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KOMATSU GALEO WA150-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 and up) – PDF DOWNLOAD
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- KOMATSU GALEO WA150-5 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:H50051 and up
- PUBLICATION NUMBER:VEBM934100
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Description
KOMATSU GALEO WA150-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 and up)
KOMATSU GALEO WA150-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 AND UP) – PDF DOWNLOAD:
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KOMATSU GALEO WA150-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 and up)
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the results of (C) that he has obtained from his own inspection.
TABLE OF CONTENTS:
KOMATSU GALEO WA150-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 and up)
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 7 GENERAL ASSEMBLY DRAWINGS................................................................................................................ 8 SPECIFICATIONS........................................................................................................................... 9 WEIGHT TABLE............................................................................................................................. 13 LIST OF LUBRICANT AND COOLANT............................................................................................................ 15 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.............................................................................................. 17 Engine mount and transfer mount.......................................................................................................... 18 Damper................................................................................................................................... 19 Cooling system........................................................................................................................... 20 Power train.............................................................................................................................. 21 Power train system diagram............................................................................................................... 22 Drive shaft.............................................................................................................................. 24 HST hydraulic piping diagram............................................................................................................. 25 HST pump................................................................................................................................. 26 High-pressure relief valve............................................................................................................... 28 Low-pressure relief valve................................................................................................................ 30 HST charge pump.......................................................................................................................... 31 Speed-related valve (DA valve)........................................................................................................... 32 High-pressure cut-off valve.............................................................................................................. 33 HST motor................................................................................................................................ 34 EP servo valve........................................................................................................................... 37 HA servo valve........................................................................................................................... 38 Forward-reverse shuttle valve............................................................................................................ 39 Transfer................................................................................................................................. 40 Clutch solenoid valve.................................................................................................................... 51 Axle..................................................................................................................................... 52 Differential............................................................................................................................. 54 Limited-slip differential................................................................................................................ 60 Final drive.............................................................................................................................. 64 Axle mounting and center hinge pin....................................................................................................... 66 Steering piping.......................................................................................................................... 71 Steering column.......................................................................................................................... 72 Priority valve........................................................................................................................... 73 Orbit-roll valve......................................................................................................................... 76 Steering cylinder........................................................................................................................ 84 Emergency steering piping................................................................................................................ 86 Emergency steering valve................................................................................................................. 87 Brake piping............................................................................................................................. 90 Brake valve.............................................................................................................................. 91 Inching valve............................................................................................................................ 95 Charge valve............................................................................................................................. 96 Accumulator (for brake)..................................................................................................................100 Slack adjuster...........................................................................................................................101 Brake....................................................................................................................................104 Parking brake control....................................................................................................................107 Parking brake............................................................................................................................108 Hydraulic piping.........................................................................................................................110 Work equipment lever linkage.............................................................................................................112 Hydraulic tank...........................................................................................................................113 3-gear pump unit.........................................................................................................................116 Accumulator (for ppc circuit)............................................................................................................118 Lock valve...............................................................................................................................119 E.C.S.S. valve...........................................................................................................................122 Accumulator (for E.C.S.S.)...............................................................................................................124 Hydraulic piping of coolingsystem.......................................................................................................125 Cooling fan motor........................................................................................................................126 Work equipment control valve.............................................................................................................128 Work equipment PPC valve.................................................................................................................141 Work equipment linkage...................................................................................................................148 Bucket...................................................................................................................................150 Bucket positioner and boom kick-out......................................................................................................151 Work equipment cylinder..................................................................................................................157 Air conditioner..........................................................................................................................158 Machine monitoring system................................................................................................................159 Machine monitor..........................................................................................................................169 List of items displayed onmonitor.......................................................................................................170 Electrical system (HSTcontroller system)................................................................................................196 HST controller...........................................................................................................................200 Engine start circuit.....................................................................................................................201 Engine stop circuit......................................................................................................................203 Preheating circuit.......................................................................................................................204 Parking brake circuit....................................................................................................................205 Electronically controlled suspension system..............................................................................................208 Sensors..................................................................................................................................209 20 TESTING AND ADJUSTING.....................................................................................................................215 STANDARD VALUE TABLE FOR ENGINE..........................................................................................................216 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................217 TESTING AND ADJUSTING....................................................................................................................223 Tools for testing, adjusting, and troubleshooting....................................................................................224 Measuring engine speed...............................................................................................................226 Special tools required...........................................................................................................226 MEASURING HIGH-IDLING AND LOW-IDLING SPEEDS......................................................................................226 MEASURING HST STALL SPEED........................................................................................................227 MEASURING HYDRAULIC SPEED........................................................................................................227 MEASURING FULL STALL SPEED.......................................................................................................227 Measuring exhaust gas color..........................................................................................................228 Special tools required...........................................................................................................228 Adjusting valve clearance............................................................................................................229 Special tools required...........................................................................................................229 Measuring compression pressure.......................................................................................................231 Special tools required...........................................................................................................231 Measuring blow-by pressure...........................................................................................................232 Special tools required...........................................................................................................232 Testing and adjusting fuel injection timing..........................................................................................233 Special tools required...........................................................................................................233 Measuring engine oil pressure........................................................................................................234 Special tools required...........................................................................................................234 Measuring, testing operating force of accelerator pedal..............................................................................235 Special tools required...........................................................................................................235 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL..........................................................................235 OPERATING ANGLE OF ACCELERATOR PEDAL.............................................................................................236 Adjusting engine stop solenoid.......................................................................................................237 Adjusting engine speed sensor........................................................................................................238 Testing and adjusting air conditioner compressor belt tension........................................................................238 Testing..........................................................................................................................238 Adjusting........................................................................................................................238 Measuring directional lever..........................................................................................................239 Special tools required...........................................................................................................239 Operating effort of directional lever............................................................................................239 Travel of directional lever......................................................................................................239 Testing and adjusting HST oil pressure...............................................................................................240 Special tools required...........................................................................................................240 Adjusting........................................................................................................................243 Measuring clutch control pressure....................................................................................................245 Special tools required...........................................................................................................245 Testing and adjusting steering wheel.................................................................................................246 Special tools required...........................................................................................................246 MEASURING PLAY OF STEERING WHEEL.................................................................................................246 Method of measurement............................................................................................................246 MEASURING OPERATING FORCE OF STEERING WHEEL......................................................................................247 Measurement method...............................................................................................................247 MEASURING OPERATING TIME FOR STEERING WHEEL......................................................................................247 Measurement method...............................................................................................................247 Testing and adjusting steering oil pressure..........................................................................................248 Special tools required...........................................................................................................248 Method of measuring main relief pressure.........................................................................................248 Method of adjusting main relief pressure.........................................................................................249 Bleeding air from steering circuit...................................................................................................250 Testing hydraulic fan................................................................................................................251 Special tools required...........................................................................................................251 Measuring fan speed..............................................................................................................251 Measuring oil pressure...........................................................................................................251 Measuring brake pedal................................................................................................................252 Operating effort of pedal........................................................................................................252 Testing and adjusting brake pedal linkage............................................................................................253 Testing..........................................................................................................................253 Adjusting........................................................................................................................253 Measuring brake performance..........................................................................................................254 Measurement method...............................................................................................................254 Testing and adjusting accumulator charge pressure....................................................................................255 Special tools required...........................................................................................................255 Measuring........................................................................................................................255 Adjusting........................................................................................................................255 Measuring brake oil pressure.........................................................................................................256 Special tools required...........................................................................................................256 Measuring........................................................................................................................256 Brake test tool..................................................................................................................257 Measuring wear of brake disc.........................................................................................................258 Special tool required............................................................................................................258 Bleeding air from brake circuit......................................................................................................259 Special tools required...........................................................................................................259 Measuring parking brake performance..................................................................................................260 Measurement method...............................................................................................................260 Testing and adjusting parking brake control cable....................................................................................261 Special tool required............................................................................................................261 Testing..........................................................................................................................261 Adjusting........................................................................................................................261 Measuring and adjusting work equipment control lever.................................................................................262 Special tools required...........................................................................................................262 Measurement......................................................................................................................262 Testing and adjusting work equipment hydraulic pressure..............................................................................263 Special tools required...........................................................................................................263 Measuring condition..............................................................................................................263 Measuring........................................................................................................................263 Adjusting........................................................................................................................263 Testing and adjusting work equipment PPC oil pressure................................................................................264 Special tools required...........................................................................................................264 Measuring condition..............................................................................................................264 Measuring........................................................................................................................264 Bleeding air.........................................................................................................................266 Special tools required...........................................................................................................266 Releasing remaining pressure in hydraulic circuit....................................................................................267 Testing and adjusting bucket positioner..............................................................................................268 Testing..........................................................................................................................268 Adjusting........................................................................................................................268 Testing and adjusting of boom kick-out...............................................................................................269 Testing..........................................................................................................................269 Adjusting........................................................................................................................269 Checking proximity switch actuation display lamp.....................................................................................270 Proximity switch actuation display lamp (red)....................................................................................270 Procedure for checking diode.........................................................................................................271 Method of connecting T-adapter for HST controller....................................................................................272 Special functions of machine monitor.................................................................................................273 Flow of modes and functions..........................................................................................................274 Operator mode....................................................................................................................277 Service mode 1...................................................................................................................277 Service mode 2...................................................................................................................277 Character display................................................................................................................277 Operating switches...............................................................................................................277 Operator mode operation and displays.............................................................................................277 Error code table.....................................................................................................................282 Procedure for switching to Service Mode 1 and screen display.....................................................................284 Real-time monitoring items.......................................................................................................289 Table of filter and oil replacement interval set items (when sipping)............................................................290 Service mode 2...................................................................................................................291 Pm clinic inspection chart...........................................................................................................292 WA150-5H H50051 and up...........................................................................................................292 TROUBLESHOOTING..........................................................................................................................295 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................296 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................297 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................298 CHECK BEFORE TROUBLESHOOTING.........................................................................................................306 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS....................................................................307 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No...........................................................................308 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................312 T-ADAPTER TABLE......................................................................................................................333 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................337 CONNECTOR LAYOUT DRAWING.............................................................................................................344 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)......................................................................................349 HST controller system diagram........................................................................................................350 Before troubleshooting code display..................................................................................................352 ERROR CODE AND POSSIBLE CAUSES TABLE.............................................................................................352 Before troubleshooting electrical system.............................................................................................353 FUSE BOX CONNECTION TABLE........................................................................................................353 Information contained in troubuleshooting table......................................................................................354 Related circuit diagram..........................................................................................................355 Phenomena code table.............................................................................................................355 Error Code [989F00] (HST motor protection caution (00))..........................................................................356 Error Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX))....................................................357 Related circuit diagram..........................................................................................................358 Error Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC)).............................................359 Related circuit diagram..........................................................................................................359 Error Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ)).............................................360 Related circuit diagram..........................................................................................................361 Error Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ)).............................................362 Related circuit diagram..........................................................................................................363 Error Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ))..............................................364 Related circuit diagram..........................................................................................................365 Troubleshooting Code [HST-1] (Defective HST controller power source (HST controller does not func................................366 Related circuit diagram..........................................................................................................367 Troubleshooting Code [HST-2] (Travel speed does not shifted).....................................................................368 Related circuit diagram..........................................................................................................370 Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be controlled..........................................371 Related circuit diagram..........................................................................................................372 HST-4 Travel speed limit cannot be changed when gear speed selector switch is in "1st" position..................................373 Related circuit diagram..........................................................................................................375 HST-5 Travel speed is not increased..............................................................................................376 Related circuit diagram..........................................................................................................378 HST-4 Travel speed limit cannot be changed when gear speed selector switch is in "1st" position......................................373 Related circuit diagram..............................................................................................................375 HST-5 Travel speed is not increased..................................................................................................376 Related circuit diagram..............................................................................................................378 Related electrical circuit diagram...................................................................................................380 Related circuit diagram..........................................................................................................380 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE)......................................................................................379 RELATED ELECTRICAL CIRCUIT DIAGRAM...................................................................................................380 ECSS-1 Malfunction of travel damper..................................................................................................381 Specification of load meter (STD)................................................................................................381 Malfunction of travel damper.....................................................................................................381 a) Travel damper does not operate................................................................................................381 b) Travel damper is not reset....................................................................................................384 TROUBLSHOOTING OF MONITOR SYSTEM (MON MODE)..............................................................................................387 Monitor system circuit diagram.......................................................................................................388 Before troubleshooting code display..................................................................................................392 ERROR CODE AND POSSIBLE CAUSES TABLE.............................................................................................392 Before troubleshooting electrical system.............................................................................................393 FUSE BOX CONNECTION TABLE........................................................................................................393 Information contained in troubuleshooting table......................................................................................394 Related circuit diagram..........................................................................................................395 Phenomena code table.............................................................................................................395 Error Code [15B0NX] (HST oil filter clogged (NX))....................................................................................396 Related circuit diagram..........................................................................................................396 Error Code [2G42ZG] (Decreased brake oil pressure (ZG))..............................................................................397 Related circuit diagram..........................................................................................................397 Error Code [989F00] (HST motor protection caution (00))..............................................................................398 Error Code [989FN1] (HST overrunning (N1))...........................................................................................399 Error Code [AB00L6] (Defective battery charging circuit (L6))........................................................................400 Related circuit diagram..........................................................................................................400 Error Code [AB00MA] (Defective battery charging circuit (MA))........................................................................401 Related circuit diagram..........................................................................................................401 Error Code [B@BAZG] (Degreased engine oil pressure (ZG)).............................................................................402 Related circuit diagram..........................................................................................................402 Error Code [B@BCNS] (Engine water temperature overheating (NS))......................................................................403 Related circuit diagram..........................................................................................................403 Error Code [B@BCZK] (Alarm indicating low coolant level (ZK))........................................................................404 Related circuit diagram..........................................................................................................404 Error Code [B@C7NS] (Axle oil temperature overheating (NS))..........................................................................405 Related circuit diagram..........................................................................................................405 Error Code [B@CRNS] (HST oil temperature overheating (NS))...........................................................................406 Related circuit diagram..........................................................................................................406 Error Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure (L6))...............................................................408 Related circuit diagram..........................................................................................................409 Error Code [DAF0KT] (Controller inside failure (KT)).................................................................................410 Error Code [DAJ0KR] (HST controller communication failure (KR))......................................................................412 Related circuit diagram..........................................................................................................413 Error Code [DD15LD] (Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)).....................................414 Related circuit diagram..........................................................................................................414 Error Code [DD16LD] (Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)).....................................415 Related circuit diagram..........................................................................................................415 Error Code [DD17LD] (Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)).....................................416 Related circuit diagram..........................................................................................................416 Error Code [DD18LD] (Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)).....................................417 Related circuit diagram..........................................................................................................417 Error Code [DDK3KB] (Multiple directional lever FR signal input (KB))................................................................418 Related circuit diagram..........................................................................................................419 Error Code [DDS5L6] (Decreased steering oil pressure (L6))...........................................................................420 Related circuit diagram..........................................................................................................420 Error Code [DGE2KX] (Engine coolant temperature (High temperature) sensor system failure (KX)).......................................421 Related circuit diagram..........................................................................................................421 Error Code [DGE3L6] (Engine coolant temperature (Low temperature) sensor system failure (L6))........................................423 Related circuit diagram..........................................................................................................423 Error Code [DGH1KX] (HST oil temperature sensor system failure (KX)).................................................................424 Related circuit diagram..........................................................................................................424 Error Code [DGR4KA] (Axle oil temperature sensor system discontinuity (KA))..........................................................425 Related circuit diagram..........................................................................................................425 Error Code [DGR4KX] (Axle oil temperature sensor system failure (KX))................................................................426 Related circuit diagram..........................................................................................................426 Error Code [DHE4L6] (Engine oil pressure sensor system discontinuity (L6))...........................................................427 Related circuit diagram..........................................................................................................427 Troubleshooting Code [MON-1] (The parking brake indicator lamp does not light ON)....................................................429 Related circuit diagram..........................................................................................................431 Related circuit diagram..........................................................................................................432 Troubleshooting Code [MON-2] (The brake oil pressure caution lamp does not light ON).................................................433 Related circuit diagram..........................................................................................................433 Troubleshooting Code [MON-3] (The engine water temperature caution lamp does not light ON, or after the engine starts, the eng.......434 Related circuit diagram..........................................................................................................434 Troubleshooting Code [MON-4] (The HST oil temperature caution lamp does not light ON, or after the engine starts, the HST oil .......435 Related circuit diagram..........................................................................................................435 Troubleshooting Code [MON-5] (The fuel level gauge does not rise or decrease. )......................................................436 Related circuit diagram..........................................................................................................436 Troubleshooting Code [MON-6] (The radiator coolant level caution lamp does not light ON).............................................437 Related circuit diagram..........................................................................................................437 Troubleshooting Code [MON-7] (The steering oil pressure caution lamp does not light ON)..............................................438 Related circuit diagram..........................................................................................................438 Troubleshooting Code [MON-8] (The emergency steering oil pressure indicator lamp does not light ON)..................................439 Related circuit diagram..........................................................................................................439 Troubleshooting Code [MON-9] (Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1))............................440 Related circuit diagram..........................................................................................................440 Troubleshooting Code [MON-10] (Input failure in monitor panel mode selector switch 1 [U] (Panel switch 2))...........................442 Related circuit diagram..........................................................................................................443 Troubleshooting Code [MON-11] (Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3))...........................444 Related circuit diagram..........................................................................................................445 Troubleshooting Code [MON-12] (Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4))...........................446 Related circuit diagram..........................................................................................................447 Troubleshooting Code [MON-13] (The alarm buzzer does not sound or stop)..............................................................448 Related circuit diagram..........................................................................................................449 Troubleshooting Code [MON-14] The wiper does not function............................................................................450 Troubleshooting Code [MON-15] The lamps do not work properly.........................................................................450 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................................................451 Electrical system diagram............................................................................................................452 Parking brake related diagram........................................................................................................456 Before troubleshooting electrical system.............................................................................................458 Fuse box connection table........................................................................................................458 Information contained in troubuleshooting table......................................................................................460 Related circuit diagram..........................................................................................................461 Troubleshooting Code [E-1] (The engine does not start)...............................................................................462 a) Defective starting motor system...............................................................................................462 Related circuit diagram..........................................................................................................465 Troubleshooting Code [E-2] (The engine does not stop)................................................................................468 Related circuit diagram..........................................................................................................469 Troubleshooting Code [E-3] (Preheating is impossible or constant)....................................................................470 a) Preheating is impossible......................................................................................................470 b) Preheating is constant........................................................................................................475 Related circuit diagram..........................................................................................................476 Cont'd Related circuit diagram...................................................................................................477 Troubleshooting Code [E-4] (The parking brake (Mechanical type) does not function)...................................................478 a) Parking brake dragging prevention does not function (mechanical type).........................................................478 b) Parking brake "non-applied" indicator does not light up (mechanical type).....................................................480 Troubleshooting Code [E-5] (Defective boom kick-out function and cancellation).......................................................482 Related circuit diagram..........................................................................................................484 Troubleshooting Code [E-6] (Defective bucket positioner function and cancellation)...................................................485 Related circuit diagram..........................................................................................................487 Troubleshooting Code [E-7] (Defective lift arm FLOATING holding function and cancellation)...........................................495 Related circuit diagram..........................................................................................................496 Troubleshooting Code [E-8] (Travel direction is not changed normally)................................................................488 a) When directional lever is set in "F", machine does not travel forward.........................................................488 Troubleshooting Code [E-9] (The wiper does not function).............................................................................497 a) The rear wiper does not function..............................................................................................497 Related circuit diagram..........................................................................................................499 b) The rear wiper does not function..............................................................................................500 Related circuit diagram..........................................................................................................501 Troubleshooting Code [E-10] (The window washer does not function)....................................................................502 Related circuit diagram..........................................................................................................504 Troubleshooting Code [E-11] (Lamps do not work properly).............................................................................505 a) Neither high beam nor low beam of headlamp light up...........................................................................505 Related circuit diagram..........................................................................................................507 b) Head lamp (Lo beam) does not light ON.........................................................................................508 Related circuit diagram..........................................................................................................508 c) Head lamp (Hi beam) does not light ON.........................................................................................509 Related circuit diagram..........................................................................................................509 d) Clearance lamp (Small lamp) does not light ON.................................................................................510 Related circuit diagram..........................................................................................................511 e) Turn signal lamp does not blink...............................................................................................512 Related circuit diagram..........................................................................................................513 f) Working lamp does not light ON................................................................................................514 Related circuit diagram..........................................................................................................515 Troubleshooting Code [E-12] (The horn does not sound)................................................................................516 Related circuit diagram..........................................................................................................517 Troubleshooting Code [E-13] (Defective of the air conditioner).......................................................................521 a) The air conditioner does not work.............................................................................................521 Related circuit diagram..........................................................................................................522 c) Does not cool or temperature cannot be adjusted...............................................................................523 Related circuit diagram..........................................................................................................525 d) Impossible to switch between recirculated air and fresh air...................................................................526 Related circuit diagram..........................................................................................................526 e) Impossible to switch vents....................................................................................................526 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).................................................................................531 Method of using troubleshooting chart................................................................................................532 Error code and cause table...........................................................................................................534 H-1 The machine does not start.......................................................................................................536 H-2 The travel speed is slow.........................................................................................................537 H-3 The thrusting force is weak......................................................................................................538 H-4 Engine stalls when traveling or engine speed drops excessively...................................................................539 H-5 The gear is not shifted..........................................................................................................540 H-6 The steering wheel does not turn.................................................................................................541 H-7 The steering wheel is heavy......................................................................................................542 H-8 Steering wheel shakes or jerks...................................................................................................543 H-9 Machine deviates naturally to one side when traveling............................................................................543 H-10 The brake does not work or does not work well...................................................................................544 H-11 The brake is not released or is dragged.........................................................................................545 H-12 The lift arm does not rise or lower.............................................................................................546 H-13 The lift arm moves slowly or the lift arm rising force is insufficient..........................................................547 H-14 When rising, the lift arm comes to move slowly at specific height...............................................................548 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).................................................548 H-16 Hydraulic drifts of the lift arm occur often....................................................................................548 H-17 The lift arm wobbles during operation...........................................................................................548 H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily.......................................549 H-19 The bucket does not tilt back...................................................................................................550 H-20 The bucket moves slowly or the tilting-back force is insufficient...............................................................551 H-21 The bucket comes to operate slowly in he midst of tilting-back..................................................................552 H-22 The bucket cylinder cannot hold down the bucket.................................................................................552 H-23 Hydraulic drifts of the bucket occur often......................................................................................552 H-24 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD").........................................553 H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily..........................................553 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....................................................553 H-27 The travel damper does not operate and machine pitches and bounces..............................................................554 TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................................555 Method of using troubleshooting charts...............................................................................................556 S-1 Starting performance is poor (Starting always takes time)........................................................................560 S-2 Engine does not start............................................................................................................562 (1) Engine does not turn.........................................................................................................562 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected).....................................................563 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)...................................................564 S-3 Engine does not pick up smoothly (Follow-up is poor).............................................................................565 S-4 Engine stops during operations...................................................................................................566 S-5 Engine does not rotate smoothly (Hunting)........................................................................................567 S-6 Engine lacks output (or lacks power).............................................................................................568 S-7 Exhaust smoke is black (Incomplete combustion)...................................................................................569 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........................................................................570 S-9 Oil becomes contaminated quickly.................................................................................................571 S-10 Fuel consumption is excessive...................................................................................................572 S-11 Oil is in cooling water, or water spurts back, or water level goes down.........................................................573 S-12 Oil pressure caution lamp lights up (Drop in oil pressure)......................................................................574 S-13 Oil level rises (Water, fuel in oil)............................................................................................575 S-14 Water temperature becomes too high (Overheating)................................................................................576 S-15 Abnormal noise is made..........................................................................................................577 S-16 Vibration is excessive..........................................................................................................578 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................579 HOW TO READ THIS MANUAL..................................................................................................................580 PRECAUTIONS WHEN PERFORMING OPERATION....................................................................................................582 SPECIAL TOOL LIST........................................................................................................................584 SKETCHES OF SPECIAL TOOLS................................................................................................................587 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.................................................................................594 REMOVAL AND INSTALLATION OF NOZZLE HOLDER................................................................................................598 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.......................................................................................600 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY..............................................................................................607 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY............................................................................................615 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER..............................................................................................617 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY................................................................................618 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...........................................................................619 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...........................................................................................621 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY............................................................................................623 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY............................................................................................625 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY.......................................................................................645 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY.......................................................................................646 REMOVAL AND INSTALLATION OF FRONT AXEL ASSEMBLY..........................................................................................652 REMOVAL AND INSTALLATION OF REAR AXEL ASSEMBLY...........................................................................................654 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY........................................................................................657 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY........................................................................................668 REMOVAL AND INSTALLATION OF HST PUMP AND 3-GEAR PUMP ASSEMBLY............................................................................691 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY.........................................................................................694 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY.........................................................................................696 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY........................................................................698 REMOVAL AND INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY.................................................................................701 REMOVAL AND INSTALLATION OF HYDRAULIC TANK...............................................................................................702 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY......................................................................................704 DISASSMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...................................................................................710 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY......................................................................................716 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)...........................................................................720 REMOVAL AND INSTALLATION OF CENTER HINGE PIN.............................................................................................729 REMOVAL AND INSTALLATION OF COUNTERWEIGHT................................................................................................737 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY................................................................................738 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................740 REMOVAL AND INSTALLATION OF MONITOR PANEL................................................................................................741 90 OTHERS....................................................................................................................................745 Hydraulic circuit diagram................................................................................................................747 Electrical circuit diagram 1/4 (1/4).....................................................................................................749 Electrical circuit diagram 1/4 (2/4).....................................................................................................751 Electrical circuit diagram 1/4 (3/4).....................................................................................................753 Electrical circuit diagram 1/4 (4/4).....................................................................................................755 Electrical circuit diagram 2/4...........................................................................................................757 Electrical circuit diagram 3/4...........................................................................................................759 Electrical circuit diagram 4/4...........................................................................................................761 Electrical circuit diagram 1/4 (1/4).....................................................................................................763 Electrical circuit diagram 1/4 (2/4).....................................................................................................765 Electrical circuit diagram 1/4 (3/4).....................................................................................................767 Electrical circuit diagram 1/4 (4/4).....................................................................................................769 Electrical circuit diagram 2/4...........................................................................................................771 Electrical circuit diagram 3/4...........................................................................................................773 Electrical circuit diagram 4/4...........................................................................................................775
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
