUE OF HOSE NUTS 21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 21
TIGHTENING TORQUE FOR FLARED NUTS 21
ELECTRIC WIRE CODE 22
CLASSIFICATION BY THICKNESS 22
CLASSIFICATION BY COLOR AND CODE 22
CONVERSION TABLES 23
METHOD OF USING THE CONVERSION TABLE 23
01 GENERAL 29
SPECIFICATION DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 34
FUEL, COOLANT AND LUBRICANTS 35
ENGINE OIL SPECIFICATIONS 36
NORMAL OPERATION 36
ARCTIC OPERATION 36
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM 37
FINAL DRIVE OIL SPECIFICATIONS 37
DRIVE AXLE OIL SPECIFICATIONS 37
DIESEL FUEL SPECIFICATIONS 37
COOLANT SPECIFICATIONS 38
SUPPLEMENTAL COOLANT ADDITIVES 40
COOLING SYSTEM TEST KIT 44
10 STRUCTURE AND FUNCTION 45
POWER TRAIN 50
OUTLINE 50
ENGINE CONTROL 52
OUTLINE 52
RADIATOR AND HYDRAULIC OIL COOLER 53
DAMPER 54
TORQUE CONVERTER AND TRANSMISSION PIPING 55
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 56
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 57
TORQUE CONVERTER 58
RELIEF VALVE 61
OUTLINE 61
FUNCTION 61
REGULATOR VALVE 62
OPERATION 62
TRANSMISSION 63
CLUTCH 66
OUTLINE 66
OPERATION 66
FORWARD 1st 67
FORWARD 2ND 68
FORWARD 3RD 69
REVERSE 1ST 70
TRANSFER 71
OUTLINE 71
TRANSMISSION PATH 71
CONTROL VALVE 72
SOLENOID VALVE 73
TRANSMISSION SOLENOID VALVE 74
UPPER VALVE 76
LINE OIL FILTER 77
PILOT OIL FILTER 77
MAIN RELIEF VALVE 78
PILOT REDUCING VALVE 79
PRIORITY VALVE 80
MODULATING VALVE AND QUICK RETURN VALVE 81
OPERATION 81
REDUCING VALVE 83
EMERGENCY MANUAL SPOOL 84
LUBRICATION VALVE 85
HYDRAULIC CIRCUIT SCHEMATICS 86
FORWARD 1st 86
OPERATION 87
TORQUE CONVERTER OIL COOLER 88
OUTLINE 88
DRIVE SHAFT 89
OUTLINE 89
CENTER SUPPORT 90
FUNCTION 90
AXLE 91
FRONT AXLE 91
FRONT DIFFERENTIAL 92
REAR AXLE 93
REAR DIFFERENTIAL 94
OUTLINE 95
FINAL DRIVE 96
OUTLINE 96
OPERATION 96
MEMORANDA 97
AXLE MOUNT 98
FRONT AXLE 99
REAR AXLE 99
CENTER HINGE PIN 100
OUTLINE 100
TIRE AND WHEEL 101
OUTLINE 101
STEERING 102
PIPING 102
STEERING COLUMN 103
STEERING PUMP 104
OUTLINE 104
MEMORANDA 106
SWITCH PUMP 107
OUTLINE 107
SWITCH PUMP (HPV 90 + 90) 108
CO – NC VALVE 110
CO VALVE 112
FUNCTION 112
OPERATION 112
NC VALVE 114
OPERATION 114
STEERING DEMAND VALVE 115
OVERLOAD RELIEF VALVE 116
FUNCTION 116
OPERATION 116
MAIN RELIEF VALVE 118
OPERATION OF DEMAND VALVE 120
WHEN STEERING SPOOL IS OPERATED 121
OPERATION OF STEERING VALVE 123
ORBIT-ROLL VALVE 126
OUTLINE 127
STRUCTURE 127
OPERATION 128
TWO-WAY RESTRICTOR VALVE 129
FUNCTION 129
OPERATION 129
DIVERTER VALVE 130
FUNCTION 130
GROUND DRIVEN STEERING 131
RELIEF VALVE 131
FUNCTION 131
OPERATION 131
HYDRAULIC CIRCUIT SCHEMATICS 132
PUMP, ENGINE WORKING NORMALLY 132
FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING 133
BRAKE 134
PIPING 134
BRAKE CIRCUIT DIAGRAM 136
BRAKE VALVE 138
OUTLINE 138
OPERATION 139
CHARGE VALVE 142
FUNCTION 142
OPERATION 144
ACCUMULATOR 146
FUNCTION 146
SLACK ADJUSTER 147
FUNCTION 147
OPERATION 148
BRAKE 150
OPERATION 150
FUNCTION 150
PARKING BRAKE 151
OUTLINE 151
OPERATION 152
SPRING CYLINDER 153
OUTLINE 153
PARKING BRAKE SOLENOID VALVE 154
FUNCTION 154
HYDRAULIC PIPING 156
MACHINE WITH JOYSTICK STEERING 158
WORK EQUIPMENT LEVER LINKAGE 162
HYDRAULIC TANK 163
OUTLINE 163
OIL FILTER BYPASS VALVE 164
BREATHER 165
FUNCTION 165
MAIN PISTON PUMP 166
OUTLINE 166
PISTON PUMP (HPV90 + 90) 167
FUNCTION 169
STRUCTURE 169
OPERATION 170
CONTROL PUMP (BAR025) 172
RELIEF VALVE 173
ES (ENGINE SENSING) VALVE 174
FUNCTION 174
OPERATION 175
SERVO VALVE 176
OPERATION 177
PPC VALVE 179
OPERATION 181
PPC RELIEF VALVE 183
FUNCTION 183
OPERATION 183
ACCUMULATOR (PPC VALVE) 184
FUNCTION 184
OPERATION 184
MAIN CONTROL VALVE 185
FUNCTION 186
RELIEF VALVE 187
FUNCTION 187
OPERATION 187
SAFETY VALVE (with suction valve) 188
FUNCTION 188
OPERATION 188
SUCTION VALVE 189
OPERATION 189
FLOAT SELECTOR VALVE AND UNLOADER VALVE 190
FUNCTION 190
OPERATION 190
OPERATION OF HYDRAULIC CIRCUIT 192
BOOM AND DUMP SPOOLS IN “HOLD” 192
LIFT SPOOL IN “RAISE” 193
LIFT SPOOL IN “LOWER” 194
BOOM SPOOL IN “FLOAT” 195
DUMP SPOOL IN “DUMP” 196
DUMP SPOOL IN “TILT BACK” 197
WORK EQUIPMENT 198
LUBRICATION 198
LINKAGE 200
BUCKET POSITIONER AND BOOM KICKOUT 202
BUCKET POSITIONER 203
BOOM KICK-OUT 203
OPERATION OF PROXIMITY SWITCH 204
BOOM RAISE 204
BUCKET TILT 206
CAB 208
ROPS CANOPY 209
AIR CONDITIONER 210
AIR CONDITIONER PIPING 210
AIR CONDITIONER CONDENSER 211
AIR CONDITIONER COMPRESSOR 211
DRY RESERVOIR 212
ELECTRIC CIRCUIT DIAGRAM 215
MACHINE MONITOR SYSTEM 233
OUTLINE 233
MAIN MONITOR 234
OUTLINE 234
DISPLAY FUNCTION 235
SWITCH FUNCTION 236
TROUBLE DATA DISPLAY MODE 237
MAINTENANCE MONITOR 238
OUTLINE 238
DISPLAY FUNCTION 239
ENGINE START AND STOP CIRCUIT 241
SAFETY RELAY 243
FUNCTION 244
ENGINE START 244
ENGINE STOP 244
PREHEATING CIRCUIT 245
OUTLINE 245
ELECTRICAL TRANSMISSION CONTROL 246
FUNCTION 246
COMBINATION SWITCH 247
OUTLINE 247
OPERATION 248
KICK-DOWN, HOLD SWITCH 249
KICK-DOWN SWITCH 249
OPERATION 249
CANCELLATION (or not actuated) 249
HOLD SWITCH 249
PARKING BRAKE 250
ELECTRIC CONTROL 250
OUTLINE 250
FUNCTION 251
PARKING BRAKE SWITCH 251
PARKING BRAKE SOLENOID VALVE 252
PARKING SAFETY RELAY 252
NEUTRALIZER RELAY 252
EMERGENCY BRAKE SWITCH 252
OPERATION 253
STARTING SWITCH OFF 253
STARTING SWITCH ON 254
PARKING BRAKE SWITCH OFF (RELEASED) 256
PARKING BRAKE SWITCH ON (actuated) 257
WHEN MAIN BRAKE OIL PRESSURE DROPS (emergency brake actuated) 258
20 TESTING, ADJUSTING AND TROUBLESHOOTING 259
STANDARD VALUE TABLE FOR ENGINE 260
STANDARD VALUE TABLE FOR CHASSIS 261
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 267
TESTING AND ADJUSTING 277
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 278
MEASURING ENGINE SPEED 280
ADJUSTING VALVE CLEARANCE 282
MEASURING COMPRESSION PRESSURE 283
MEASURING BLOW-BY PRESSURE 284
FUEL INJECTION TIMING 285
MEASURING ENGINE OIL PRESSURE 287
MEASURING EXHAUST TEMPERATURE 288
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 289
ALTERNATOR BELT TENSION 290
AIR CONDITIONER COMPRESSOR BELT TENSION 291
MEASURING ACCELERATOR PEDAL 292
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE 293
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL 296
STEERING OIL PRESSURE 298
GROUND DRIVEN STEERING OIL PRESSURE 299
BLEEDING AIR FROM STEERING CIRCUIT 301
STEERING STOP VALVE 302
TESTING WHEEL BRAKE PERFORMANCE 303
TESTING WHEEL BRAKE OIL PRESSURE DROP 304
MEASURING WEAR OF WHEEL BRAKE DISC 306
ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE 307
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT 309
TESTING PARKING BRAKE PERFORMANCE 310
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE 311
PARKING BRAKE PAD 312
PPC PRESSURE 314
ADJUSTING PPC VALVE LINKAGE 316
WORK EQUIPMENT HYDRAULIC PRESSURE 317
BLEEDING AIR FROM PISTON PUMP 319
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT 320
ADJUSTING WORK EQUIPMENT LEVER LINKAGE 321
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 323
BUCKET PROXIMITY SWITCH 324
BOOM PROXIMITY SWITCH 325
TESTING PROXIMITY ACTUATION PILOT LAMP 326
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR 327
ADJUSTING JOYSTICK LEVER POTENTIOMETER 328
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH 330
TROUBLESHOOTING 331
POINTS TO REMEMBER WHEN TROUBLESHOOTING 332
SEQUENCE OF EVENTS IN TROUBLESHOOTING 333
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 334
POINTS TO REMEMBER WHEN HANDLING ELECTRICAL EQUIPMENT 334
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 339
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 340
CHECKS BEFORE TROUBLESHOOTING 342
CONNECTOR TYPES AND MOUNTING LOCATIONS 343
CONNECTOR ARRANGEMENT DIAGRAM 347
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 352
EXPLANATION OF FUNCTION OF ELECTRICAL CONTROL MECHANISM 365
TRANSMISSION CONTROL SYSTEM 365
MAIN MONITOR SYSTEM 366
MAINTENANCE MONITOR SYSTEM 367
JOYSTICK STEERING 368
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 369
CHART OF ACTION CODES AND FAILURE CODES AND RE-ENACTION 371
TRANSMISSION CONTROLLER LED DISPLAY 373
METHOD OF USING JUDGEMENT TABLE 374
METHOD OF USING TROUBLESHOOTING CHARTS 375
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 377
METHOD OF USING TROUBLESHOOTING ENGINE RELATED CHARTS 379
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 383
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKE TIME) 384
S-2 ENGINE DOES NOT START 385
(1) ENGINE DOES NOT TURN 385
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 386
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START 387
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 388
S-4 ENGINE STOPS DURING OPERATION 389
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 390
S-6 ENGINE LACKS OUTPUT (NO POWER) 391
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 392
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 393
S-9 OIL BECOMES CONTAMINATED QUICKLY 394
S-10 FUEL CONSUMPTION IS EXCESSIVE 395
S-11 OIL IN COOLANT WATER, OR WATER SPURTS BACK OR WATER LEVEL GOES DOWN 396
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 397
S-13 OIL LEVEL RISES 398
S-14 COOLANT WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 399
S-15 ABNORMAL NOISE IS MADE 400
S-16 VIBRATION IS EXCESSIVE 401
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T-MODE) 403
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS 404
ACTION TAKEN BY CONTROLLERS WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 406
ELECTRICAL DIAGRAM FOR TANSMISSION CONTROLLER SYSTEM 411
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK UP LAMP RELAY) IS DISPLAYED 412
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED 413
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED 414
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED 415
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED 416
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED 417
T-7 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 418
T-8 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 420
T-9 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED 424
T-10 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED 427
T-11 FAIURE CODE [23] (SHORT CIRCUIT, DISCONNECTION, ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 428
T-12 SHIFT-UP SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) AND HOLD SIGNAL SYSTEM (AUTO-SHIFT (OP) 429
T-13 KICK-DOWN SIGNAL SYSTEM AND SHIFT DOWN SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) 429
T-14 TRANSMISSION CUT-OFF SIGNAL SYSTEM 430
T-15 NEUTRALIZER SIGNAL SYSTEM 431
T-16 BUZZER SIGNAL SYSTEM 432
T-17 NETWORK SYSTEM 433
T-18 TRANSMISSION CONTROLLER POWER SOURCE 434
T-19 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 435
T-20 ABNORMALITY IN MACHINE SELECTION WIRE HARNESS 436
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 437
TROUBLE DATA DISPLAY 439
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM 441
M-1 MAIN MONITOR DOES NOT WORK BACKUP LAMP RELAY) IS DISPLAYED 442
M-2 WHEN STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT UP 443
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 444
M-4 ABNORMALITY IN SHIFT INDICATOR 445
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP 448
M-6 TURN SIGNAL DISPLAY NOT LIGHT UP 449
M-7 ABNORMALITY IN PARKING DISPLAY 450
M-8 ABNORMALITY IN PREHEATING SYSTEM 451
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 455
M-10 ABNORMALITY IN FRONT WORKING LAMP 456
M-11 ABNORMALITY IN REAR WORKING LAMP 458
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 460
M-13 ABNORMALITY IN LOW IDLE SELECTION 462
M-14 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY 464
M-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 465
M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP) 467
M-17 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR NOT ACTUATED 469
M-18 ABNORMALITY IN BUZZER 470
M-19 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 471
M-20 ABNORMALITY IN FAILURE DISPLAY MODE 472
M-21 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER 473
M-22 ABNORMALITY IN AUTO-GREASING SYSTEM (OP) 474
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP) 476
TROUBLEHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 477
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR 479
K-1 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO 480
K-2 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) 481
K-3 WHEN ENGINE IS STARTED IMMEDIATLY AFTER STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE GO OUT 482
K-4 WHEN STARTER SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 483
K-5 WHEN STARTER SWITCH IS TURNED ON (ENGINE STARTED), CAUTION) ITEMS FLASH 485
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND 492
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS 493
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES 494
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHT UP 495
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHT SWITCH IS TURNED ON 496
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHT SWITCH IS TURNED OFF 497
K-12 SERVICE METER DOES NOT WORK 498
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 498
K-14 ABNORMALITY IN GAUGE DISPLAY 499
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 503
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING 505
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING 506
ENGINE PRE-LUBRICATION SYSTEM 507
ELECTRICAL DIA – BOOM KICK-OUT / BUCKET POSITIONER 511
E-1 ENGINE DOES NOT START 512
E-2 ENGINE DOES NOT STOP (STD SPEC ) 517
E-3 ABNORMALITY IN PREHEATING SYSTEM 519
E-4 PARKING BRAKE DOES NOT HAVE EFFECT 523
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 524
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH TURNED ON 526
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED 526
E-8 KICK-DOWN SWITCH DOES NOT WORK 528
E-9 BOOM KICK-OUT DOES NOT WORK 530
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION 534
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP 537
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP 537
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF 537
E-14 ABNORMALITY IN LOW IDLE SELECTION 537
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 537
E-16 ABNORMALITY IN BUZZER 537
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 539
H-1 MACHINE DOES NOT MOVE 540
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE) 541
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 542
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 543
H-5 STEERING DOES NOT TURN 544
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK (OP)] 545
H-7 TURNING, RESPONSE OF STEERING IS POOR 546
H-8 TURNING RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK(OP)] 547
H-9 STEERING IS HEAVY 548
H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK(OP)] 548
H-11 STEERING WHEEL SHAKES OR JERKS 549
H-12 STEERING WHEEL SHAKES OR JERKS SHOCK [MACHINE WITH JOYSTICK (OP)] 550
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING 550
H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 551
H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 552
H-16 BOOM DOES NOT RISE 553
H-17 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER 554
H-18 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT 555
H-19 BOOM CYLINDER CANNOT HOLD DOWN BUCKET 555
H-20 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT 555
H-21 BOOM FLUCTUATES WHILE WORKING 556
H-22 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE 556
H-23 BUCKET DOES NOT TILT BACK 557
H-24 BUCKET MOVES SLOWLY AND HAS INSUFFICIENT TILT BACK POWER 558
H-25 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK 559
H-26 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET 559
H-27 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT 559
H-28 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD 560
H-29 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT 560
H-30 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY 561
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J-MODE) 563
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM 564
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS 566
ELECTRIC DIAGRAM FOR JOYSTICK STEERING SYSTEM 570
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED 572
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED 573
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED 574
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED 575
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED 576
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING RIGHT SOLENOID CUT RELAY OUTPUT) IS DISPLAYED 577
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED 578
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED 579
J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE 580
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT 581
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 582
J-12 DISCONNECTION IN STEERING LEFT SOLENOID 583
30 DISASSEMBLY AND ASSEMBLY 585
METHOD OF USING MANUAL 589
PRECAUTIONS DURING OPERATION 590
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 590
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 591
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 592
OTHER PRECAUTIONS 592
SPECIAL TOOL LIST 593
SKETCHES OF SPECIAL TOOLS 601
ENGINE 609
ALTERNATOR 609
CYLINDER HEAD 609
DAMPER 609
ENGINE OIL COOLER 609
ENGINE FRONT SEAL 609
ENGINE REAR SEAL 609
FUEL INJECTION PUMP FOR LEFT BANK 609
FUEL INJECTION PUMP FOR RIGHT BANK 609
NOZZLE HOLDER 609
STARTING MOTOR 609
TURBOCHARGER 609
WATER PUMP 609
RADIATOR 610
REMOVAL 610
INSTALLATION 613
ENGINE 614
REMOVAL 614
INSTALLATION 620
TORQUE CONVERTER AND TRANSMISSION 621
REMOVAL 621
INSTALLATION 629
TORQUE CONVERTER 631
DISASSEMBLY 631
ASSEMBLY 635
TORQUE CONVERTER VALVE 640
DISASSEMBLY 640
ASSEMBLY 640
TRANSMISSION 641
DISASSEMBLY 641
ASSEMBLY 657
TRANSMISSION VALVE 673
REMOVAL 673
INSTALLATION 673
UPPER VALVE 674
DISASSEMBLY 674
ASSEMBLY 675
LOWER VALVE 676
DISASSEMBLY 676
ASSEMBLY 676
RELIEF VALVE 677
DISASSEMBLY 677
ASSEMBLY 677
TRANSFER 678
DISASSEMBLY 678
ASSEMBLY 686
PTO 696
DISASSEMBLY 696
ASSEMBLY 698
CENTER SUPPORT 701
REMOVAL 701
INSTALLATION 702
DISASSEMBLY 703
ASSEMBLY 705
DRIVE SHAFT 708
DISASSEMBLY 708
ASSEMBLY 710
FRONT AXLE 712
REMOVAL 712
INSTALLATION 714
REAR AXLE 715
REMOVAL 715
INSTALLATION 721
DIFFERENTIAL 723
REMOVAL 723
INSTALLATION 725
DISASSEMBLY 726
ASSEMBLY 730
FINAL DRIVE 736
DISASSEMBLY 736
ASSEMBLY 739
ORBIT-ROLL 742
REMOVAL 742
INSTALLATION 743
GROUND DRIVEN STEERING PUMP 744
REMOVAL 744
INSTALLATION 744
DIVERTER VALVE 745
REMOVAL 745
INSTALLATION 745
DISASSEMBLY 746
ASSEMBLY 747
ACCUMULATOR CHARGE VALVE 749
REMOVAL 749
INSTALLATION 749
DISASSEMBLY 750
ASSEMBLY 751
STEERING STOP VALVE 753
REMOVAL 753
INSTALLATION 753
STEERING CYLINDER 754
REMOVAL 754
INSTALLATION 755
STEERING VALVE 756
REMOVAL 756
INSTALLATION 757
BRAKE VALVE 758
REMOVAL 758
INSTALLATION 758
SLACK ADJUSTER 759
REMOVAL 759
INSTALLATION 759
DISASSEMBLY 760
ASSEMBLY 761
BRAKE 762
REMOVAL 762
INSTALLATION 763
DISASSEMBLY 764
ASSEMBLY 767
PARKING BRAKE CALIPERS 771
REMOVAL 771
INSTALLATION 772
DISASSEMBLY 773
ASSEMBLY 774
PARKING BRAKE PAD 776
REMOVAL 776
INSTALLATION 777
PARKING BRAKE SPRING CYLINDER 778
REMOVAL 778
INSTALLATION 778
BRAKE OIL TANK 779
REMOVAL 779
INSTALLATION 779
HYDRAULIC PUMP 780
REMOVAL 780
INSTALLATION 782
HYDRAULIC TANK AND FILTER CASE 783
REMOVAL 783
INSTALLATION 784
PPC VALVE 785
REMOVAL 785
INSTALLATION 786
DISASSEMBLY 787
ASSEMBLY 787
WORK EQUIPMENT CONTROL VALVE 788
REMOVAL 788
INSTALLATION 789
DISASSEMBLY 790
ASSEMBLY 792
CAB 794
REMOVAL 794
INSTALLATION 797
FLOOR FRAME 798
REMOVAL 798
INSTALLATION 801
CENTER HINGE PIN 802
REMOVAL 802
INSTALLATION 808
WORK EQUIPMENT 812
REMOVAL 812
INSTALLATION 817
BOOM FRONT END BUSHING 818
REPLACEMENT 818
BUCKET CYLINDER 819
REMOVAL 819
INSTALLATION 819
LIFT CYLINDER 821
REMOVAL 821
INSTALLATION 822
HYDRAULIC CYLINDER 823
DISASSEMBLY 823
ASSEMBLY 825
AIR CONDITIONER UNIT 827
REMOVAL 827
INSTALLATION 828
AIR CONDITIONER COMPRESSOR 829
REMOVAL 829
INSTALLATION 829
RECEIVER TANK 830
REMOVAL 830
INSTALLATION 830
AIR CONDITIONER CONDENSER 831
REMOVAL 831
INSTALLATION 832
TRANSMISSION AND STEERING CONTROLLER 833
REMOVAL 833
INSTALLATION 833
MAIN MONITOR 834
REMOVAL 834
INSTALLATION 835
FUEL TANK 836
REMOVAL 836
INSTALLATION 837
COUNTERWEIGHT – STANDARD 838
REMOVAL 838
INSTALLATION 839
COUNTERWEIGHT – HIGH-LIFT 840
REMOVAL 840
INSTALLATION 841
40 MAINTENANCE STANDARD 843
ENGINE MOUNT 844
TRANSMISSION MOUNT 845
DAMPER 846
HYDRAULIC PUMPS 848
TORQUE CONVERTER CHARGING, PPC AND BRAKE 848
TORQUE CONVERTER 850
REGULATOR VALVE 851
TRANSMISSION 852
CLUTCH 852
GEAR 854
TRANSMISSION CONTROL VALVE 856
UPPER VALVE 856
LOWER VALVE 858
DRIVE SHAFT 861
CENTER SUPPORT 862
DIFFERENTIAL 863
Assembly Torques 863
Gears 864
FINAL DRIVE 866
AXLE MOUNT 868
CENTER HINGE PIN 870
STEERING COLUMN 872
STEERING DEMAND VALVE 873
DIVERTER VALVE 875
STEERING CYLINDER MOUNT 876
GROUND DRIVEN STEERING PUMP 877
BRAKE VALVE 878
SLACK ADJUSTER 881
BRAKE 882
PARKING BRAKE 884
PPC VALVE 886
PPC RELIEF VALVE 888
CONTROL PUMP (BAR025) 889
MAIN CONTROL VALVE 891
HYDRAULIC CYLINDER 893
BUCKET LINKAGE 895
BUCKET POSITIONER AND BOOM KICK-OUT 897
90 OTHERS (SHOP MANUAL FOLDOUTS) 899
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 1 OF 6) 901
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 2 OF 6) 903
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 3 OF 6) 905
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 4 OF 6) 907
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 5 OF 6) 909
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 6 OF 6) 911
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 1 OF 4) 913
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 2 OF 4) 915
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 3 OF 4) 917
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 4 OF 4) 919
FOLDOUT 20-217 CONNECTOR ARRANGEMENT DIAGRAM (1 OF 3) 921
FOLDOUT 20-219 CONNECTOR ARRANGEMENT DIAGRAM (2 OF 3) 923
FOLDOUT 20-409 ELECTRICAL DIAGRAM FOR TRANSMISSION CONTROLLER 925
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 1 OF 4) 927
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 2 OF 4) 929
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 3 OF 4) 931
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 4 OF 4) 933
FOLDOUT 20-603 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM 935
FOLDOUT 20-703 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING, AND PREHEATING 937MAIN MENU 0
COVER PAGE 1
CONTENTS 2
00 FOREWORD 13
SAFETY 13
SAFETY NOTICE 13
IMPORTANT SAFETY NOTICE 13
GENERAL PRECAUTIONS 13
PREPARATIONS FOR WORK 13
PRECAUTIONS DURING WORK 13
GENERAL 15
HOW TO READ THE SHOP MANUAL 16
VOLUMES 16
DISTRIBUTION AND UPDATING 16
FILING METHOD 16
REVISED EDITION MARK 16
REVISIONS 16
SYMBOLS 16
HOISTING INSTRUCTIONS 17
HOISTING 17
WIRE ROPES 17
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 20
TIGHTENING TORQUE OF HOSE NUTS 21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 21
TIGHTENING TORQUE FOR FLARED NUTS 21
ELECTRIC WIRE CODE 22
CLASSIFICATION BY THICKNESS 22
CLASSIFICATION BY COLOR AND CODE 22
CONVERSION TABLES 23
METHOD OF USING THE CONVERSION TABLE 23
01 GENERAL 29
SPECIFICATION DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 34
FUEL, COOLANT AND LUBRICANTS 35
ENGINE OIL SPECIFICATIONS 36
NORMAL OPERATION 36
ARCTIC OPERATION 36
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM 37
FINAL DRIVE OIL SPECIFICATIONS 37
DRIVE AXLE OIL SPECIFICATIONS 37
DIESEL FUEL SPECIFICATIONS 37
COOLANT SPECIFICATIONS 38
SUPPLEMENTAL COOLANT ADDITIVES 40
COOLING SYSTEM TEST KIT 44
10 STRUCTURE AND FUNCTION 45
POWER TRAIN 50
OUTLINE 50
ENGINE CONTROL 52
OUTLINE 52
RADIATOR AND HYDRAULIC OIL COOLER 53
DAMPER 54
TORQUE CONVERTER AND TRANSMISSION PIPING 55
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 56
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 57
TORQUE CONVERTER 58
RELIEF VALVE 61
OUTLINE 61
FUNCTION 61
REGULATOR VALVE 62
OPERATION 62
TRANSMISSION 63
CLUTCH 66
OUTLINE 66
OPERATION 66
FORWARD 1st 67
FORWARD 2ND 68
FORWARD 3RD 69
REVERSE 1ST 70
TRANSFER 71
OUTLINE 71
TRANSMISSION PATH 71
CONTROL VALVE 72
SOLENOID VALVE 73
TRANSMISSION SOLENOID VALVE 74
UPPER VALVE 76
LINE OIL FILTER 77
PILOT OIL FILTER 77
MAIN RELIEF VALVE 78
PILOT REDUCING VALVE 79
PRIORITY VALVE 80
MODULATING VALVE AND QUICK RETURN VALVE 81
OPERATION 81
REDUCING VALVE 83
EMERGENCY MANUAL SPOOL 84
LUBRICATION VALVE 85
HYDRAULIC CIRCUIT SCHEMATICS 86
FORWARD 1st 86
OPERATION 87
TORQUE CONVERTER OIL COOLER 88
OUTLINE 88
DRIVE SHAFT 89
OUTLINE 89
CENTER SUPPORT 90
FUNCTION 90
AXLE 91
FRONT AXLE 91
FRONT DIFFERENTIAL 92
REAR AXLE 93
REAR DIFFERENTIAL 94
OUTLINE 95
FINAL DRIVE 96
OUTLINE 96
OPERATION 96
MEMORANDA 97
AXLE MOUNT 98
FRONT AXLE 99
REAR AXLE 99
CENTER HINGE PIN 100
OUTLINE 100
TIRE AND WHEEL 101
OUTLINE 101
STEERING 102
PIPING 102
STEERING COLUMN 103
STEERING PUMP 104
OUTLINE 104
MEMORANDA 106
SWITCH PUMP 107
OUTLINE 107
SWITCH PUMP (HPV 90 + 90) 108
CO – NC VALVE 110
CO VALVE 112
FUNCTION 112
OPERATION 112
NC VALVE 114
OPERATION 114
STEERING DEMAND VALVE 115
OVERLOAD RELIEF VALVE 116
FUNCTION 116
OPERATION 116
MAIN RELIEF VALVE 118
OPERATION OF DEMAND VALVE 120
WHEN STEERING SPOOL IS OPERATED 121
OPERATION OF STEERING VALVE 123
ORBIT-ROLL VALVE 126
OUTLINE 127
STRUCTURE 127
OPERATION 128
TWO-WAY RESTRICTOR VALVE 129
FUNCTION 129
OPERATION 129
DIVERTER VALVE 130
FUNCTION 130
GROUND DRIVEN STEERING 131
RELIEF VALVE 131
FUNCTION 131
OPERATION 131
HYDRAULIC CIRCUIT SCHEMATICS 132
PUMP, ENGINE WORKING NORMALLY 132
FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING 133
BRAKE 134
PIPING 134
BRAKE CIRCUIT DIAGRAM 136
BRAKE VALVE 138
OUTLINE 138
OPERATION 139
CHARGE VALVE 142
FUNCTION 142
OPERATION 144
ACCUMULATOR 146
FUNCTION 146
SLACK ADJUSTER 147
FUNCTION 147
OPERATION 148
BRAKE 150
OPERATION 150
FUNCTION 150
PARKING BRAKE 151
OUTLINE 151
OPERATION 152
SPRING CYLINDER 153
OUTLINE 153
PARKING BRAKE SOLENOID VALVE 154
FUNCTION 154
HYDRAULIC PIPING 156
MACHINE WITH JOYSTICK STEERING 158
WORK EQUIPMENT LEVER LINKAGE 162
HYDRAULIC TANK 163
OUTLINE 163
OIL FILTER BYPASS VALVE 164
BREATHER 165
FUNCTION 165
MAIN PISTON PUMP 166
OUTLINE 166
PISTON PUMP (HPV90 + 90) 167
FUNCTION 169
STRUCTURE 169
OPERATION 170
CONTROL PUMP (BAR025) 172
RELIEF VALVE 173
ES (ENGINE SENSING) VALVE 174
FUNCTION 174
OPERATION 175
SERVO VALVE 176
OPERATION 177
PPC VALVE 179
OPERATION 181
PPC RELIEF VALVE 183
FUNCTION 183
OPERATION 183
ACCUMULATOR (PPC VALVE) 184
FUNCTION 184
OPERATION 184
MAIN CONTROL VALVE 185
FUNCTION 186
RELIEF VALVE 187
FUNCTION 187
OPERATION 187
SAFETY VALVE (with suction valve) 188
FUNCTION 188
OPERATION 188
SUCTION VALVE 189
OPERATION 189
FLOAT SELECTOR VALVE AND UNLOADER VALVE 190
FUNCTION 190
OPERATION 190
OPERATION OF HYDRAULIC CIRCUIT 192
BOOM AND DUMP SPOOLS IN “HOLD” 192
LIFT SPOOL IN “RAISE” 193
LIFT SPOOL IN “LOWER” 194
BOOM SPOOL IN “FLOAT” 195
DUMP SPOOL IN “DUMP” 196
DUMP SPOOL IN “TILT BACK” 197
WORK EQUIPMENT 198
LUBRICATION 198
LINKAGE 200
BUCKET POSITIONER AND BOOM KICKOUT 202
BUCKET POSITIONER 203
BOOM KICK-OUT 203
OPERATION OF PROXIMITY SWITCH 204
BOOM RAISE 204
BUCKET TILT 206
CAB 208
ROPS CANOPY 209
AIR CONDITIONER 210
AIR CONDITIONER PIPING 210
AIR CONDITIONER CONDENSER 211
AIR CONDITIONER COMPRESSOR 211
DRY RESERVOIR 212
ELECTRIC CIRCUIT DIAGRAM 215
MACHINE MONITOR SYSTEM 233
OUTLINE 233
MAIN MONITOR 234
OUTLINE 234
DISPLAY FUNCTION 235
SWITCH FUNCTION 236
TROUBLE DATA DISPLAY MODE 237
MAINTENANCE MONITOR 238
OUTLINE 238
DISPLAY FUNCTION 239
ENGINE START AND STOP CIRCUIT 241
SAFETY RELAY 243
FUNCTION 244
ENGINE START 244
ENGINE STOP 244
PREHEATING CIRCUIT 245
OUTLINE 245
ELECTRICAL TRANSMISSION CONTROL 246
FUNCTION 246
COMBINATION SWITCH 247
OUTLINE 247
OPERATION 248
KICK-DOWN, HOLD SWITCH 249
KICK-DOWN SWITCH 249
OPERATION 249
CANCELLATION (or not actuated) 249
HOLD SWITCH 249
PARKING BRAKE 250
ELECTRIC CONTROL 250
OUTLINE 250
FUNCTION 251
PARKING BRAKE SWITCH 251
PARKING BRAKE SOLENOID VALVE 252
PARKING SAFETY RELAY 252
NEUTRALIZER RELAY 252
EMERGENCY BRAKE SWITCH 252
OPERATION 253
STARTING SWITCH OFF 253
STARTING SWITCH ON 254
PARKING BRAKE SWITCH OFF (RELEASED) 256
PARKING BRAKE SWITCH ON (actuated) 257
WHEN MAIN BRAKE OIL PRESSURE DROPS (emergency brake actuated) 258
20 TESTING, ADJUSTING AND TROUBLESHOOTING 259
STANDARD VALUE TABLE FOR ENGINE 260
STANDARD VALUE TABLE FOR CHASSIS 261
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 267
TESTING AND ADJUSTING 277
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 278
MEASURING ENGINE SPEED 280
ADJUSTING VALVE CLEARANCE 282
MEASURING COMPRESSION PRESSURE 283
MEASURING BLOW-BY PRESSURE 284
FUEL INJECTION TIMING 285
MEASURING ENGINE OIL PRESSURE 287
MEASURING EXHAUST TEMPERATURE 288
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 289
ALTERNATOR BELT TENSION 290
AIR CONDITIONER COMPRESSOR BELT TENSION 291
MEASURING ACCELERATOR PEDAL 292
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE 293
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL 296
STEERING OIL PRESSURE 298
GROUND DRIVEN STEERING OIL PRESSURE 299
BLEEDING AIR FROM STEERING CIRCUIT 301
STEERING STOP VALVE 302
TESTING WHEEL BRAKE PERFORMANCE 303
TESTING WHEEL BRAKE OIL PRESSURE DROP 304
MEASURING WEAR OF WHEEL BRAKE DISC 306
ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE 307
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT 309
TESTING PARKING BRAKE PERFORMANCE 310
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE 311
PARKING BRAKE PAD 312
PPC PRESSURE 314
ADJUSTING PPC VALVE LINKAGE 316
WORK EQUIPMENT HYDRAULIC PRESSURE 317
BLEEDING AIR FROM PISTON PUMP 319
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT 320
ADJUSTING WORK EQUIPMENT LEVER LINKAGE 321
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 323
BUCKET PROXIMITY SWITCH 324
BOOM PROXIMITY SWITCH 325
TESTING PROXIMITY ACTUATION PILOT LAMP 326
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR 327
ADJUSTING JOYSTICK LEVER POTENTIOMETER 328
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH 330
TROUBLESHOOTING 331
POINTS TO REMEMBER WHEN TROUBLESHOOTING 332
SEQUENCE OF EVENTS IN TROUBLESHOOTING 333
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 334
POINTS TO REMEMBER WHEN HANDLING ELECTRICAL EQUIPMENT 334
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 339
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 340
CHECKS BEFORE TROUBLESHOOTING 342
CONNECTOR TYPES AND MOUNTING LOCATIONS 343
CONNECTOR ARRANGEMENT DIAGRAM 347
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 352
EXPLANATION OF FUNCTION OF ELECTRICAL CONTROL MECHANISM 365
TRANSMISSION CONTROL SYSTEM 365
MAIN MONITOR SYSTEM 366
MAINTENANCE MONITOR SYSTEM 367
JOYSTICK STEERING 368
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 369
CHART OF ACTION CODES AND FAILURE CODES AND RE-ENACTION 371
TRANSMISSION CONTROLLER LED DISPLAY 373
METHOD OF USING JUDGEMENT TABLE 374
METHOD OF USING TROUBLESHOOTING CHARTS 375
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 377
METHOD OF USING TROUBLESHOOTING ENGINE RELATED CHARTS 379
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 383
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKE TIME) 384
S-2 ENGINE DOES NOT START 385
(1) ENGINE DOES NOT TURN 385
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 386
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START 387
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 388
S-4 ENGINE STOPS DURING OPERATION 389
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 390
S-6 ENGINE LACKS OUTPUT (NO POWER) 391
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 392
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 393
S-9 OIL BECOMES CONTAMINATED QUICKLY 394
S-10 FUEL CONSUMPTION IS EXCESSIVE 395
S-11 OIL IN COOLANT WATER, OR WATER SPURTS BACK OR WATER LEVEL GOES DOWN 396
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 397
S-13 OIL LEVEL RISES 398
S-14 COOLANT WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 399
S-15 ABNORMAL NOISE IS MADE 400
S-16 VIBRATION IS EXCESSIVE 401
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T-MODE) 403
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS 404
ACTION TAKEN BY CONTROLLERS WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 406
ELECTRICAL DIAGRAM FOR TANSMISSION CONTROLLER SYSTEM 411
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK UP LAMP RELAY) IS DISPLAYED 412
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED 413
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED 414
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED 415
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED 416
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED 417
T-7 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 418
T-8 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 420
T-9 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED 424
T-10 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED 427
T-11 FAIURE CODE [23] (SHORT CIRCUIT, DISCONNECTION, ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 428
T-12 SHIFT-UP SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) AND HOLD SIGNAL SYSTEM (AUTO-SHIFT (OP) 429
T-13 KICK-DOWN SIGNAL SYSTEM AND SHIFT DOWN SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) 429
T-14 TRANSMISSION CUT-OFF SIGNAL SYSTEM 430
T-15 NEUTRALIZER SIGNAL SYSTEM 431
T-16 BUZZER SIGNAL SYSTEM 432
T-17 NETWORK SYSTEM 433
T-18 TRANSMISSION CONTROLLER POWER SOURCE 434
T-19 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 435
T-20 ABNORMALITY IN MACHINE SELECTION WIRE HARNESS 436
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 437
TROUBLE DATA DISPLAY 439
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM 441
M-1 MAIN MONITOR DOES NOT WORK BACKUP LAMP RELAY) IS DISPLAYED 442
M-2 WHEN STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT UP 443
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 444
M-4 ABNORMALITY IN SHIFT INDICATOR 445
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP 448
M-6 TURN SIGNAL DISPLAY NOT LIGHT UP 449
M-7 ABNORMALITY IN PARKING DISPLAY 450
M-8 ABNORMALITY IN PREHEATING SYSTEM 451
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 455
M-10 ABNORMALITY IN FRONT WORKING LAMP 456
M-11 ABNORMALITY IN REAR WORKING LAMP 458
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 460
M-13 ABNORMALITY IN LOW IDLE SELECTION 462
M-14 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY 464
M-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 465
M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP) 467
M-17 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR NOT ACTUATED 469
M-18 ABNORMALITY IN BUZZER 470
M-19 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 471
M-20 ABNORMALITY IN FAILURE DISPLAY MODE 472
M-21 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER 473
M-22 ABNORMALITY IN AUTO-GREASING SYSTEM (OP) 474
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP) 476
TROUBLEHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 477
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR 479
K-1 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO 480
K-2 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) 481
K-3 WHEN ENGINE IS STARTED IMMEDIATLY AFTER STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE GO OUT 482
K-4 WHEN STARTER SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 483
K-5 WHEN STARTER SWITCH IS TURNED ON (ENGINE STARTED), CAUTION) ITEMS FLASH 485
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND 492
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS 493
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES 494
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHT UP 495
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHT SWITCH IS TURNED ON 496
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHT SWITCH IS TURNED OFF 497
K-12 SERVICE METER DOES NOT WORK 498
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 498
K-14 ABNORMALITY IN GAUGE DISPLAY 499
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 503
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING 505
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING 506
ENGINE PRE-LUBRICATION SYSTEM 507
ELECTRICAL DIA – BOOM KICK-OUT / BUCKET POSITIONER 511
E-1 ENGINE DOES NOT START 512
E-2 ENGINE DOES NOT STOP (STD SPEC ) 517
E-3 ABNORMALITY IN PREHEATING SYSTEM 519
E-4 PARKING BRAKE DOES NOT HAVE EFFECT 523
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 524
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH TURNED ON 526
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED 526
E-8 KICK-DOWN SWITCH DOES NOT WORK 528
E-9 BOOM KICK-OUT DOES NOT WORK 530
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION 534
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP 537
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP 537
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF 537
E-14 ABNORMALITY IN LOW IDLE SELECTION 537
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 537
E-16 ABNORMALITY IN BUZZER 537
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 539
H-1 MACHINE DOES NOT MOVE 540
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE) 541
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 542
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 543
H-5 STEERING DOES NOT TURN 544
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK (OP)] 545
H-7 TURNING, RESPONSE OF STEERING IS POOR 546
H-8 TURNING RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK(OP)] 547
H-9 STEERING IS HEAVY 548
H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK(OP)] 548
H-11 STEERING WHEEL SHAKES OR JERKS 549
H-12 STEERING WHEEL SHAKES OR JERKS SHOCK [MACHINE WITH JOYSTICK (OP)] 550
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING 550
H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 551
H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 552
H-16 BOOM DOES NOT RISE 553
H-17 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER 554
H-18 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT 555
H-19 BOOM CYLINDER CANNOT HOLD DOWN BUCKET 555
H-20 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT 555
H-21 BOOM FLUCTUATES WHILE WORKING 556
H-22 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE 556
H-23 BUCKET DOES NOT TILT BACK 557
H-24 BUCKET MOVES SLOWLY AND HAS INSUFFICIENT TILT BACK POWER 558
H-25 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK 559
H-26 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET 559
H-27 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT 559
H-28 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD 560
H-29 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT 560
H-30 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY 561
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J-MODE) 563
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM 564
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS 566
ELECTRIC DIAGRAM FOR JOYSTICK STEERING SYSTEM 570
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED 572
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED 573
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED 574
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED 575
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED 576
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING RIGHT SOLENOID CUT RELAY OUTPUT) IS DISPLAYED 577
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED 578
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED 579
J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE 580
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT 581
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 582
J-12 DISCONNECTION IN STEERING LEFT SOLENOID 583
30 DISASSEMBLY AND ASSEMBLY 585
METHOD OF USING MANUAL 589
PRECAUTIONS DURING OPERATION 590
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 590
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 591
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 592
OTHER PRECAUTIONS 592
SPECIAL TOOL LIST 593
SKETCHES OF SPECIAL TOOLS 601
ENGINE 609
ALTERNATOR 609
CYLINDER HEAD 609
DAMPER 609
ENGINE OIL COOLER 609
ENGINE FRONT SEAL 609
ENGINE REAR SEAL 609
FUEL INJECTION PUMP FOR LEFT BANK 609
FUEL INJECTION PUMP FOR RIGHT BANK 609
NOZZLE HOLDER 609
STARTING MOTOR 609
TURBOCHARGER 609
WATER PUMP 609
RADIATOR 610
REMOVAL 610
INSTALLATION 613
ENGINE 614
REMOVAL 614
INSTALLATION 620
TORQUE CONVERTER AND TRANSMISSION 621
REMOVAL 621
INSTALLATION 629
TORQUE CONVERTER 631
DISASSEMBLY 631
ASSEMBLY 635
TORQUE CONVERTER VALVE 640
DISASSEMBLY 640
ASSEMBLY 640
TRANSMISSION 641
DISASSEMBLY 641
ASSEMBLY 657
TRANSMISSION VALVE 673
REMOVAL 673
INSTALLATION 673
UPPER VALVE 674
DISASSEMBLY 674
ASSEMBLY 675
LOWER VALVE 676
DISASSEMBLY 676
ASSEMBLY 676
RELIEF VALVE 677
DISASSEMBLY 677
ASSEMBLY 677
TRANSFER 678
DISASSEMBLY 678
ASSEMBLY 686
PTO 696
DISASSEMBLY 696
ASSEMBLY 698
CENTER SUPPORT 701
REMOVAL 701
INSTALLATION 702
DISASSEMBLY 703
ASSEMBLY 705
DRIVE SHAFT 708
DISASSEMBLY 708
ASSEMBLY 710
FRONT AXLE 712
REMOVAL 712
INSTALLATION 714
REAR AXLE 715
REMOVAL 715
INSTALLATION 721
DIFFERENTIAL 723
REMOVAL 723
INSTALLATION 725
DISASSEMBLY 726
ASSEMBLY 730
FINAL DRIVE 736
DISASSEMBLY 736
ASSEMBLY 739
ORBIT-ROLL 742
REMOVAL 742
INSTALLATION 743
GROUND DRIVEN STEERING PUMP 744
REMOVAL 744
INSTALLATION 744
DIVERTER VALVE 745
REMOVAL 745
INSTALLATION 745
DISASSEMBLY 746
ASSEMBLY 747
ACCUMULATOR CHARGE VALVE 749
REMOVAL 749
INSTALLATION 749
DISASSEMBLY 750
ASSEMBLY 751
STEERING STOP VALVE 753
REMOVAL 753
INSTALLATION 753
STEERING CYLINDER 754
REMOVAL 754
INSTALLATION 755
STEERING VALVE 756
REMOVAL 756
INSTALLATION 757
BRAKE VALVE 758
REMOVAL 758
INSTALLATION 758
SLACK ADJUSTER 759
REMOVAL 759
INSTALLATION 759
DISASSEMBLY 760
ASSEMBLY 761
BRAKE 762
REMOVAL 762
INSTALLATION 763
DISASSEMBLY 764
ASSEMBLY 767
PARKING BRAKE CALIPERS 771
REMOVAL 771
INSTALLATION 772
DISASSEMBLY 773
ASSEMBLY 774
PARKING BRAKE PAD 776
REMOVAL 776
INSTALLATION 777
PARKING BRAKE SPRING CYLINDER 778
REMOVAL 778
INSTALLATION 778
BRAKE OIL TANK 779
REMOVAL 779
INSTALLATION 779
HYDRAULIC PUMP 780
REMOVAL 780
INSTALLATION 782
HYDRAULIC TANK AND FILTER CASE 783
REMOVAL 783
INSTALLATION 784
PPC VALVE 785
REMOVAL 785
INSTALLATION 786
DISASSEMBLY 787
ASSEMBLY 787
WORK EQUIPMENT CONTROL VALVE 788
REMOVAL 788
INSTALLATION 789
DISASSEMBLY 790
ASSEMBLY 792
CAB 794
REMOVAL 794
INSTALLATION 797
FLOOR FRAME 798
REMOVAL 798
INSTALLATION 801
CENTER HINGE PIN 802
REMOVAL 802
INSTALLATION 808
WORK EQUIPMENT 812
REMOVAL 812
INSTALLATION 817
BOOM FRONT END BUSHING 818
REPLACEMENT 818
BUCKET CYLINDER 819
REMOVAL 819
INSTALLATION 819
LIFT CYLINDER 821
REMOVAL 821
INSTALLATION 822
HYDRAULIC CYLINDER 823
DISASSEMBLY 823
ASSEMBLY 825
AIR CONDITIONER UNIT 827
REMOVAL 827
INSTALLATION 828
AIR CONDITIONER COMPRESSOR 829
REMOVAL 829
INSTALLATION 829
RECEIVER TANK 830
REMOVAL 830
INSTALLATION 830
AIR CONDITIONER CONDENSER 831
REMOVAL 831
INSTALLATION 832
TRANSMISSION AND STEERING CONTROLLER 833
REMOVAL 833
INSTALLATION 833
MAIN MONITOR 834
REMOVAL 834
INSTALLATION 835
FUEL TANK 836
REMOVAL 836
INSTALLATION 837
COUNTERWEIGHT – STANDARD 838
REMOVAL 838
INSTALLATION 839
COUNTERWEIGHT – HIGH-LIFT 840
REMOVAL 840
INSTALLATION 841
40 MAINTENANCE STANDARD 843
ENGINE MOUNT 844
TRANSMISSION MOUNT 845
DAMPER 846
HYDRAULIC PUMPS 848
TORQUE CONVERTER CHARGING, PPC AND BRAKE 848
TORQUE CONVERTER 850
REGULATOR VALVE 851
TRANSMISSION 852
CLUTCH 852
GEAR 854
TRANSMISSION CONTROL VALVE 856
UPPER VALVE 856
LOWER VALVE 858
DRIVE SHAFT 861
CENTER SUPPORT 862
DIFFERENTIAL 863
Assembly Torques 863
Gears 864
FINAL DRIVE 866
AXLE MOUNT 868
CENTER HINGE PIN 870
STEERING COLUMN 872
STEERING DEMAND VALVE 873
DIVERTER VALVE 875
STEERING CYLINDER MOUNT 876
GROUND DRIVEN STEERING PUMP 877
BRAKE VALVE 878
SLACK ADJUSTER 881
BRAKE 882
PARKING BRAKE 884
PPC VALVE 886
PPC RELIEF VALVE 888
CONTROL PUMP (BAR025) 889
MAIN CONTROL VALVE 891
HYDRAULIC CYLINDER 893
BUCKET LINKAGE 895
BUCKET POSITIONER AND BOOM KICK-OUT 897
90 OTHERS (SHOP MANUAL FOLDOUTS) 899
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 1 OF 6) 901
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 2 OF 6) 903
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 3 OF 6) 905
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 4 OF 6) 907
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 5 OF 6) 909
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 6 OF 6) 911
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 1 OF 4) 913
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 2 OF 4) 915
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 3 OF 4) 917
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 4 OF 4) 919
FOLDOUT 20-217 CONNECTOR ARRANGEMENT DIAGRAM (1 OF 3) 921
FOLDOUT 20-219 CONNECTOR ARRANGEMENT DIAGRAM (2 OF 3) 923
FOLDOUT 20-409 ELECTRICAL DIAGRAM FOR TRANSMISSION CONTROLLER 925
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 1 OF 4) 927
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 2 OF 4) 929
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 3 OF 4) 931
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 4 OF 4) 933
FOLDOUT 20-603 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM 935
FOLDOUT 20-703 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING, AND PREHEATING 937

DESCRIPTION:

Komatsu Avance WA900-3LC Wheel Loader Shop Manual CEBM003702 – PDF DOWNLOAD

• SERIAL NUMBERS  WA900-3LC 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.
NOTICE

G.B  16/12/24