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Komatsu Model WA500-3 Service Repair Manual – PDF Download
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- Komatsu Model WA500-3 Service Repair Manual
- SERIAL NUMBER:50001 and up
- PUBLICATION NUMBER:SEBM009014
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Description
Komatsu Model WA500-3 Service Repair Manual
Screenshot of the Manual:
KOMATSU MODEL WA500-3 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
Komatsu Model WA500-3 Service Repair Manual
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 man uai is divided into the following chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams. and maintenance standards.
TESTING AND ADJUSTING
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing. installing. disassembling and assembling each component, as well as precautions forthem.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described In STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition. this section may give the specifications of attachments and options together.
Table of Contents:
Komatsu Model WA500-3 Service Repair Manual
COVER................................................................................................................................................................. 1 CONTENTS.............................................................................................................................................................. 2 01 GENERAL............................................................................................................................................................ 28 GENERAL ASSEMBLY DRAWING.......................................................................................................................................... 29 SPECIFICATIONS.................................................................................................................................................... 32 WEIGHT TABLE...................................................................................................................................................... 35 LIST OF LUBRICANT AND WATER....................................................................................................................................... 36 10 STRUCTURE AND FUNCTION............................................................................................................................................. 39 GENERAL........................................................................................................................................................... 40 RADIATOR AND OIL COOLER........................................................................................................................................... 42 DAMPER............................................................................................................................................................ 45 TORQUE CONVERTER AND TRANSMISSION PIPING.......................................................................................................................... 47 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................................................................. 50 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN......................................................................................................................... 51 TORQUE CONVERTER AND PTO.......................................................................................................................................... 52 TRANSMISSION...................................................................................................................................................... 54 TRANSMISSION CONTROL VALVE........................................................................................................................................ 66 ECMV (ELECTRONIC CONTROL MODULATION VALVE)........................................................................................................................ 68 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE........................................................................................................................ 74 LUBRICATING RELIEF VALVE.......................................................................................................................................... 76 TORQUE CONVERTER OIL FILTER....................................................................................................................................... 77 PILOT FILTER...................................................................................................................................................... 78 TRANSFER.......................................................................................................................................................... 79 DRIVE SHAFT....................................................................................................................................................... 80 CENTER SUPPORT.................................................................................................................................................... 81 AXLE.............................................................................................................................................................. 82 DIFFERENTIAL...................................................................................................................................................... 84 LIMITED SLIP DIFFERENTIAL (OP).................................................................................................................................... 87 FINAL DRIVE....................................................................................................................................................... 92 AXLE MOUNT........................................................................................................................................................ 94 CENTER HINGE PIN.................................................................................................................................................. 96 STEERING PIPING................................................................................................................................................... 97 STEERING COLUMN................................................................................................................................................... 98 STEERING VALVE.................................................................................................................................................... 99 ORBIT-ROLL VALVE.................................................................................................................................................. 113 STOP VALVE........................................................................................................................................................ 117 DIVERTER VALVE.................................................................................................................................................... 118 BRAKE PIPING ..................................................................................................................................................... 121 BRAKE CIRCUIT DIAGRAM............................................................................................................................................. 124 BRAKE VALVE....................................................................................................................................................... 126 CHARGE VALVE...................................................................................................................................................... 131 ACCUMULATOR (FOR BRAKE)........................................................................................................................................... 135 SLACK ADJUSTER ................................................................................................................................................... 136 BRAKE............................................................................................................................................................. 139 PARKING BRAKE CONTROL............................................................................................................................................. 141 PARKING BRAKE..................................................................................................................................................... 142 PARKING BRAKE SOLENOID VALVE...................................................................................................................................... 143 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.................................................................................................................... 144 HYDRAULIC PIPING.................................................................................................................................................. 145 HYDRAULIC CIRCUIT SYSTEM.......................................................................................................................................... 146 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................................... 148 WORK EQUIPMENT LEVER LINKAGE ..................................................................................................................................... 150 HYDRAULIC TANK.................................................................................................................................................... 151 ACCUMULATOR (FOR PPC VALVE)....................................................................................................................................... 154 PPC VALVE......................................................................................................................................................... 155 PPC RELIEF VALVE.................................................................................................................................................. 162 CUT-OFF VALVE..................................................................................................................................................... 163 E.C.S.S. CONTROL VALVE............................................................................................................................................ 166 MAIN CONTROL VALVE................................................................................................................................................ 168 WORK EQUIPMENT LINKAGE............................................................................................................................................ 182 BUCKET............................................................................................................................................................ 184 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................................................................... 185 OPERATION OF PROXIMITY SWITCH..................................................................................................................................... 188 CAB............................................................................................................................................................... 192 POPS CANOPY....................................................................................................................................................... 194 AIR CONDITIONER................................................................................................................................................... 196 ELECTRIC CIRCUIT DIAGRAM ......................................................................................................................................... 200 MACHINE MONITOR SYSTEM ........................................................................................................................................... 208 MAIN MONITOR...................................................................................................................................................... 210 MAINTENANCE MONITOR............................................................................................................................................... 215 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM........................................................................................................ 218 JOYSTICK TRANSMISSION SYSTEM...................................................................................................................................... 228 E.C.S.S. (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)............................................................................................................ 229 TRANSMISSION AND E.C.S.S. CONTROLLER.............................................................................................................................. 237 WORK EQUIPMENT CONTROL SYSTEM .................................................................................................................................... 239 REMOTE POSITION, JOYSTICK STEERING CONTROLLER .................................................................................................................... 244 SENSORS........................................................................................................................................................... 245 ENGINE STARTING CIRCUIT........................................................................................................................................... 250 ENGINE STOP CIRCUIT .............................................................................................................................................. 252 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM).................................................................................................................. 254 ELECTRIC TRANSMISSION CONTROL..................................................................................................................................... 256 KICK-DOWN, HOLD SWITCH............................................................................................................................................ 259 KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM ............................................................................................................................. 260 ELECTRIC PARKING BRAKE CONTROL.................................................................................................................................... 263 20 TESTING AND ADJUSTING.............................................................................................................................................. 275 STANDARD VALUE TABLE FOR ENGINE................................................................................................................................... 276 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................................................. 278 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS................................................................................................................. 288 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................ 313 SKETCHES OF SPECIAL TOOLS......................................................................................................................................... 314 MEASURING ENGINE SPEED (SERIAL NO.: 50001-52000).................................................................................................................. 315 MEASURING EXHAUST GAS COLOR....................................................................................................................................... 317 ADJUSTING VALVE CLEARANCE (SERIAL NO.: 50001-52000)............................................................................................................... 318 MEASURING COMPRESSION PRESSURE ( SERIAL NO.: 50001-52000)......................................................................................................... 320 MEASURING BLOW-BY PRESSURE........................................................................................................................................ 323 MEASURING ENGINE OIL PRESSURE (SERIAL NO.: 50001-52000)........................................................................................................... 324 HANDLING EQUIPMENT IN FUEL SYSTEM (SERIAL NO.: 52001 AND UP)...................................................................................................... 326 RELEASING REMAINING PRESSURE IN FUEL SYSTEM (SERIAL NO.: 52001 AND UP)............................................................................................ 326 CHECK FOR LEAKAGE IN FUEL SYSTEM (SERIAL NO.: 52001 AND UP)....................................................................................................... 327 BLEEDING AIR FROM FUEL SYSTEM (SERIAL NO.: 52001 AND UP).......................................................................................................... 328 MEASURING FUEL PRESSURE (SERIAL NO.: 52001 AND UP)................................................................................................................ 330 TESTING AND ADJUSTING FUEL INJECTION TIMING (SERIAL NO.: 50001-52000)............................................................................................. 331 REDUCED CYLINDER MODE OPERATION (SERIAL NO.: 52001 AND UP)........................................................................................................ 332 METHOD OF REDUCED CYLINDER MODE OPERATION (SERIAL NO.: 52001 AND UP).............................................................................................. 333 TESTING AND ADJUSTING ALTERNATOR BELT TENSION (SERIAL NO.: 50001-52000)........................................................................................... 335 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................................ 336 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR (SERIAL NO.: 50001-52000)....................................................................... 337 MEASURING EXHAUST TEMPERATURE (SERIAL NO.: 50001-52000)........................................................................................................... 339 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) (SERIAL NO.: 50001-52000).......................................................................................... 341 ADJUSTING SPEED SENSOR............................................................................................................................................ 343 ADJUSTING FUEL CONTROL CABLE (SERIAL NO.: 50001-52000)............................................................................................................ 345 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.: 50001-52000)............................................................................................ 346 TESTING AND ADJUSTING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE................................................................................................. 348 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT........................................................................................... 353 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS........................................................................................................ 354 TESTING AND ADJUSTING STEERING OIL PRESSURE ...................................................................................................................... 356 TESTING AND ADJUSTING STEERING STOP VALVE......................................................................................................................... 352 TESTING BRAKE OIL PRESSURE ....................................................................................................................................... 357 MEASURING BRAKE DISC WEAR......................................................................................................................................... 358 MEASURING BRAKE PERFORMANCE....................................................................................................................................... 359 MEASURING PARKING BRAKE OIL PRESSURE.............................................................................................................................. 360 TESTING WEAR OF PARKING BRAKE DISC................................................................................................................................ 362 MANUAL RELEASE METHOD FOR PARKING BRAKE........................................................................................................................... 363 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................................................................................................................. 364 TESTING AND ADJUSTING PPC OIL PRESSURE............................................................................................................................ 366 ADJUSTING PPC VALVE LINKAGE....................................................................................................................................... 370 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....................................................................................................................... 371 ADJUSTING WORK EQUIPMENT LEVER LINKAGE............................................................................................................................ 373 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT................................................................................................................... 374 INITIAL TEACHING METHOD FOR TRANSMISSION CONTROLLER............................................................................................................... 375 TESTING AND ADJUSTING OF BUCKET POSITIONER........................................................................................................................ 377 TESTING AND ADJUSTING OF BOOM KICK-OUT ........................................................................................................................... 379 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)....................................................................................................................... 381 BLEEDING AIR...................................................................................................................................................... 383 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................................................................................. 384 TROUBLESHOOTING................................................................................................................................................... 385 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................................................... 386 SEQUENCE OF EVENTS IN TROUBLESHOOTING ........................................................................................................................ 387 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.............................................................................................................. 388 CHECK BEFORE TROUBLESHOOTING.................................................................................................................................. 396 CONNECTOR TYPES AND MOUNTING LOCATIONS ....................................................................................................................... 397 CONNECTOR ARRANGEMENT DIAGRAM................................................................................................................................. 405 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................................................... 406 EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM........................................................................................................ 426 METNOD OF DISPLAYED ACTION CODE AND FAILURE CODE.............................................................................................................. 446 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION...................................................................................................... 448 TRANSMISSION CONTROLLER LED DISPLAY........................................................................................................................... 458 METHOD OF USING JUDGEMENT TABLE............................................................................................................................... 459 METHOD OF USING TROUBLESHOOTING CHARTS ....................................................................................................................... 460 METHOD OF USING MATRIX TROUBLESHOOTING TABLES................................................................................................................. 462 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................................................................................... 464 SERIAL NO.: 50001-52000................................................................................................................................... 464 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................ 465 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................................... 469 S-2 ENGINE DOSE NOT START ............................................................................................................................ 471 (1) ENGINE DOSE NOT TURN.......................................................................................................................... 471 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...................................................................... 472 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOSE NOT START (FUEL IS BEING INJECTED).................................................................... 473 S-3 ENGINE DOSE NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................................................................. 474 S-4 ENGINE STOPS DURING OPERATIONS.................................................................................................................... 475 S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)......................................................................................................... 476 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).............................................................................................................. 477 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION..................................................................................................... 478 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................................... 479 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................................. 480 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................................... 481 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOSE DOWN.......................................................................... 482 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................... 483 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL).............................................................................................................. 484 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................................. 485 S-15 ABNORMAL NOISE IS MADE........................................................................................................................... 486 S-16 VIBRATION IS EXCESSIVE........................................................................................................................... 487 SERIAL NO.: 52001 AND UP ................................................................................................................................. 488 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................ 489 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................................... 492 S-2 ENGING DOSE NOT START............................................................................................................................. 493 a) ENGING DOSE NOT TURN........................................................................................................................... 493 b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT.................................................................................................... 494 c) EXHAUST SMOKE COMES OUT BUT ENGINE DOSE NOT START (FUEL IS BEING INJECTED)..................................................................... 495 S-3 ENGINE DOSE NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................................................................. 496 S-4 ENGINE STOPS DURING OPERATIONS.................................................................................................................... 497 S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)......................................................................................................... 498 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).............................................................................................................. 499 S-7 EXHAUST SMOKE IS LACK (INCOMPLETE COMBUSTION)..................................................................................................... 500 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................................... 501 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................................. 502 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................................... 503 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOSE DOWN)......................................................................... 504 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................... 505 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL).............................................................................................................. 506 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................................. 507 S-15 ABNORMAL NOISE IS MADE........................................................................................................................... 508 S-16 VIBRATION IS EXCESSIVE........................................................................................................................... 509 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE).................................................................................................... 510 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS.......................................................................................... 511 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................ 513 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM............................................................................................. 521 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED................................... 525 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED.......................................... 526 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WIYH POWER SOURCE IN R SOLENOID) IS DISPLAYED.......................................... 527 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED........................................ 528 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLEDOID) IS DISPLAYED........................................ 529 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED........................................ 530 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED........................................ 531 T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED................................................... 532 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED............................................................ 533 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED................................................................. 536 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED......................................................................... 539 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.......................................................... 540 T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED............................................................................. 542 T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED................................................................ 543 T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL SWITCH SYSTEM) IS DISPLAYED.......................................................................... 544 T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED.......................................................................... 544 T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED........................................................................ 545 T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED........................................................................ 545 T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED........................................................................ 546 T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED........................................................................ 546 T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED..................................................................... 547 T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED...................................................... 548 T-23 HOLD SWITCH SYSTEM................................................................................................................................... 550 T-24 KICK-DOWN SWITCH SYSTEM.............................................................................................................................. 550 T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM................................................................................................................... 551 T-26 NEUTRALIZER RELAY SIGNAL SYSTEM...................................................................................................................... 552 T-27 BUZZER SIGNAL SYSTEM................................................................................................................................. 554 T-28 NETWORK SYSTEM....................................................................................................................................... 555 T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM ......................................................................................................... 556 T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM.......................................................................................................... 557 T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM.......................................................................................... 558 T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM........................................................................................................... 559 T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM........................................................................................................... 559 T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM......................................................................................................... 560 T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM......................................................................................................... 560 T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM......................................................................................................... 561 T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM......................................................................................................... 561 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)............................................................................................................... 562 TROUBLE DATA DISPLAY...................................................................................................................................... 565 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..................................................................................................... 571 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM....................................................................................................... 575 ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM.............................................................................................. 576 M-1 MAIN MONITOR DOSE NOT WORK............................................................................................................................ 577 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP........................................................ 578 M-3 SPEEDOMETER DISPLAY DOSE NOT WORK PROPERLY............................................................................................................ 580 M-4 ABNORMALITY IN SHIFT INDICATOR........................................................................................................................ 581 a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F..................................................................................................... 581 b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R..................................................................................................... 581 c) DOSE NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F.............................................. 581 d) DOSE NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R.............................................. 582 e) DOSE NOT DISPLAY 1ST-4TH........................................................................................................................... 582 M-5 HIGH BEAM DOES NOT LIGHT UP........................................................................................................................... 583 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................. 584 a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP......................................................................................................... 584 b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP ........................................................................................................ 584 M-7 ABNORMALITY IN PARKING DISPLAY........................................................................................................................ 585 a) PARKING LAMP DISPLAY DOES NOT LIGHT UP............................................................................................................. 585 b) PARKING LAMP DISPLAY STAYS LIGHTED UP.............................................................................................................. 585 M-8 ABNORMALITY IN PREHEATING SYSTEM...................................................................................................................... 586 (1) ABNORMALITY IN PREHEATING SYSTEM (QHS)............................................................................................................ 586 a) DOSE NOT CARRY OUT PREHEATING.................................................................................................................. 586 b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS................................................................................................... 587 c) PREHEATING STAYS ON............................................................................................................................ 587 d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION......................................................................................... 588 (2) ABNORMALITY IN PREHEATING SYSTEM.................................................................................................................. 589 a) DOSE NOT CARRY OUT PREHEATING.................................................................................................................. 589 b) PREHEATING STAYS ON............................................................................................................................ 589 M-9 NIGHT LIGHTING DOES NOT LIGHT UP...................................................................................................................... 591 M-10 ABNORMALITY IN FRONT WORKING LAMP.................................................................................................................... 592 a) NEITHER MONITOR DISPLAY NOT FRONT WORKING LAMP LIGHT UP............................................................................................ 592 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP ...................................................................................... 592 c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP....................................................................................... 592 M-11 ABNORMALITY IN REAR WORKING LAMP..................................................................................................................... 594 a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP............................................................................................. 594 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP....................................................................................... 594 c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP....................................................................................... 594 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.................................................................................................................. 596 a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE......................... 596 b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOSE OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED........ 596 c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED................................... 596 d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF).......................................... 596 e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED............................................ 597 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING........................................................................................................ 598 a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS(INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N.......................... 598 b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOSE NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N.... 598 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED............................ 601 a) ACTUATED CONTINUOUSLY.............................................................................................................................. 601 b) NOT ACTUATED....................................................................................................................................... 601 M-15 ABNORMALITY IN BUZZER................................................................................................................................ 602 a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)............................................................ 602 b) BUZZER ALWAYS SOUNDS............................................................................................................................... 602 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY................................................................................................ 603 M-17 ABNORMALITY IN FAILURE DISPLAY MODE.................................................................................................................. 605 a) DOES NOT ENTER FAILURE DISPLAY MODE................................................................................................................ 605 b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOSE NOT ADVANCE...................................................................... 605 M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER............................................................................................... 607 M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY..................................................................................................... 608 a) EMERGENCY STEERING NORMAL DISPLAY DOSE NOT LIGHT UP................................................................................................ 608 b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP ................................................................................................ 608 M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY.................................................................................................. 609 a) EMERGENCY STEERING ACTUATION DISPLAY DOSE NOT LIGHT UP............................................................................................. 609 b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP.............................................................................................. 609 M-21 ABNORMALITY IN AUTO-GREASING SYSTEM.................................................................................................................. 610 a) FORCED GREASING CANNOT BE CARRIED OUT ............................................................................................................. 610 b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...................................................................................................... 610 c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)......................................................................... 610 d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)........................................................................................................ 611 e) MONITOR DISPLAY GOSE OUT........................................................................................................................... 611 M-22 ABNORMALITY IN ECSS SYSTEM........................................................................................................................... 612 a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED..................................................................................................... 612 b) MONITOR DISPLAY LIGHTS BUT ECSS FUNCTION DOSE NOT WORK............................................................................................. 612 c) DISPLAY DOES NOT LIGHT UP.......................................................................................................................... 612 M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK).................................................................................... 613 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)........................................................................................................ 614 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..................................................................................................... 615 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK.................. 619 a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP........................................................................................................... 619 b) SOME LAMPS DO NOT LIGHT UP......................................................................................................................... 620 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)................................. 621 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT...................... 623 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH................................................................................. 624 a) ENGINE OIL LEVEL DISPLAY FLASHES................................................................................................................... 624 b) ENGINE WATER LEVEL DISPLAY FLASHES................................................................................................................. 626 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH............................................................................... 628 a) ENGINE OIL PRESSURE DISPLAY FLASHES................................................................................................................ 628 b) BATTERY CHARGE LEVEL DISPLAY FLASHES............................................................................................................... 630 c) BRAKE OIL PRESSURE DISPLAY FLASHES................................................................................................................. 632 d) AIR CLEANER DISPLAY FLASHES........................................................................................................................ 633 K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND.......................................................................................... 635 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS.................................................................................. 636 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH................................................................. 637 a) CHECK LAMP......................................................................................................................................... 637 b) CAUTION LAMP....................................................................................................................................... 637 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY DUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP ......................................... 638 a) CHECK LAMP......................................................................................................................................... 638 b) CAUTION LAMP....................................................................................................................................... 638 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP).............................. 639 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP............................................................... 640 K-12 SERVICE METER DOES NOT WORK.......................................................................................................................... 641 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED................................................................................................. 643 K-14 ABNORMALITY IN GAUGE ITEMS .......................................................................................................................... 645 a) ABNORMALITY IN FUEL GAUGE.......................................................................................................................... 645 b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...................................................................................................... 647 c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.............................................................................................. 649 K-15 MAINTENANCE MONITOR CHECK............................................................................................................................ 651 a) CHECK SWITCH SYSTEM................................................................................................................................ 651 b) CHECK LED SYSTEM................................................................................................................................... 651 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................................................................. 653 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING・STOP AND PREHEATING SYSTEM................................................................... 654 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM....................................................................................................... 656 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM....................................................................................................... 658 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM................................................................................. 659 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM............................................................................................. 660 E-1 ENGINE DOES NOT START................................................................................................................................. 664 a) STARTING MOTOR DOES NOT TURN....................................................................................................................... 664 b) STARTING MOTOR TURNS............................................................................................................................... 674 E-2 ENGINE DOES NOT STOP.................................................................................................................................. 676 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING................................................................................................................ 676 E-4 ABNORMALITY IN PREHEATING SYSTEM (QHS)................................................................................................................ 678 a) DOES NOT CARRY OUT PREHEATING...................................................................................................................... 678 b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS....................................................................................................... 679 c) PREHEATING STAYS ON................................................................................................................................ 679 d) PREHEATING TIME BECOMES SHORTER, OR THERE IE VARIATION............................................................................................. 680 E-5 PARKING BRAKE DOES NOT HAVE EFFECT ................................................................................................................... 681 a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (ACTUATED)...................................................................... 681 b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE)........................................................... 681 E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.................................................................................................... 682 E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON........................................................................................... 686 E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY).............................................. 686 E-9 KICK-DOWN SWITCH DOES NOT WORK........................................................................................................................ 689 a) KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)......................................................... 689 b) KICK-DOWN IS NOT CANCELED.......................................................................................................................... 690 E-10 BOOM KICK-OUT CANNOT BE USED......................................................................................................................... 691 E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION............................................................................................................ 694 E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP .................................................................................................... 697 E-13 ABNORMALITY IN LIGHTING UP OF REAER WORKING LAMP..................................................................................................... 697 E-14 ABNORMALITY IN TRANSMISSION CUT-OFF.................................................................................................................. 697 E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING........................................................................................................ 697 E-16 ABNORMALITY IN BUZZER................................................................................................................................ 697 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)................................................................................................... 698 H-1 MACHINE DOES NOT START................................................................................................................................ 699 H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES, DOES NOT SHIFT GEAR............................................................. 702 H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR................................................................................................ 705 H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR............................................................................................. 707 H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.............................................................................................................. 709 H-6 STEERING WHEEL DOSE NOT TURN.......................................................................................................................... 710 H-7 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]........................................................................................................ 711 H-8 TURNING, RESPONSE OF STEERING IS POOR................................................................................................................. 712 H-9 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]......................................................................................... 713 H-10 STEERING IS HEAVY.................................................................................................................................... 715 H-11 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]............................................................................................................ 715 H-12 STEERING WHEEL SHAKES OR JERKS....................................................................................................................... 716 H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK].................................................................................. 717 H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING............................................................................... 717 H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR................................................................................................... 718 H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG......................................................................................................... 720 H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR................................................................................................ 721 H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASED SYSTEM)................................................................... 722 H-19 NEITHER BOOM NOR BUCKET MOVE......................................................................................................................... 723 H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER.......................................................................................................... 724 H-21 BOOM DOES NOT MOVE................................................................................................................................... 725 H-22 BOOM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]............................................................................................... 726 H-23 BOOM IS SLOW OR BOOM LACKS POWER..................................................................................................................... 727 H-24 BOOM IS SLOW OR BOOM LACKS POWER [MACHINES WITH REMOTE BOOM CONTROL]................................................................................. 728 H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT......................................................................................... 729 H-26 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE............................................................................. 729 H-27 REMOTE BOOM CONTROL DOES NOT WORK [MACHINES WITH REMOTE BOOM CONTROL]................................................................................ 730 H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM.................................................................................................................... 731 H-29 BUCKET DOES NOT MOVE................................................................................................................................. 732 H-30 BUCKET IS SLOW OR LACKS POWER........................................................................................................................ 733 H-31 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.................................................................................................................. 734 H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS].......................................................................... 735 TROUBLESHOOTING OF ECSS (ELECTRICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).................................................................................. 737 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.......................................................................................................... 738 ELECTRICAL CIRCUIT DIAGRAM FOR ECSS....................................................................................................................... 742 D-1 ECSS DOES NOT WORK.................................................................................................................................... 744 a) ERROR CODE [D0] IS DISPLAYED....................................................................................................................... 746 b) ERROR CODE [D1] IS DISPLAYED (SERIAL NO.: 50001-52000)............................................................................................. 746 c) ERROR CODE [D2] IS DISPLAYED (SERIAL NO.: 50001-52000)............................................................................................. 747 d) ERROR CODE [D3] IS DISPLAYED (SERIAL NO.: 50001-52000)............................................................................................. 747 e) NO ABNORMALITY DISPLAYED IS GIVEN.................................................................................................................. 749 D-2 ECSS CANNOT BE CANCELED............................................................................................................................... 752 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)............................................................................................... 753 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS.............................................................................................. 754 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................ 755 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM............................................................................................................ 759 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED................................................................. 761 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED...................................................... 763 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED....................................................... 764 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED................................................................... 765 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED.................................................................... 766 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED................................................... 767 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED..................................................... 768 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DISPLAYED......................................... 769 J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE.................................................................................................................. 770 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM................................................................................................ 771 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID............................................................................................................. 772 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.............................................................................................................. 773 TROUBLESHOOTING OF REMOTE BOOM POSITIONER CONTROLLER SYSTEM (W MODE).......................................................................................... 774 JUDGMENT TABLE FOR REMOTE BOOM POSITIONER CONTROLLER SYSTEM RELATED PARTS................................................................................. 775 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................ 776 ELECTRICAL CIRCUIT DIAGRAM FOR REMOTE BOOM POSITIONER SYSTEM.............................................................................................. 778 W-1 FAILURE CODE [43] (SHORT CIRCUIT, DISCONNECTION IN DAMPING SOLENOID SYSTEM) IS DISPLAYED.............................................................. 780 W-2 FAILURE CODE [44] (SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID) IS DISPLAYED......................................................... 781 W-3 FAILURE CODE [45] (SHORT CIRCUIT IN POWER SOURCE AY RETURN END OF DAMPING SOLENOID) IS DISPLAYED...................................................... 781 W-4 FAILURE CODE [49] (SHORT CIRCUIT, DISCONNECTION IN BOOM LEVER KICK-OUT RELAY SYSTEM) IS DISPLAYED..................................................... 782 W-5 FAILURE CODE [51] (DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH) IS DISPLAYED......................................................... 783 W-6 FAILURE CODE [52] (SHORT CIRCUIT, DISCONNECTION IN BOOM ANGLE POTENTIOMETER SYSTEM) IS DISPLAYED...................................................... 784 W-7 SENSOR CANNOT BE ADJUSTED............................................................................................................................. 785 W-8 ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM............................................................................................................. 785 W-9 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP................................................................................................... 787 a) REMOTE POSITIONER SWITCH SYSTEM.................................................................................................................... 787 b) REMOTE POSITION LED SYSTEM......................................................................................................................... 787 W-10 REMOTE POSITIONER RAISE SET LED DOES NOT FLASH....................................................................................................... 788 a) REMOTE POSITIONER RAISE SET SWITCH SYSTEM.......................................................................................................... 788 b) REMOTE POSITIONER RAISE SET LED SYSTEM............................................................................................................. 788 W-11 REMOTE POSITIONER LOWER SET LED DOES NOT FLASH....................................................................................................... 789 a) REMOTE POSITIONER LOWER SET SWITCH SYSTEM.......................................................................................................... 789 b) REMOTE POSITIONER LOWER SET LED SYSTEM............................................................................................................. 789 W-12 BUZZER FOR SWITCH OPERATION DOES NOT SOUND........................................................................................................... 790 W-13 SHOCK WHEN STOPPING BOOM (ABNORMALITY IN BOOM LEVER DETENT SWITCH)................................................................................... 791 W-14 SHORT CIRCUIT IN BOOM RAISE, LOWER PRESSURE DETECTION SWITCH......................................................................................... 792 TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE)............................................................................... 793 ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM........................................................................ 795 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..................................................................................................... 797 C-1 WHEN ENGINE IS RUNNING, ENGINE OIL LEVEL DISPLAY SHOWS "ABNORMAL"..................................................................................... 799 C-2 WHEN ENGINE IS RUNNING, BATTERY ELECTROLYTE LEVEL DISPLAY SHOWS "ABNORMAL"............................................................................ 800 C-3 ABNORMALITY IN ENGINE WATER LEVEL DISPLAY............................................................................................................. 801 a) DISPLAY SHOWS "ABNORMAL"........................................................................................................................... 801 b) DISPLAY SHOWS " DISCONNECTION"..................................................................................................................... 801 c) DISPLAY SHOWS "SHORT CIRCUIT"...................................................................................................................... 801 C-4 ABNORMALITY IN BRAKE OIL PRESSURE DISPLAY............................................................................................................. 803 a) WHEN ENGINE IS RUNNING, DISPLAY SHOWS "ABNORMAL"................................................................................................... 803 b) DISPLAY SHOWS "DISCONNECTION"...................................................................................................................... 804 c) DISPLAY SHOWS "SHORT CIRCUIT"...................................................................................................................... 804 C-5 ABNORMALITY IN ENGINE OIL PRESSURE DISPLAY............................................................................................................ 805 a) WHEN ENGINE IS RUNNING, DISPLAY SHOWS "ABNORMAL"................................................................................................... 805 b) WHEN ENGINE IS STOPPED OR RUNNING, DISPLAY SHOWS "DISCONNECTION"................................................................................... 805 c) ONLY WHEN ENGINE IS STOPPED, DISPLAY SHOWS "DISCONNECTION"......................................................................................... 805 d) DISPLAY SHOWS "SHORT CIRCUIT"...................................................................................................................... 806 C-6 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), BATTERY CHARGE DISPLAY SHOWS "ABNORMAL"............................................................... 807 C-7 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), AIR CLEANER DISPLAY SHOWS "ABNORMAL".................................................................. 808 C-8 CAUTION ITEM DISPLAY SHOWS "ABNORMAL", BUT ALARM BUZZER DOES NOT SOUND................................................................................ 809 C-9 MONITOR DISPLAY DOES NOT SHOW "ABNORMAL", BUT ALARM BUZZER SOUNDS..................................................................................... 810 C-10 CAUTION ITEM DISPLAY SHOWS "ABNORMAL", BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH.................................................... 811 a) CHECK LAMP......................................................................................................................................... 811 b) CAUTION LAMP....................................................................................................................................... 811 C-11 MONITOR DISPLAY DOES NOT SHOW ANY ABNORMALITY, BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP................................................. 812 a) CHECK LAMP......................................................................................................................................... 812 b) CAUTION LAMP....................................................................................................................................... 812 C-12 SERVICE METER DOES NOT WORK.......................................................................................................................... 813 C-13 SERVICE METER IS RUNNING WHEN ENGING IS STOPPED...................................................................................................... 813 C-14 ABNORMALITY IN FUEL GAUGE............................................................................................................................ 814 a) DISPLAY SHOWS "DISCONNECTION" OR LOW FUEL LEVEL.................................................................................................... 814 b) DISPLAY ALWAYS SHOWS FULL AND DOES NOT GO DOWN..................................................................................................... 814 C-15 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE........................................................................................................ 815 a) DISPLAY SHOWS "SHORT CIRCUIT"...................................................................................................................... 815 b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE....................................................................................................... 815 C-16 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE................................................................................................ 816 a) DISPLAY SHOWS "SHORT CIRCUIT"...................................................................................................................... 816 b) DISPLAY ALWAYS SHOWS LOWEST LEVEL AND DOES NOT GO UP............................................................................................... 816 C-17 WHEN STARTING SWITCH IS TURNED TO ON, MONITOR IS NOT ACTUATED (KOMATSU IS NOT DISPLAYED)............................................................. 817 a) MAIN MONITOR CHECK LAMPS DO NOT LIGHT UP........................................................................................................... 817 b) MAIN MONITOR CHECK LAMPS LIGHT UP.................................................................................................................. 818 C-18 DOES NOT SWITCH TO WORKING MEMORY (ENGINE RUNNING) MODE, OR SWITCHES TO CHECK BEFORE STARTING MODE WHEN ENGINE IS RUNNING............................ 819 C-19 ABNORMALITY IN MDC MONITOR DISPLAY................................................................................................................... 820 a) DISPLAY COLOR IS ABNORMAL.......................................................................................................................... 820 b) DISPLAY FLICKERS................................................................................................................................... 820 C-20 EVEN WHEN SWITCH IS OPERATED, NOTHING FUNCTIONS...................................................................................................... 821 C-21 DOES NOT SWITCH TO TV/VIDEO MODE..................................................................................................................... 822 a) STAYS AT PARKING BRAKE APPLIED DISPLAY............................................................................................................. 822 b) DISPLAY DOES NOT LIGHT UP.......................................................................................................................... 824 C-22 ABNORMALITY IN MEMORY DATA........................................................................................................................... 826 a) LOAD METER DATA IS NOT SAVED TO MEMORY............................................................................................................. 826 b) MAINTENANCE TIME IS NOT SAVED TO MEMORY............................................................................................................ 826 C-23 ENGINE SPEED STAYS AT 0 RPM.......................................................................................................................... 827 C-24 PRESSURE SENSOR DISPLAY SHOWS "DISCONNECTION"........................................................................................................ 828 a) SENSOR POWER SOURCE DISPLAY ALSO SHOWS "ABNORMAL".................................................................................................. 828 b) ONLY PRESSURE SENSOR DISPLAY SHOWS "DISCONNECTION"................................................................................................. 828 C-25 LOAD METER CANNOT WEIGHT LOAD........................................................................................................................ 829 a) CANNOT CARRY OUT CALIBRATION....................................................................................................................... 829 b) CAN CARRY OUT CALIBRATION.......................................................................................................................... 830 C-26 ABNORMALITY IN LEVER SWITCH.......................................................................................................................... 831 a) SUB-TOTAL SWITCH DOES NOT WORK..................................................................................................................... 831 b) CANCEL SWITCH DOES NOT WORK........................................................................................................................ 831 C-27 PRINTER DOES NOT PRINT OUT........................................................................................................................... 832 C-28 ABNORMALITY IN ANTENNA SYSTEM........................................................................................................................ 833 C-29 ABNORMALITY IN SPEAKER SYSTEM........................................................................................................................ 834 a) ABNORMALITY IN RIGHT SPEAKER....................................................................................................................... 834 b) ABNORMALITY IN LEFT SPEAKER........................................................................................................................ 834 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)........................................................................................................ 835 TABLE OF ERROR CODES...................................................................................................................................... 836 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED.......................................................................... 837 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................... 845 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM (1/2)............................................................................................. 848 ENG-1 ERROR CODE E-1b [ABNORMALITY IN NE SPEED SENSOR SYSTEM]............................................................................................. 851 ENG-2 ERROR CODE E-1c [ABNORMALITY IN G SPEED SENSOR SYSTEM].............................................................................................. 852 ENG-3 ERROR CODE E-22 [OVERRUN]........................................................................................................................... 853 ENG-4 ERROR CODE E-31 [ABNORMALITY IN THROTTLE SENSOR SYSTEM]............................................................................................. 854 ENG-5 ERROR CODE E-3c [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]....................................................................................... 856 ENG-6 ERROR CODE E-3d [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]..................................................................................... 859 ENG-7 ERROR CODE E-51 [ABNORMALITY IN PREHEATER RELAY COIL SYSTEM]........................................................................................ 860 ENG-8 ERROR CODE E-54 [SHORT CIRCUIT IN STARTING SWITCH C SIGNAL SYSTEM].................................................................................. 861 ENG-9 ERROR CODE E-56 [ABNORMALITY IN POWER SUPPLY SYSTEM 1].............................................................................................. 862 ENG-10 ERROR CODE E-57 [ABNORMALITY IN POWER SUPPLY SYSTEM 2]............................................................................................. 863 ENG-11 ERROR CODE E-5A [ABNORMALITY IN Q ADJUSTMENT SWITCH SIGNAL]........................................................................................ 864 ENG-12 ERROR CODE E-6A [ABNORMALITY IN LOW WATER TEMPERATURE SENSOR SYSTEM]............................................................................... 865 ENG-13 ERROR CODE E-70 [OVERCURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]...................................................................................... 866 ENG-14 ERROR CODE E-71 [OVERCURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]...................................................................................... 867 ENG-15 ERROR CODE E-74 [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM].................................................................................... 868 ENG-16 ERROR CODE E-75 [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM].................................................................................... 869 ENG-17 ERROR CODE E-77 [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]........................................................................... 870 ENG-18 ERROR CODE E-79 [ABNORMALITY IN HIGH COMMON RAIL FUEL PRESSURE 1] ERROR CODE E-7A [ABNORMALITY IN HIGH COMMON RAIL FUEL PRESSURE 2]................ 873 ENG-19 ERROR CODE E-7b [NO-PRESSURE FEED BY FUEL SUPPLY PUMP 1] ERROR CODE E-7c [NO-PRESSURE FEED BY FUEL SUPPLY PUMP 2].................................. 875 ENG-20 ERROR CODE E-7d [ABNORMALITY IN COMMON RAIL HIGH FUEL PRESSURE].................................................................................... 878 ENG-21 ERROR CODE E-80 [DEFECTIVE CONTROLLER]............................................................................................................. 879 ENG-22 ERROR CODE E-81 [DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM]....................................................................................... 880 ENG-23 ERROR CODE E-82 [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM]....................................................................................... 881 ENG-24 ERROR CODE E-83 [DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM]....................................................................................... 882 ENG-25 ERROR CODE E-84 [DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM]....................................................................................... 883 ENG-26 ERROR CODE E-85 [DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM]....................................................................................... 884 ENG-27 ERROR CODE E-86 [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM]....................................................................................... 885 ENG-28 ERROR CODE E-8A [SHORT CIRCUIT IN NO.1,NO.2,NO.3 FUEL INJECTOR SYSTEM]............................................................................. 886 ENG-29 ERROR CODE E-8b [SHORT CIRCUIT IN NO.4,NO.5,NO.6 FUEL INJECTOR SYSTEM]............................................................................. 887 30 DISASSEMBLY AND ASSEMBLY........................................................................................................................................... 888 METHOD OF USING MANUAL............................................................................................................................................ 890 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................................................... 891 SPECIAL TOOL LIST................................................................................................................................................. 893 SKETCHES OF SPECIAL TOOLS......................................................................................................................................... 898 STARTING MOTOR.................................................................................................................................................... 901 REMOVAL AND INSTALLATION...................................................................................................................................... 901 ALTERNATOR........................................................................................................................................................ 902 REMOVAL AND INSTALLATION...................................................................................................................................... 902 ENGINE OIL COOLER................................................................................................................................................. 904 REMOVAL....................................................................................................................................................... 904 INSTALLATION.................................................................................................................................................. 905 FUEL INJECTION PUMP (SERIAL NO.:50001-52000)...................................................................................................................... 906 REMOVAL AND INSTALLTION....................................................................................................................................... 906 FUEL SUPPLY PUMP (SERIAL NO.:52001 AND UP)........................................................................................................................ 907 REMOVAL....................................................................................................................................................... 907 INSTALLATION.................................................................................................................................................. 909 WATER PUMP........................................................................................................................................................ 910 REMOVAL....................................................................................................................................................... 910 INSTALLATION.................................................................................................................................................. 911 NOZZLE HOLDER (SERIAL NO.:50001-52000)............................................................................................................................ 912 REMOVAL AND INSTALLATION...................................................................................................................................... 912 FUEL INJECTOR (SERIAL NO.:52001 AND UP)........................................................................................................................... 913 REMOVAL....................................................................................................................................................... 913 INSTALLATION.................................................................................................................................................. 915 TURBOCHARGER...................................................................................................................................................... 917 REMOVAL....................................................................................................................................................... 917 INSTALLATION.................................................................................................................................................. 918 ENGINE FRONT SEAL................................................................................................................................................. 919 REMOVAL AND INSTALLATION...................................................................................................................................... 919 ENGINE REAR SEAL.................................................................................................................................................. 920 REMOVAL....................................................................................................................................................... 920 INSTALLATION.................................................................................................................................................. 921 CYLINDER HEAD..................................................................................................................................................... 923 REMOVAL....................................................................................................................................................... 923 INSTALLATION.................................................................................................................................................. 931 RADIATOR.......................................................................................................................................................... 936 REMOVAL....................................................................................................................................................... 936 INSTALLATION.................................................................................................................................................. 939 ENGINE............................................................................................................................................................ 940 REMOVAL....................................................................................................................................................... 940 INSTALLATION.................................................................................................................................................. 948 DAMPER............................................................................................................................................................ 949 REMOVAL AND INSTALLATION...................................................................................................................................... 949 DISASSEMBLY................................................................................................................................................... 950 ASSEMBLY...................................................................................................................................................... 953 TORQUE CONVERTER, TRANSMISSION.................................................................................................................................... 958 REMOVAL....................................................................................................................................................... 958 INSTALLATION.................................................................................................................................................. 960 DISCONNECTION................................................................................................................................................. 961 CONNECTION.................................................................................................................................................... 962 TORQUE CONVERTER.................................................................................................................................................. 963 DISASSEMBLY................................................................................................................................................... 963 ASSEMBLY...................................................................................................................................................... 967 TRANSMISSION...................................................................................................................................................... 974 DISASSEMBLY................................................................................................................................................... 974 ASSEMBLY...................................................................................................................................................... 991 TRANSFER..........................................................................................................................................................1008 DISASSEMBLY...................................................................................................................................................1008 ASSEMBLY......................................................................................................................................................1012 PARKING BRAKE.....................................................................................................................................................1017 DISASSEMBLY...................................................................................................................................................1017 ASSEMBLY......................................................................................................................................................1020 TRANSMISSION CONTROL VALVE........................................................................................................................................1023 REMOVAL AND INSTALLATION......................................................................................................................................1023 CENTER SUPPORT....................................................................................................................................................1024 REMOVAL.......................................................................................................................................................1024 INSTALLATION..................................................................................................................................................1025 DISASSEMBLY...................................................................................................................................................1026 ASSEMBLY......................................................................................................................................................1028 DRIVE SHAFT.......................................................................................................................................................1031 DISASSEMBLY...................................................................................................................................................1031 ASSEMBLY......................................................................................................................................................1034 FRONT AXLE........................................................................................................................................................1037 REMOVAL.......................................................................................................................................................1037 INSTALLATION..................................................................................................................................................1038 FRONT DIFFERENTIAL................................................................................................................................................1039 REMOVAL.......................................................................................................................................................1039 INSTALLATION..................................................................................................................................................1041 REAR AXLE.........................................................................................................................................................1042 REMOVAL.......................................................................................................................................................1042 INSTALLATION..................................................................................................................................................1047 REAR DIFFERENTIAL.................................................................................................................................................1048 REMOVAL.......................................................................................................................................................1048 INSTALLATION..................................................................................................................................................1049 DIFFERENTIAL GEAR.................................................................................................................................................1050 DISASSEMBLY...................................................................................................................................................1050 ASSEMBLY......................................................................................................................................................1054 LIMITED SLIP DIFFERENTIAL.........................................................................................................................................1062 DISASSEMBLY...................................................................................................................................................1062 ASSEMBLY......................................................................................................................................................1066 FINAL DRIVE.......................................................................................................................................................1076 DISASSEMBLY...................................................................................................................................................1076 ASSEMBLY......................................................................................................................................................1079 ORBIT-ROLL........................................................................................................................................................1083 REMOVAL AND INSTALLATION......................................................................................................................................1083 DISASSEMBLY...................................................................................................................................................1084 ASSEMBLY......................................................................................................................................................1089 STEERING CYLINDER.................................................................................................................................................1096 REMOVAL.......................................................................................................................................................1096 INSTALLATION..................................................................................................................................................1097 DISASSEMBLY...................................................................................................................................................1098 ASSEMBLY......................................................................................................................................................1100 STEERING VALVE....................................................................................................................................................1102 REMOVAL.......................................................................................................................................................1102 INSTALLATION..................................................................................................................................................1104 BRAKE VALVE.......................................................................................................................................................1105 REMOVAL.......................................................................................................................................................1105 INSTALLATION..................................................................................................................................................1106 SLACK ADJUSTER....................................................................................................................................................1107 REMOVAL ADN INSTALLATION......................................................................................................................................1107 DISASSEMBLY...................................................................................................................................................1108 ASSEMBLY......................................................................................................................................................1109 BRAKE (FRONT, REAR)...............................................................................................................................................1110 REMOVAL AND INSTALLATION......................................................................................................................................1110 DISASSEMBLY...................................................................................................................................................1111 ASSEMBLY......................................................................................................................................................1114 ACCUMULATOR CHARGE VALVE..........................................................................................................................................1118 REMOVAL.......................................................................................................................................................1118 INSTALLATION..................................................................................................................................................1119 DISASSEMBLY...................................................................................................................................................1120 ASSEMBLY......................................................................................................................................................1122 HYDRAULIC PUMP....................................................................................................................................................1124 REMOVAL.......................................................................................................................................................1124 INSTALLATION..................................................................................................................................................1125 HYDRAULIC TAKE....................................................................................................................................................1126 REMOVAL.......................................................................................................................................................1126 INSTALLATION..................................................................................................................................................1127 HYDRAULIC FILTER..................................................................................................................................................1128 REMOVAL AND INSTALLATION......................................................................................................................................1128 PPC VALVE.........................................................................................................................................................1129 REMOVAL AND INSTALLATION......................................................................................................................................1129 DISASSEMBLY AND ASSEMBLY......................................................................................................................................1130 MAIN CONTROL VALVE................................................................................................................................................1131 REMOVAL.......................................................................................................................................................1131 INSTALLATION..................................................................................................................................................1133 DISASSEMBLY...................................................................................................................................................1134 ASSEMBLY......................................................................................................................................................1137 BUCKET CYLINDER...................................................................................................................................................1140 REMOVAL.......................................................................................................................................................1140 INSTALLATION..................................................................................................................................................1141 BOOM CYLINDER.....................................................................................................................................................1142 REMOVAL.......................................................................................................................................................1142 INSTALLATION..................................................................................................................................................1143 BOOM AND BUCKET CYLINDERS.........................................................................................................................................1144 DISASSEMBLY...................................................................................................................................................1144 ASSEMBLY......................................................................................................................................................1146 CENTER HINGE PIN..................................................................................................................................................1149 REMOVAL.......................................................................................................................................................1149 INSTALLATION..................................................................................................................................................1155 WORK EQUIPMENT....................................................................................................................................................1158 REMOVAL.......................................................................................................................................................1158 INSTALLATION..................................................................................................................................................1162 BULKHEAD..........................................................................................................................................................1163 REMOVAL.......................................................................................................................................................1163 INSTALLATION..................................................................................................................................................1167 ENGINE HOOD.......................................................................................................................................................1168 REMOVAL.......................................................................................................................................................1168 INSTALLATION..................................................................................................................................................1169 FLOOR FRAME.......................................................................................................................................................1170 REMOVAL.......................................................................................................................................................1170 INSTALLATION..................................................................................................................................................1175 COUNTERWEIGHT.....................................................................................................................................................1176 REMOVAL AND INSTALLATION......................................................................................................................................1176 FUEL TANK.........................................................................................................................................................1177 REMOVAL.......................................................................................................................................................1177 INSTALLATION..................................................................................................................................................1180 CAB...............................................................................................................................................................1181 REMOVAL.......................................................................................................................................................1181 INSTALLATION..................................................................................................................................................1183 AIR CONDITIONER UNIT..............................................................................................................................................1184 REMOVAL.......................................................................................................................................................1184 INSTALLATION..................................................................................................................................................1185 AIR CONDITIONER CONDENSER.........................................................................................................................................1186 REMOVAL.......................................................................................................................................................1186 INSTALLATION..................................................................................................................................................1187 RECEIVER TANK.....................................................................................................................................................1188 REMOVAL.......................................................................................................................................................1188 INSTALLATION..................................................................................................................................................1189 AIR CONDITIONER COMPRESSOR........................................................................................................................................1190 REMOVAL.......................................................................................................................................................1190 INSTALLATION..................................................................................................................................................1191 40 MAINTENANCE STANDARD...............................................................................................................................................1192 ENGINE MOUNT......................................................................................................................................................1193 TRANSMISSION MOUNT................................................................................................................................................1194 DAMPER............................................................................................................................................................1195 TORQUE CONVERTER CHARGING PUMP....................................................................................................................................1196 TORQUE CONVERTER, PTO.............................................................................................................................................1197 TRANSMISSION......................................................................................................................................................1198 TRANSFER..........................................................................................................................................................1206 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE........................................................................................................................1208 LUBRICATION RELIEF VALVE..........................................................................................................................................1209 DRIVE SHAFT.......................................................................................................................................................1210 CENTER SUPPORT....................................................................................................................................................1211 DIFFERENTIAL......................................................................................................................................................1212 LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)...........................................................................................................................1216 FINAL DRIVE.......................................................................................................................................................1218 AXLE MOUNT........................................................................................................................................................1219 CENTER HINGE PIN..................................................................................................................................................1221 STEERING COLUMN...................................................................................................................................................1223 STEERING PUMP.....................................................................................................................................................1224 STEERING VALVE....................................................................................................................................................1225 STEERING CYLINDER MOUNT...........................................................................................................................................1226 BRAKE VALVE.......................................................................................................................................................1227 SLACK ADJUSTER....................................................................................................................................................1230 BRAKE.............................................................................................................................................................1231 PARKING BRAKE.....................................................................................................................................................1233 HYDRAULIC PUMP....................................................................................................................................................1234 SWITCH, PPC PUMP..................................................................................................................................................1235 PPC VALVE.........................................................................................................................................................1236 CUT-OFF VALVE.....................................................................................................................................................1238 MAIN CONTROL VALVE................................................................................................................................................1239 HYDRAULIC CYLINDERS...............................................................................................................................................1243 BUCKET LINKAGE....................................................................................................................................................1245 BUCKET............................................................................................................................................................1247 BUCKET POSITIONER AND BOOM KICK-OUT...............................................................................................................................1248 ROPS CAB..........................................................................................................................................................1250 90 OTHERS.............................................................................................................................................................1252 TRANSMISSION......................................................................................................................................................1253 BRAKE PIPING SERIAL NO.:50001-52000...............................................................................................................................1254 HYDRAULIC PINGING SERIAL NO.:50001-52000..........................................................................................................................1255 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM SERIAL NO.:50001-52000...................................................................................................1256 WORK EQUIPMENT HYDRAULC CIRCUIT DIAGRAM (MACHINE WITH OPTIONAL SPECIFICATION) SERIAL NO.:50001-52000..............................................................1257 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM SERIAL NO.:52001 AND UP..................................................................................................1258 ELECTRIC CIRCUIT DIAGRAM (1/4) SERIAL NO.:50001-52000.............................................................................................................1259 ELECTRIC CIRCUIT DIAGRAM (2/4) SERIAL NO.:50001-52000.............................................................................................................1260 ELECTRIC CIRCUIT DIAGRAM (3/4) SERIAL NO.:50001-52000.............................................................................................................1261 ELECTRIC CIRCUIT DIAGRAM (4/4) SERIAL NO.:50001-52000.............................................................................................................1262 ELECTRIC CIRCUIT DIAGRAM (1/5) SERIAL NO.:52001 AND UP............................................................................................................1263 ELECTRIC CIRCUIT DIAGRAM (2/5) SERIAL NO.:52001 AND UP............................................................................................................1264 ELECTRIC CIRCUIT DIAGRAM (3/5) SERIAL NO.:52001 AND UP............................................................................................................1265 ELECTRIC CIRCUIT DIAGRAM (4/5) SERIAL NO.:52001 AND UP............................................................................................................1266 ELECTRIC CIRCUIT DIAGRAM (5/5) SERIAL NO.:52001 AND UP............................................................................................................1267 ELECTRICAL PARKING BRAKE CONTROL..................................................................................................................................1268 CONNECTOR ARRANGEMENT DIAGRAM (1/2) SERIAL NO.:50001-52000........................................................................................................1269 CONNECTOR ARRANGEMENT DIAGRAM (2/2) SERIAL NO.:50001-52000........................................................................................................1270 CONNECTOR ARRANGEMENT DIAGRAM (1/2) SERIAL NO.:52001 AND UP.......................................................................................................1271 CONNECTOR ARRANGEMENT DIAGRAM (2/2) SERIAL NO.:52001 AND UP.......................................................................................................1274
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