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KOMATSU WA1200-3 SHOP MANUAL SEBM018237 – PDF DOWNLOAD
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Description
KOMATSU WA1200-3 SHOP MANUAL SEBM018237 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA1200-3 SHOP MANUAL SEBM018237 – PDF DOWNLOAD
Language : English
Pages : 2492
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA1200-3 SHOP MANUAL SEBM018237 – PDF DOWNLOAD
COVER ........................................................................................................................................................................................ 1 CONTENTS...................................................................................................................................................................................... 2 01 GENERAL ................................................................................................................................................................................... 35 GENERAL ASSEMBLY DRAWING ................................................................................................................................................................. 36 SPECIFICATIONS ........................................................................................................................................................................... 37 WEIGHT TABLE ............................................................................................................................................................................. 40 LIST OF LUBRICANT AND WATER............................................................................................................................................................... 42 10 STRUCTURE AND FUNCTION..................................................................................................................................................................... 45 OUTLINE................................................................................................................................................................................... 46 TADIATOR AND HYDRAULIC OIL COOLER ........................................................................................................................................................ 48 DAMPER ................................................................................................................................................................................... 49 TORQUE CONVERTER AND TRANSMISSION PIPING ................................................................................................................................................. 50 TORQUE CONVERTER ......................................................................................................................................................................... 52 MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE....................................................................................................................................... 60 TORQUE CONVERTER REGULATOR VALVE ......................................................................................................................................................... 64 ECMV ..................................................................................................................................................................................... 66 TRANSMISSION.............................................................................................................................................................................. 72 TRANSMISSION CONTROL VALVE................................................................................................................................................................ 82 LUBRICATING OIL RELIEF VALVE ............................................................................................................................................................. 93 TRANSFER ................................................................................................................................................................................. 94 TORQUE CONVERTER OIL COOLER .............................................................................................................................................................. 96 CENTER SUPPORT ........................................................................................................................................................................... 97 AXLE ..................................................................................................................................................................................... 98 FINAL DRIVE............................................................................................................................................................................... 103 AXLE MOUNT ............................................................................................................................................................................... 106 CENTER HINGE PIN ......................................................................................................................................................................... 108 JACK-UP POINT............................................................................................................................................................................. 109 ARRANGEMENT OF STEERING EQUIPMENT......................................................................................................................................................... 111 AJSS (ADVANCED JOYSTICK STEERING SYSTEM).................................................................................................................................................. 112 STEERING PUMP ............................................................................................................................................................................ 113 SWITCH PUMP .............................................................................................................................................................................. 116 SERVO VALVE .............................................................................................................................................................................. 119 STEERING DEMAND VALVE..................................................................................................................................................................... 123 ROTARY VALVE ............................................................................................................................................................................. 134 EPC VALVE ................................................................................................................................................................................ 137 DIVERTER VALVE ........................................................................................................................................................................... 138 ARRANGEMENT OF BRAKE EQUIPMENT............................................................................................................................................................ 142 BRAKE VALVE .............................................................................................................................................................................. 144 HARGE VALVE .............................................................................................................................................................................. 149 ACCUMULATOR (FOR BRAKE)................................................................................................................................................................... 153 SLACK ADJUSTER............................................................................................................................................................................ 154 BRAKE..................................................................................................................................................................................... 157 PARKING BRAKE............................................................................................................................................................................. 158 PARKING BRAKE OIL CIRCUIT CHECK VALVE ASSEMBLY............................................................................................................................................ 160 ARRANGEMENT OF HYDRAULIC EQUIPMENT ....................................................................................................................................................... 164 WORK EQUIPMENT LEVER LINKAGE ............................................................................................................................................................. 166 HYDRAULIC TANK ........................................................................................................................................................................... 167 WORK EQUIPMENT PUMP NO.1 ................................................................................................................................................................. 170 WORK EQUIPMENT PUMP NO.2 ................................................................................................................................................................. 183 WORK EQUIPMENT PUMP NEUTRAL CUT VALVE (NC VALVE).......................................................................................................................................... 200 PPC VALVE (PROPORTIONAL PRESSURE VALVE) .................................................................................................................................................. 202 PPC RELIEF VALVE ......................................................................................................................................................................... 206 ACCUMULATOR(FOR PPC VALVE) ............................................................................................................................................................... 207 MAIN CONTROL VALVE ....................................................................................................................................................................... 208 WORK EQUIPMENT LINKAGE ................................................................................................................................................................... 222 OPERATION OF PROXIMITY SWITCH ............................................................................................................................................................ 224 AIR CONDITIONER .......................................................................................................................................................................... 226 MACHINE MONITOR SYSTEM.................................................................................................................................................................... 229 MAIN MONITOR ............................................................................................................................................................................. 233 CGC MONITOR............................................................................................................................................................................... 237 MULTI MONITOR............................................................................................................................................................................. 278 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM.......................................................................................................................... 314 MODULATED CLUTCH (MOD/C) CONTROL SYSTEM .................................................................................................................................................. 329 WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM....................................................................................................................................... 333 WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER .......................................................................................................................................... 343 ENGINE STARTING CIRCUIT................................................................................................................................................................... 344 ENGINE STOPPING CIRCUIT................................................................................................................................................................... 350 ETHER INJECTION CIRCUIT................................................................................................................................................................... 352 ELECTRIC PARKING BRAKE CONTROL ........................................................................................................................................................... 354 PARKING BRAKE SOLENOID VALVE ............................................................................................................................................................. 364 EMERGENCY PARKING BRAKE RESET SOLENOID VALVE.............................................................................................................................................. 365 KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT SELECTOR SWITCH.............................................................................................................................. 366 BATTERY DISCONNECTOR SWITCH............................................................................................................................................................... 368 EMERGENCY ENGINE STOP SWITCH (FOR RIO TINTO).............................................................................................................................................. 370 HYDRAULIC OIL LEVEL CAUTION DISPLAY (FOR RIO TINTO)....................................................................................................................................... 373 20 TESTING AND ADJUSTING...................................................................................................................................................................... 377 STANDARD VALUE TABLE ..................................................................................................................................................................... 377 STANDARD VALUE TABLE FOR ENGINE....................................................................................................................................................... 378 STANDARD VALUE TABLE FOR CHASSIS...................................................................................................................................................... 379 STANDARD VALUE TABLE FOR ELECTRICAL PARTS ............................................................................................................................................ 385 TESTING AND ADJUSTING..................................................................................................................................................................... 407 ITEMS TO BE PREPARED LIST OF DEVICES FOR TROUBLESHOOTING.............................................................................................................................. 410 SAFETY PRECAUTIONS BEFORE STARTING WORK............................................................................................................................................... 414 ITEMS RELATED TO ENGINE MEASURING ENGINE SPEED........................................................................................................................................ 417 MEASURING EXHAUST GAS COLOR........................................................................................................................................................... 421 MEASURING BLOW-BY PRESSURE............................................................................................................................................................ 422 MEASURING ENGINE OIL PRESSURE......................................................................................................................................................... 424 MEASURING EXHAUST TEMPERATURE......................................................................................................................................................... 426 MEASURING BOOSTP RESSURE.............................................................................................................................................................. 428 PERFORMANCE CHECK OF RADIATOR......................................................................................................................................................... 430 MEASURING WIND VELOCITY THROUGH RADIATOR AND OIL COOLER............................................................................................................................... 431 TESTING AND ADJUSTING FAN BELT TENSION................................................................................................................................................ 433 TESTING AND ADJUSTING BELT TENSION OF AIR CONDITIONER COMPRESSOR...................................................................................................................... 433 ADJUSTING ROTATION SENSOR............................................................................................................................................................. 434 POWER TRAIN TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE...................................................................................................... 436 TRACTION CONTROL FUNCTION CHECK PROCEDURE............................................................................................................................................. 444 PERFORMANCE CHECK OF TORQUE CONVERTER OIL COOLER...................................................................................................................................... 445 MEASURING FAN SPEED FOR ADDITIONAL COOLER............................................................................................................................................. 446 FLUSHING PROCEDURE FOR HYDRAULIC CIRCUIT OF TORQUE CONVERTER AND TRANSMISSION......................................................................................................... 447 HOW TO MOVE MACHINE WHEN TRANSMISSION VALVE IS BROKEN................................................................................................................................. 448 HOW TO MEASURE CLEARANCE (PLAY) IN CENTER HINGE BEARING............................................................................................................................... 452 MEASUREMENT PROCEDURE FOR WEAR OF REAR AXLE SUPPORT................................................................................................................................... 454 STEERING SYSTEM TESTING AND ADJUSTING STEERING OIL PRESSURE........................................................................................................................... 455 TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE................................................................................................................................. 457 BLEEDING AIR FROM STEERING CIRCUIT.................................................................................................................................................... 459 ADJUSTING STEERING STOPPER BOLT....................................................................................................................................................... 461 ADJUSTING STEERING FOLLOW-UP LINKAGE.................................................................................................................................................. 462 TESTING STEERING EPC VALVE............................................................................................................................................................ 467 TESTING AND ADJUSTING STEERING SURGE CUT VALVE OIL PRESSURE........................................................................................................................... 469 TESTING AND ADJUSTING STEERING MAIN RELIEF VALVE OIL PRESSURE......................................................................................................................... 471 MEASURING ROTARY VALVE OUTPUT PRESSURE................................................................................................................................................ 475 BRAKE SYSTEM TESTING DROP OF WHEEL BRAKE OIL PRESSURE................................................................................................................................. 477 TESTING WHEEL BRAKE FUNCTION.......................................................................................................................................................... 478 CHECKING SLACK ADJUSTER............................................................................................................................................................... 479 MEASURING WEAR OF WHEEL BRAKE DISC.................................................................................................................................................... 481 TESTING AND ADJUSTING CHARGE CUT-IN AND CUT-OUT PRESSURE OF ACCUMULATOR............................................................................................................... 482 TESTING BRAKE ACCUMULATOR FOR LEAKAGE................................................................................................................................................. 486 TESTING EMERGENCY PARKING BRAKE VALVE FOR OIL LEAKAGE................................................................................................................................. 488 TESTING BRAKE VALVE FOR OIL LEAKAGE................................................................................................................................................... 490 TESTING BRAKE COOLING OIL PRESSURE.................................................................................................................................................... 494 PERFORMANCE CHECK OF BRAKE OIL COOLER................................................................................................................................................. 496 TESTING PARKING BRAKE PERFORMANCE .................................................................................................................................................... 497 TESTING WEAR OF PARKING BRAKE DISC.................................................................................................................................................... 498 HOW TO RESET PARKING BRAKE MANUALLY................................................................................................................................................... 499 MEASURING PARKING BRAKE OIL PRESSURE.................................................................................................................................................. 500 HYDRAULIC EQUIPMENT TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE................................................................................................................. 501 MEASUREMENT PROCEDURE OF WORK EQUIPMENT OIL PRESSURE WITH OIL PRESSURE GAUGE.......................................................................................................... 505 TESTING AND ADJUSTING PPC OIL PRESSURE................................................................................................................................................ 507 ADJUSTING PPC VALVE LINKAGE........................................................................................................................................................... 512 MEASURING POINTS OF HYDRAULIC PUMP OIL PRESSURE....................................................................................................................................... 514 HYDRAULIC PUMP PIPING LINE............................................................................................................................................................ 516 TESTING AND ADJUSTING PV CONTROL RELIEF VALVE OIL PRESSURE............................................................................................................................ 518 TESTING AND ADJUSTING DIFFERENTIAL PRESSURE VALVE CONTROL OIL PRESSURE................................................................................................................ 519 TESTING WORK EQUIPMENT PUMP ES VALVE OUTPUT PRESSURE.................................................................................................................................. 522 TESTING AND ADJUSTING WORK EQUIPMENT PUMP CO VALVE (CUT-OFF) OIL PRESSURE............................................................................................................. 524 TESTING WORK EQUIPMENT CONTROL VALVE OPERATION BY WORK EQUIPMENT SPEED (WORK EQUIPMENT SPEED IS LOW).................................................................................. 532 PERFORMANCE CHECK OF HYDRAULIC OIL COOLER (CHECK BY TEMPERATUREDIFFERENCE)............................................................................................................ 540 PERFORMANCE CHECK OF HYDRAULIC OIL COOLER (CHECK BY MEASURING OIL PRESSURE)........................................................................................................... 541 BLEEDING AIR FROM EACH PART........................................................................................................................................................... 545 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT.................................................................................................................................... 552 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS................................................................................. 553 WORK EQUIPMENT SYSTEM CHECKING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER LINKAGE..................................................................................................... 565 ELECTRICAL EQUIPMENT TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH.................................................................................................................... 569 TESTING AND ADJUSTING LIFT ARM POTENTIOMETER.......................................................................................................................................... 570 ADJUSTING LIFT ARM HORIZONTAL DETECTION SWITCH........................................................................................................................................ 571 PROCEDURE FOR SETTING INITIAL VALUE FOR REMOTE LIFT ARM POSITIONER (METHOD OF INPUTTING BASE POINT)................................................................................... 572 CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP........................................................................................................................................ 575 INITIAL LEARNING METHOD OF TRANSMISSION CONTROLLER.................................................................................................................................... 576 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) .......................................................................................................................................... 577 ADJUSTING STEERING LEVER ANGLE AND FRAME ANGLE SENSORS................................................................................................................................ 578 CHECKING AND ADJUSTING INSTALLED POSITIONS OF POTENTIOMETERS.......................................................................................................................... 580 PROCEDURE FOR CHECKING DIODE.......................................................................................................................................................... 584 CHECKING GREASING CONDITION OF CENTER HINGE PIN PORTION............................................................................................................................... 585 METHOD OF ADJUSTING AUTO-GREASE INJECTOR DISCHARGE AMOUNT............................................................................................................................. 586 METHOD OF SETTING AUTO-GREASE TIMER .................................................................................................................................................. 587 VHMS CONTROLLER BASIC PRECAUTIONS..................................................................................................................................................... 589 TESTING AND MAINTAINING VHMS CONTROLLER............................................................................................................................................... 595 VHMS CONTROLLER INITIAL SETTING PROCEDURE............................................................................................................................................. 596 PRECAUTIONS FOR REPLACING VHMS CONTROLLER............................................................................................................................................. 614 MEASUREMENT PROCEDURE BY DOWNLOADING DATA IN VHMS CONTROLLER.......................................................................................................................... 622 MEASUREMENT PROCEDURE BY CGC MONITOR.................................................................................................................................................. 629 MEASUREMENT PROCEDURE BY MULTI MONITOR................................................................................................................................................ 631 SPECIAL FUNCTIONS OF MACHINE CONTROL MONITOR (MULTI MONITOR).......................................................................................................................... 633 OUTLINE OF MEASUREMENT PROCEDURE FOR PM CLINIC........................................................................................................................................ 688 PREPARATION FOR MEASUREMENT FOR PM CLINIC............................................................................................................................................. 690 Pm clinic check sheet................................................................................................................................................................. 692 TROUBLESHOOTING........................................................................................................................................................................... 697 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................................................... 698 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................................................................. 699 CHECKS BEFORE TROUBLESHOOTING......................................................................................................................................................... 700 TROUBLESHOOTING PROCEDURE FOR WORK EQUIPMENT HYDRAULIC SYSTEM AND STEERING SYSTEM..................................................................................................... 712 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT ............................................................................................................................... 722 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................ 731 CONNECTOR ARRANGEMENT DIAGRAM......................................................................................................................................................... 738 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................................ 748 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE............................................................................................................................................... 784 EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM ............................................................................................................................... 787 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE..................................................................................................................................... 793 FAILURE CODES LIST.................................................................................................................................................................... 806 METHOD OF USING JUDGEMENT TABLE....................................................................................................................................................... 813 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................ 814 METHOD OF USING MATRIX TROUBLESHOOTING TABLES ........................................................................................................................................ 816 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE).................................................................................................................................. 819 DISPLAY METHOD OF CUMMINS ENGINE CONTROLLERFAILURE CODES AND CONTENTS OF DISPLAY.................................................................................................. 820 FAILURE CODES AND ACTIONS TABLE................................................................................................................................................... 821 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)............................................................................................................................ 829 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS..................................................................................................................... 832 OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY...................................................................................... 834 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM..................................................................................................................... 844 T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed........................................................... 846 T-2 Error code [11] (Disconnection in modulated clutch outlet rotation signal sensor system) is displayed......................................................................... 847 T-3 Error code [12] (Short circuit, disconnection, or short circuit with power source in F solenoid system) is displayed.......................................................... 848 T-4 Error code [13] (Short circuit, disconnection, or short circuit with power source in R solenoid system) is displayed.......................................................... 849 T-5 Error code [14] (Short circuit, disconnection, or short circuit with power source in 1st solenoid system) is displayed........................................................ 850 T-6 Error code [15] (Short circuit, disconnection, or short circuit with power source in 2nd solenoid system) is displayed........................................................ 851 T-7 Error code [16] (Short circuit, disconnection, or short circuit with power source in 3rd solenoid system) is displayed........................................................ 852 T-8 Error code [18] (Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid system) is displayed....................................... 853 T-9 Error code [20] (Short circuit or disconnection in joystick FNR switch system) is displayed................................................................................... 854 T-10 Error code [21] (Short circuit or disconnection in joystick shift-up/shift-down switch system) is displayed.................................................................. 855 T-11 Error code [22] (Disconnection in travel speed sensor system) is displayed................................................................................................... 856 T-12 Error code [23] (Short circuit or disconnection in engine speed sensor system) is displayed.................................................................................. 857 T-13 Failure code [24] (Short circuit, disconnection in EEP ROM) is displayed..................................................................................................... 858 T-14 Error code [25] (Short circuit in transmission oil temperature sensor system) is displayed................................................................................... 859 T-15 Error code [26] (Short circuit in F ECMV fill switch system) is displayed.................................................................................................... 860 T-16 Error code [27] (Short circuit in R ECMV fill switch system) is displayed.................................................................................................... 860 T-17 Error code [28] (Short circuit in 1st ECMV fill switch system) is displayed.................................................................................................. 861 T-18 Error code [29] (Short circuit in 2nd ECMV fill switch system) is displayed.................................................................................................. 861 T-19 Error code [30] (Short circuit in 3rd ECMV fill switch system) is displayed.................................................................................................. 862 T-20 Error code [32] (Disconnection in F or R ECMV fill switch system) is displayed............................................................................................... 863 T-21 Error code [33] (Disconnection in 1st, 2nd, or 3rd ECMV fill switch system) is displayed..................................................................................... 864 T-22 Error code [34] (Disconnection or 3rd short circuit with power source in F bypass solenoid system) is displayed.............................................................. 865 T-23 Error code [35] (Short circuit in F bypass solenoid system) is displayed..................................................................................................... 866 T-24 Error code [36] (Disconnection or short circuit with power source in R bypass solenoid system) is displayed.................................................................. 867 T-25 Error code [37] (Short circuit in R bypass solenoid system) is displayed..................................................................................................... 868 T-26 Error code [38] (Disconnection or short circuit with power source in 1st bypass solenoid system) is displayed................................................................ 869 T-27 Error code [39] (Short circuit in 1st bypass solenoid system) is displayed................................................................................................... 870 T-28 Auto/Manual selector switch system........................................................................................................................................... 871 T-29 Kickdown switch system....................................................................................................................................................... 871 T-30 Transmission cut-off switch signal system.................................................................................................................................... 872 T-31 Steering lock switch signal system........................................................................................................................................... 873 T-32 Neutralizer relay signal system.............................................................................................................................................. 874 T-33 Buzzer signal system......................................................................................................................................................... 875 T-34 Network system............................................................................................................................................................... 876 T-35 Transmission controller power supply system.................................................................................................................................. 877 T-36 Short circuit in travel speed sensor system.................................................................................................................................. 878 T-37 Short circuit in modulated clutch outlet rotation sensor system.............................................................................................................. 879 T-38 Disconnection in transmission oil temperature sensor system.................................................................................................................. 880 T-39 F1 (Forward 1st gear) signal system.......................................................................................................................................... 881 T-40 Abnormality in auto shift indicator lamp..................................................................................................................................... 882 TROUBLESHOOTING OF MODULATED CLUTCH CONTROLLER SYSTEM (MC MODE)....................................................................................................................... 885 JUDGEMENT TABLE FOR MODULATED CLUTCH CONTROL SYSTEM RELATED PARTS................................................................................................................. 886 OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY...................................................................................... 888 ELECTRIC CIRCUIT DIAGRAM OF MODULATED CLUTCH CONTROL SYSTEM....................................................................................................................... 894 MC-1 Error code [70] (Disconnection in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system) is displayed.................................................................. 896 MC-2 Error code [72] (Abnormality in accelerator pedal sensor system) is displayed................................................................................................ 898 MC-3 Error code [73] (Short circuit in F/R ECMV fill switch system) is displayed.................................................................................................. 899 MC-4 Error code [74] (Disconnection in 1st, 2nd, or 3rd ECMV fill switch system) is displayed..................................................................................... 900 MC-5 Error code [75] (Short circuit with chassis ground in 1st, 2nd, or 3rd ECMV fill switch system) is displayed................................................................. 901 MC-6 Error code [76] (Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system) is displayed............................................................................... 902 MC-7 Error code [77] (Short circuit or disconnection in drive force control dial system) is displayed............................................................................. 903 MC-8 Error code [78] (Short circuit or disconnection in travel speed control dial system) is displayed ........................................................................... 904 MC-9 Error code [80] (Short circuit or disconnection in wheel rotation sensor system) is displayed ............................................................................... 905 MC-10 Error code [81] (Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation sensor system) is displayed .......................... 906 MC-11 Error code [82] (Short circuit, disconnection, or short circuit with power source in engine speed sensor system) is displayed............................................... 907 MC-12 Error code [83] (Short circuit or disconnection in travel speed sensor system) is displayed................................................................................. 908 MC-13 Error code [84] (Short circuit, disconnection, or short circuit with power source in neutral cut solenoid system) is displayed ............................................. 910 MC-14 Error code [85] (Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system) is displayed ................................... 911 MC-15 Short circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system ............................................................................................... 912 MC-16 Disconnection in F ECMV fill switch system ................................................................................................................................. 913 MC-17 Disconnection in R ECMV fill switch system.................................................................................................................................. 913 MC-18 Disconnection in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system............................................................................................................. 914 MC-19 Abnormality in electronic governor voltage command system................................................................................................................... 915 MC-20 Abnormality in transmission cut-off signal system........................................................................................................................... 916 MC-21 Abnormality in modulated clutch ECMV fill switch system .................................................................................................................... 917 MC-22 Abnormality in right brake pedal switch system.............................................................................................................................. 918 MC-23 Abnormality in travel speed control ON/OFF switch system.................................................................................................................... 919 MC-24 Abnormality in RPM-SET ON/OFF switch system ................................................................................................................................ 920 MC-25 Abnormality in engine rotation output signal system ........................................................................................................................ 921 MC-26 Abnormality in power supply system of modulated clutch control system....................................................................................................... 922 MC-27 Abnormality in network system............................................................................................................................................... 923 MC-28 Abnormality in F1 (Forward 1st gear) input signal system.................................................................................................................... 923 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER (JOYSTICK STEERING CONTROL) SYSTEM (J MODE).............................................................................................. 925 JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL SYSTEM RELATED PARTS................................................................................................................... 926 OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY ..................................................................................... 928 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM .......................................................................................................................... 932 J-1 Error code [55] (Abnormality in travel speed sensor system) is displayed ..................................................................................................... 933 J-2 Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed ............................................................. 934 J-3 Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed ...................................................... 935 J-4 Error code [58] (Deviation of steering lever angle sensor and frame angle sensor potentiometer signals ....................................................................... 936 J-5 Error code [59] (Disconnection or short circuit with chassis ground in frame angle sensor system) is displayed................................................................ 937 J-6 Error code [61] (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed............................................... 938 J-7 Error code [62] (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed ................................................. 939 J-8 Error code [63] (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed .... 940 J-9 Short circuit with chassis ground in travel speed sensor system .............................................................................................................. 941 J-10 Steering speeds in both directions are different ............................................................................................................................ 942 J-11 Abnormality in console switch (adjustment of steering lever angle sensor and frame angle sensor is impossible) .............................................................. 943 J-12 Abnormality in power source and voltage...................................................................................................................................... 944 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROL) SYSTEM (W MODE)......................................................................................... 945 JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROLLER SYSTEM) RELATED PARTS............................................................................ 946 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................................ 948 ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROLLER SYSTEM .................................................................................................................. 950 W-1 Failure code [43] (Short circuit, disconnection in damping solenoid) is displayed ............................................................................................ 952 W-2 Failure code [44] (Short circuit in power source at hot end of damping solenoid) is displayed................................................................................. 953 W-3 Failure code [45] (Short circuit in power source at return end of damping solenoid) is displayed.............................................................................. 953 W-4 Failure code [49] (Short circuit, disconnection in boom lever kick-out relay system) is displayed ............................................................................ 954 W-5 Failure code [51] (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed ................................................................................ 955 W-6 Failure code [52] (Short circuit, disconnection in boom angle potentiometer system) is displayed.............................................................................. 956 W-7 Sensor cannot be adjusted .................................................................................................................................................... 957 W-8 Abnormality in engine speed signal system .................................................................................................................................... 957 W-9 Remote positioner RAISE, LOWER LEDs do not light up........................................................................................................................... 958 W-10 Remote positioner RAISE stop lamp (CGC monitor) does not flash (for 2.5 seconds) ............................................................................................ 959 W-11 Remote positioner LOWER stop lamp (CGC monitor) does not flash (for 2.5 seconds) ............................................................................................ 959 W-12 Buzzer for switch operation does not sound .................................................................................................................................. 960 W-13 Shock when stopping boom (abnormality in boom lever detent switch) .......................................................................................................... 961 W-14 Short circuit in boom RAISE, LOWER pressure detection switch................................................................................................................. 962 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)....................................................................................................................................... 963 TROUBLE DATA DISPLAY ............................................................................................................................................................. 965 ELECTRICAL CIRCUIT DIAGRAM OF MAIN MONITOR SYSTEM ................................................................................................................................ 966 M-1 Main monitor does not work.................................................................................................................................................... 968 M-2 When starting switch is turned ON (within 3 seconds) and engine is started (PRE-LUBE) immediately, all lamps stay lighted up ................................................. 969 M-3 Speedometer display does not work properly ................................................................................................................................... 970 M-4 Abnormality in shift indicator ............................................................................................................................................... 971 a) Displays N even when directional lever is at F............................................................................................................................. 971 b) Displays N even when directional lever is at R............................................................................................................................. 971 c) Does not display N even when FNR (Forward-reverse) switch is set in N ..................................................................................................... 972 d) Does not display F even when FNR (Forward-reverse) switch is set in F ..................................................................................................... 972 e) Does not display R even when FNR (Forward-reverse) switch is set in R ..................................................................................................... 972 M-5 Turn signal display does not light up ........................................................................................................................................ 974 a) L.H. turn signal display does not light up ................................................................................................................................ 974 b) R.H. turn signal display does not light up ................................................................................................................................ 974 M-6 Abnormality in parking display................................................................................................................................................ 975 a) Parking lamp display does not light up .................................................................................................................................... 975 b) Parking lamp display stays lighted up...................................................................................................................................... 975 M-7 Night lighting does not light up ............................................................................................................................................. 976 M-8 Abnormality in front working lamp ............................................................................................................................................ 977 a) Neither monitor display nor front working lamp light up.................................................................................................................... 977 b) Working lamp lights up but monitor display does not light up .............................................................................................................. 977 c) Monitor display lights up but front working lamp does not light up ........................................................................................................ 977 M-9 Abnormality in rear working lamp ............................................................................................................................................. 979 a) Neither monitor display nor rear working lamp light up .................................................................................................................... 979 b) Rear working lamp lights up but monitor display does not light up ......................................................................................................... 979 c) Monitor display lights up but working lamp does not light up .............................................................................................................. 979 M-10 Abnormality in transmission cut-off ......................................................................................................................................... 981 a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change................................................. 981 b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off function is actuated when pedal is depressed ............................... 981 c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated .......................................................... 981 d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF) ................................................................. 981 e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated ................................................................... 982 M-11 Abnormality in emergency steering normal display Emergency steering normal display does not light up ........................................................................ 983 M-12 Abnormality in emergency steering actuation display ......................................................................................................................... 984 a) Emergency steering actuation display does not light up .................................................................................................................... 984 b) Emergency steering actuation display stays lighted up...................................................................................................................... 984 M-13 Abnormality in parking brake dragging warning................................................................................................................................ 985 a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even when directional lever is at N ................................................ 985 b) When parking brake is applied, buzzer does not sound and CAUTION lamp does not light up even when directional lever is at position other than N ........................... 985 M-14 Abnormality in parking brake dragging warning (When joystick steering mode) ................................................................................................. 987 a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even when directional lever is at N ................................................ 987 b) When parking brake is applied, buzzer does not sound and CAUTION lamp does not light up even when directional lever is at position other than N ........................... 987 M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously, or they are not actuated ................................................... 989 a) Actuated continuously...................................................................................................................................................... 989 b) Not actuated............................................................................................................................................................... 989 M-16 Abnormality in buzzer........................................................................................................................................................ 990 a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check).................................................................................... 990 b) Buzzer always sounds ...................................................................................................................................................... 990 M-17 Condition of monitor switches is not stored in memory........................................................................................................................ 992 M-18 Service meter does not advance or advances while engine is stopped .......................................................................................................... 993 a) Service meter does not advance............................................................................................................................................. 993 b) Service meter advances while engine is stopped ............................................................................................................................ 993 M-19 Buzzer is not made to sound by transmission controller ...................................................................................................................... 994 M-20 Abnormality in auto-greasing system ......................................................................................................................................... 995 a) Forced greasing cannot be carried out ..................................................................................................................................... 995 b) Monitor display flashes rapidly (2 times/sec) ............................................................................................................................. 995 c) Monitor display flashes slowly (1 time/sec) ............................................................................................................................... 995 M-21 Failure code is not sent to main monitor (abnormality in network)............................................................................................................ 997 TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (V MODE).................................................................................................................................... 999 OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY ................................................................................1002 LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR .....................................................................................................................................1018 ELECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM .......................................................................................................................................1020 V-1 [E901] (Engine oil level below LOW level) is displayed .......................................................................................................................1022 V-2 [E902] (Engine oil pressure below specified pressure) is displayed ...........................................................................................................1022 V-4 [E904] (Engine coolant temperature above specified temperature) is displayed .................................................................................................1022 V-5 [E905] [Fuel level below specified level (before engine starts)] is displayed.................................................................................................1023 V-6 [E906] [Fuel level below specified level (While engine is running)] is displayed .............................................................................................1025 V-7 [E907] (Torque converter oil temperature above 120°C) is displayed............................................................................................................1027 V-8 [E908] (Torque converter oil temperature above 130°C) is displayed ...........................................................................................................1028 V-9 [E911] (Hydraulic oil temperature above 105°C) is displayed ..................................................................................................................1029 V-10 [E912] (Low front or rear brake oil pressure) is displayed ..................................................................................................................1030 V-11 [E913] (Low front brake oil pressure) is displayed ..........................................................................................................................1032 V-12 [E915] (Low rear brake oil pressure) is displayed ...........................................................................................................................1034 V-13 [916] (Disconnection or short circuit with chassis ground in battery fluid level sensor “1”) is displayed ...................................................................1036 V-14 [917] (Disconnection or short circuit with chassis ground in battery fluid level sensor “2”) is displayed ...................................................................1037 V-15 [918] (Disconnection or short circuit with chassis ground in battery fluid level sensor “3”) is displayed ...................................................................1038 V-16 [E925] [Brake fluid level below specified level (before engine starts)] is displayed ........................................................................................1039 V-17 [E926] [Brake fluid level below specified level (While engine is running)] is displayed......................................................................................1040 V-18 [E927] [Coolant level below LOW level (before engine starts] is displayed ...................................................................................................1041 V-19 [E928] [Coolant level below LOW level (While engine is running)] is displayed ...............................................................................................1042 V-20 [E931] (Clogging of transmission oil filter) is displayed ...................................................................................................................1043 V-21 [E932] [Clogging of air cleaner (1)] is displayed ...........................................................................................................................1045 V-22 [E933] [Clogging of air cleaner (2)] is displayed ...........................................................................................................................1047 V-23 [E934] [Clogging of air cleaner (3)] is displayed............................................................................................................................1048 V-24 [E935] [Clogging of air cleaner (4)] is displayed............................................................................................................................1049 V-25 [E937] (Abnormal charge by alternator) is displayed .........................................................................................................................1050 V-101 [E811] (Abnormality in NSW power source system) is displayed in history.....................................................................................................1051 V-102 [E812] (Short circuit with chassis ground in 24-V circuit of sensor power supply)...........................................................................................1052 V-103 [E813] (Short circuit with chassis ground in 12-V circuit of sensor power supply)...........................................................................................1054 V-104 [E814] (Short circuit with chassis ground in 5-V circuit of sensor power supply)............................................................................................1055 V-105 [E818] (Wrong connection of connector) is displayed in history..............................................................................................................1056 V-107 [E824] (Communication with CGC and engine controller is impossible) is displayed in history ................................................................................1057 V-108 [E825] (Abnormality in S-NET communication between VHMS – transmission controller) is displayed in history .................................................................1058 V-109 [E826] (Abnormality in S-NET communication between VHMS – modulated clutch controller) is displayed in history .............................................................1060 V-110 [E827] (Abnormality in S-NET communication between VHMS – work equipment controller) is displayed in history ...............................................................1062 V-111 [E828] (Abnormality in S-NET communication between VHMS – main monitor) is displayed in history ............................................................................1064 V-113 [E841] (Short circuit with power source in buzzer output system) is displayed in history....................................................................................1067 V-114 [E843] (Short circuit with power source in check lamp system) is displayed in history ......................................................................................1068 V-115 [E844] (Short circuit with power source in flash synchronizing signal system) is displayed in history ......................................................................1069 V-116 [E861] (Disconnection or short circuit with chassis ground in boom bottom pressure sensor system) is displayed in history...................................................1070 V-117 [E862] (Disconnection or short circuit with chassis ground in boom head pressure sensor system) is displayed in history.....................................................1072 V-118 [E863] (Disconnection or short circuit with chassis ground in rear brake oil pressure sensor system) is displayed in history................................................1074 V-119 [E864] (Disconnection or short circuit with chassis ground in work equipment relief pressure sensor system) is displayed in history.........................................1076 V-120 [E865] (Disconnection or short circuit with chassis ground in front brake oil pressure sensor system) is displayed in history ..............................................1078 V-121 [E866] (Disconnection or short circuit with chassis ground in transmission main relief pressure sensor system) is displayed in history......................................1080 V-122 [E867] (Disconnection or short circuit with chassis ground in steering relief pressure sensor system) is displayed in history...............................................1082 V-123 [E868] (Disconnection or short circuit with chassis ground in torque converter outlet oil pressure sensor system) is displayed in history ..................................1084 V-124 [E871] (Disconnection or short circuit with chassis ground in transmission modulation pressure sensor system) is displayed in history.......................................1086 V-125 [E872] (Disconnection or short circuit with chassis ground in transmission lubricating oil pressure sensor system) is displayed in history .................................1088 V-126 [E874] (Short circuit with chassis ground in torque converter oil temperature sensor system) is displayed in history .......................................................1090 V-127 [E875] (Short circuit with chassis ground and with power source in hydraulic oil temperature sensor system) is displayed in history ........................................1091 V-128 [E877] (Short circuit with chassis ground in ambient temperature sensor system) is displayed in history.....................................................................1092 V-129 [E878] (Disconnection or short circuit with chassis ground in PPC relief pressure sensor system) is displayed in history ...................................................1094 V-130 [E884] (Disconnection or short circuit with chassis ground in torque converter inlet oil pressure sensor system) is displayed in history ...................................1096 V-201 Disconnection or short circuit with power source in 24-V system of sensor power supply .....................................................................................1098 V-202 Disconnection or short circuit with power source in 12-V system of sensor power supply .....................................................................................1100 V-203 Disconnection or short circuit with power source in 5-V system of sensor power supply ......................................................................................1101 V-204 Disconnection or short circuit with chassis ground in buzzer output system..................................................................................................1102 V-205 Disconnection or short circuit with chassis ground in check lamp system.....................................................................................................1103 V-206 Disconnection or short circuit with chassis ground in flash synchronizing signal system ....................................................................................1104 V-207 Short circuit with power source in boom bottom pressure sensor system ......................................................................................................1105 V-208 Short circuit with power source in boom head pressure sensor system ........................................................................................................1106 V-209 Short circuit with power source in rear brake oil pressure sensor system....................................................................................................1107 V-210 Short circuit with power source in front brake oil pressure sensor system ..................................................................................................1108 V-211 Short circuit with power source in work equipment relief pressure sensor system.............................................................................................1109 V-212 Short circuit with power source in transmission relief pressure sensor system ..............................................................................................1110 V-213 Short circuit with power source in steering relief pressure sensor system ..................................................................................................1111 V-214 Short circuit with power source in torque converter outlet oil pressure sensor system.......................................................................................1112 V-215 Short circuit with power source in transmission modulation pressure sensor system ..........................................................................................1113 V-216 Disconnection or short circuit with power source in torque converter oil temperature sensor.................................................................................1114 V-217 Disconnection in hydraulic oil temperature sensor system....................................................................................................................1115 V-218 Disconnection in ambient temperature sensor system..........................................................................................................................1116 V-219 Short circuit with power source in PPC relief sensor system ................................................................................................................1117 V-220 Short circuit with chassis ground in fuel level sensor system...............................................................................................................1118 V-221 Short circuit with power source in battery fluid level sensor “1”...........................................................................................................1119 V-222 Short circuit with power source in battery fluid level sensor “2”...........................................................................................................1120 V-223 Short circuit with power source in battery fluid level sensor “3”...........................................................................................................1121 V-224 Short circuit with chassis ground or power source in brake fluid level sensor...............................................................................................1122 V-225 Short circuit with power source in coolant level sensor ....................................................................................................................1123 V-226 Short circuit with chassis ground or power source in transmission oil filter clogging sensor ...............................................................................1124 V-227 Short circuit with power source in air cleaner clogging (1) relay system ...................................................................................................1125 V-228 Short circuit with power source in air cleaner clogging (2) relay system ...................................................................................................1126 V-229 Short circuit with power source in air cleaner clogging (3) relay system ...................................................................................................1126 V-230 Short circuit with power source in air cleaner clogging (4) relay system ...................................................................................................1127 V-231 Abnormal charge by alternator...............................................................................................................................................1128 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...........................................................................................................................1129 BEFORE CARRYING OUT TROUBLESHOOTING OF WORK EQUIPMENT HYDRAULIC SYSTEM (HOW TO USE MULTI-MONITOR).................................................................................1130 GENERAL TROUBLESHOOTING OF WORK EQUIPMENT HYDRAULIC SYSTEM .......................................................................................................................1140 WORK EQUIPMENT HYDRAULIC SYSTEM GROUP.............................................................................................................................................1142 BEFORE CARRYING OUT TROUBLESHOOTING OF STEERING HYDRAULIC SYSTEM (HOW TO USE MULTI-MONITOR).......................................................................................1203 CONFIRMATION ON SPECIFICATION VALUES RELATED TO STEERING (CONFIRMATION OF LOW PERFORMANCE) .......................................................................................1215 GENERAL TROUBLESHOOTING OF STEERING HYDRAULIC SYSTEM..............................................................................................................................1216 STEERING HYDRAULIC SYSTEM GROUP...................................................................................................................................................1217 GENERAL TROUBLESHOOTING OF BRAKE HYDRAULIC SYSTEM.................................................................................................................................1257 BRAKE HYDRAULIC SYSTEM GROUP......................................................................................................................................................1258 IMPORTANT TROUBLESHOOTING ITEMS...................................................................................................................................................1310 H-1 Torque converter overheat.................................................................................................................................................1310 H-2 Performance or response of steering is degraded...........................................................................................................................1312 H-3 Joystick lever is heavy...................................................................................................................................................1314 H-4 Steering is unstable or jolts.............................................................................................................................................1316 H-5 Wheel brake does not work or its performance is low.......................................................................................................................1318 H-6 Lift arm speed is low or lift arm rising force is insufficient............................................................................................................1320 H-7 Large shocks are made when lift arm stops.................................................................................................................................1324 H-8 Hydraulic oil overheat....................................................................................................................................................1325 COMMON TROUBLESHOOTING ITEMS......................................................................................................................................................1328 H-1 Machine does not move.....................................................................................................................................................1328 H-2 Machine lacks power or speed (every speed range) .........................................................................................................................1329 H-3 Excessive time lag when starting machine or shifting gear.................................................................................................................1330 H-4 Torque converter oil temperature is high..................................................................................................................................1331 H-4 Torque converter oil temperature is high..................................................................................................................................1332 H-6 Turning, response of steering is poor.....................................................................................................................................1333 H-7 Joystick lever is heavy...................................................................................................................................................1334 H-8 Steering wheel shakes or jerks............................................................................................................................................1335 H-9 Turning radius is different between left and right at maximum steering....................................................................................................1336 H-10 Wheel brakes do not work or braking effect is poor.......................................................................................................................1336 H-11 Wheel brakes are not released or brakes drag.............................................................................................................................1337 H-12 Boom does not rise.......................................................................................................................................................1338 H-13 Boom moves slowly or does not have sufficient lifting power..............................................................................................................1339 H-14 When raising boom, becomes slow at certain height........................................................................................................................1340 H-15 Boom cylinder cannot hold down bucket....................................................................................................................................1340 H-16 Boom has large amount of hydraulic drift.................................................................................................................................1340 H-17 Boom fluctuates while working............................................................................................................................................1341 H-18 Boom drops momentarily when lever is operated from HOLD to RAISE.........................................................................................................1341 H-19 Bucket does not tilt.....................................................................................................................................................1342 H-20 Bucket is moves slowly or has insufficient tilt back power...............................................................................................................1343 H-21 Bucket movement becomes slow during tilt back............................................................................................................................1344 H-22 Bucket cylinder cannot hold down bucket..................................................................................................................................1344 H-23 Bucket has large amount of hydraulic drift...............................................................................................................................1344 H-24 Bucket fluctuates while traveling under load (work equipment valve HOLD).................................................................................................1345 H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT .......................................................................................................1345 H-26 Boom and bucket levers do not move smoothly..............................................................................................................................1346 TROUBLESHOOTING BY FAILUE CODE (DISPLAY OF CODE)......................................................................................................................................1347 FAILURE CODES LIST................................................................................................................................................................1350 BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM1........................................................................................................................1359 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE....................................................................................................................................1362 Failure code [15B0NX] Transmission oil filter clogging............................................................................................................................1364 Failure code [2G41MB] Front and rear brake pressure reduction (When engine is started)............................................................................................1366 Failure code [2G42ZG] Front brake pressure reduction (While engine is running)....................................................................................................1368 Failure code [2G43ZG] Rear brake pressure reduction (While engine is running).....................................................................................................1370 Failure code [AA1ANX] Air cleaner clogging [1]....................................................................................................................................1372 Failure code [AA1BNX] Air cleaner clogging [2]....................................................................................................................................1374 Failure code [AA1CNX] Air cleaner clogging [3]....................................................................................................................................1376 Failure code [AA1DNX] Air cleaner clogging [4]....................................................................................................................................1378 Failure code [AB00MA] Defective alternator charge.................................................................................................................................1380 Failure code [B@BCZK] Coolant level reduction (Before engine is started)..........................................................................................................1382 Failure code [b@BCZK] Coolant level reduction (While engine is running)...........................................................................................................1384 Failure code [B@BFZK] Fuel level reduction (Before engine is started).............................................................................................................1386 Failure code [b@BFZK] Fuel level reduction (While engine is running)..............................................................................................................1388 Failure code [B@C5ZK] Brake oil level reduction (Before engine is started)........................................................................................................1390 Failure code [b@C5ZK] Brake oil level reduction (While engine is running).........................................................................................................1391 Failure code [B@CENS] High torque converter oil temperature (above 120°C).........................................................................................................1392 Failure code [b@CENS] Abnormally high torque converter oil temperature (above 130°C)..............................................................................................1393 Failure code [B@GAZK] Battery electrolyte level reduction [1].....................................................................................................................1394 Failure code [B@GBZK] Battery electrolyte level reduction [2].....................................................................................................................1395 Failure code [B@GCZK] Battery electrolyte level reduction [3].....................................................................................................................1396 Failure code [B@HANS] Abnormally high hydraulic oil temperature (overheat)........................................................................................................1397 Failure code [D100KZ] Caution buzzer system abnormality...........................................................................................................................1398 Failure code [D160KZ] Backup lamp system abnormality..............................................................................................................................1399 Failure code [D191KZ] Steering neutral interlock relay system abnormality.........................................................................................................1400 Failure code [D5ZPKB] Check lamp system abnormality (Hot short)...................................................................................................................1401 Failure code [D5ZQKB] Blink synchronizing signal power supply abnormality (Hot short).............................................................................................1402 Failure code [DAF0KR] Monitor panel (Main monitor) S-net communication error......................................................................................................1403 Failure code [DAQ0KT] Transmission controller abnormality.........................................................................................................................1405 Failure code [DAQSKR] Transmission controller S-net communication abnormality.....................................................................................................1406 Failure code [DB9SKR] Work equipment controller S-net communication error.........................................................................................................1408 Failure code [DBB0KK] VHMS power supply abnormality...............................................................................................................................1410 Failure code [DBB0KQ] VHMS selector connector wrong connection....................................................................................................................1412 Failure code [DBB3KK] VHMS backup power supply abnormality........................................................................................................................1414 Failure code [DBB5KP] VHMS sensor power supply (5 V) abnormality..................................................................................................................1416 Failure code [DBB6KP] VHMS sensor power supply (24 V) abnormality.................................................................................................................1417 Failure code [DBB7KP] VHMS sensor power supply (12 V) abnormality.................................................................................................................1419 Failure code [DBBQKR] CAN communication error (VHMS controller – multi-monitor)...................................................................................................1420 Failure code [DBBRKR] CAN communication error (J1939).............................................................................................................................1421 Failure code [DBD0KT] Modulated clutch system abnormality.........................................................................................................................1424 Failure code [DBDSKR] S-net communication error (MOD/C controller)................................................................................................................1426 Failure code [DDA7LD] RPM set ON/OFF switch system abnormality....................................................................................................................1428 Failure code [DDD7KX] Vehicle speed control dial system abnormality...............................................................................................................1430 Failure code [DDD8KX] Drive force control dial system abnormality.................................................................................................................1432 Failure code [DDF2KZ] Joystick F, N, R selector switch system abnormality.........................................................................................................1434 Failure code [DDF3KZ] Joystick shift up/down switch system abnormality............................................................................................................1436 Failure code [DDNGL4] Boom PPC pressure switch system abnormality.................................................................................................................1438 Failure code [DDNJL4] Work equipment PPC pressure switch system abnormality.......................................................................................................1440 Failure code [DDQ2L6] Steering lock pressure switch system abnormality............................................................................................................1442 Failure code [DDT8KA] 1st, 2nd or 3rd fill signal system abnormality..............................................................................................................1444 Failure code [dDT8KA] Gear speed fill signal abnormality (Disconnection)..........................................................................................................1446 Failure code [DDT8KB] Gear speed fill signal abnormality (Ground fault)...........................................................................................................1447 Failure code [DDTDKA] F or R fill signal system abnormality (Disconnection).......................................................................................................1448 Failure code [DDTDKB] F or R fill signal system abnormality (Hot short)...........................................................................................................1450 Failure code [DDTKKB] 1st fill signal system abnormality..........................................................................................................................1451 Failure code [DDTLKB] 2nd fill signal system abnormality..........................................................................................................................1452 Failure code [DDTMKB] 3rd fill signal system abnormality..........................................................................................................................1453 Failure code [DDTNKB] R fill signal system abnormality............................................................................................................................1454 Failure code [DDTQKB] F fill signal system abnormality............................................................................................................................1455 Failure code [DGE5KX] Ambient temperature sensor system abnormality...............................................................................................................1456 Failure code [DGF1KB] Transmission oil temperature sensor system abnormality......................................................................................................1457 Failure code [DGT1KX] Torque converter oil temperature sensor system abnormality..................................................................................................1458 Failure code [DGT2KX] Hydraulic oil temperature sensor system abnormality.........................................................................................................1459 Failure code [DH20KX] Torque converter outlet oil pressure sensor system abnormality..............................................................................................1460 Failure code [DH24KX] Work equipment relief oil pressure sensor system abnormality................................................................................................1462 Failure code [DHPCKX] Boom bottom pressure sensor system abnormality..............................................................................................................1464 Failure code [DHPDKX] Boom head pressure sensor system abnormality................................................................................................................1466 Failure code [DHT3KX] Transmission main pressure sensor system abnormality........................................................................................................1468 Failure code [DHT4KX] Main PPC oil pressure sensor system abnormality.............................................................................................................1470 Failure code [DHT5KX] Torque converter inlet oil pressure sensor system abnormality...............................................................................................1472 Failure code [DHT8KX] Steering oil pressure sensor system abnormality.............................................................................................................1474 Failure code [DHT9KX] Transmission modulated pressure sensor system abnormality...................................................................................................1476 Failure code [DHTAKX] Transmission lubricating oil pressure sensor system abnormality.............................................................................................1478 Failure code [DHU2KX] Front brake oil pressure sensor system abnormality..........................................................................................................1480 Failure code [DHU3KX] Rear brake oil pressure sensor system abnormality...........................................................................................................1482 Failure code [DK10L5] Accelerator pedal signal system abnormality.................................................................................................................1484 Failure code [DK5FKX] Steering lever angle sensor system abnormality..............................................................................................................1486 Failure code [DKA0KX] Boom angle sensor system abnormality........................................................................................................................1488 Failure code [DKD0KX] Frame angle sensor system abnormality.......................................................................................................................1490 Failure code [DKD0KZ] Steering frame angle and lever angle sensors are shifted....................................................................................................1492 Failure code [DLE2KZ] Engine speed sensor system abnormality......................................................................................................................1494 Failure code [dLE2KZ] Engine speed sensor system abnormality......................................................................................................................1496 Failure code [DLF6L8] Wheel rotation signal system abnormality....................................................................................................................1498 Failure code [DLFAKA] Modulated clutch speed sensor system abnormality............................................................................................................1499 Failure code [DLT2KZ] Modulated clutch output speed sensor system abnormality.....................................................................................................1500 Failure code [DLT3KZ] Travel speed sensor system abnormality......................................................................................................................1502 Failure code [DLt3KZ] Travel speed sensor system abnormality......................................................................................................................1504 Failure code [dLT3KZ] Travel speed sensor system abnormality......................................................................................................................1506 Failure code [DV00KB] Buzzer output system abnormality (Hot short)................................................................................................................1508 Failure code [DW23KB] F bypass valve system abnormality (Hot short)...............................................................................................................1509 Failure code [DW23KZ] F bypass valve system abnormality(Disconnection or hot short)...............................................................................................1510 Failure code [DW24KB] R bypass valve system abnormality (Hot short)...............................................................................................................1511 Failure code [DW24KZ] R bypass valve system abnormality (Disconnection or hot short)..............................................................................................1512 Failure code [DW25KB] 1st bypass valve system abnormality (Hot short).............................................................................................................1513 Failure code [DW25KZ] 1st bypass valve system abnormality (Disconnection or hot short)............................................................................................1514 Failure code [DW72KZ] Boom kick-out solenoid system abnormality...................................................................................................................1515 Failure code [DWJ2KZ] R drain valve system abnormality............................................................................................................................1516 Failure code [DWNAKZ] Modulation NC solenoid system abnormality...................................................................................................................1517 Failure code [DXF0KZ] Steering basic pressure EPC solenoid system abnormality.....................................................................................................1519 Failure code [DXH4KZ] Transmission 1st solenoid system abnormality................................................................................................................1520 Failure code [DXH5KZ] Transmission 2nd solenoid system abnormality................................................................................................................1522 Failure code [DXH6KZ] Transmission 3rd solenoid system abnormality................................................................................................................1524 Failure code [DXH7KZ] Transmission R solenoid system abnormality..................................................................................................................1526 Failure code [DXH8KZ] Transmission F solenoid system abnormality..................................................................................................................1528 Failure code [DXHNKB] Damping solenoid system abnormality (Short circuit).........................................................................................................1530 Failure code [DXHNKY] Damping solenoid system abnormality (Short circuit to power line)...........................................................................................1531 Failure code [DXHNKZ] Damping solenoid system abnormality (Disconnection or short circuit)........................................................................................1532 Failure code [DXHPKZ] Modulation ECMV solenoid system abnormality.................................................................................................................1533 TROUBLESHOOTING OF ELECTRICAL SYSTEM (Without failure code) (E-MODE).................................................................................................................1535 BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM.........................................................................................................................1538 INFORMATION IN TROUBLESHOOTING TABLE..............................................................................................................................................1542 TRANSMISSION CONTROLLER SYSTEM....................................................................................................................................................1544 E-1 Auto/Manual selector switch system abnormality............................................................................................................................1544 E-2 Kick-down switch system abnormality.......................................................................................................................................1545 E-3 Transmission cut-off signal system abnormality............................................................................................................................1546 E-4 Steering lock switch signal system abnormality............................................................................................................................1547 E-5 Neutralizer relay signal abnormality......................................................................................................................................1548 E-6 Buzzer signal system abnormality..........................................................................................................................................1549 E-7 Network system abnormality................................................................................................................................................1550 E-8 Transmission controller power supply system abnormality...................................................................................................................1552 E-9 Ground fault or short circuit in travel speed sensor system...............................................................................................................1553 E-10 Ground fault or short circuit in modulated clutch output speed sensor system.............................................................................................1554 E-11 Disconnection in transmission oil temperature sensor.....................................................................................................................1555 E-12 F1 (Forward 1st) signal system abnormality...............................................................................................................................1556 E-13 Auto shift indicator lamp system abnormality.............................................................................................................................1557 MODULATED CLUTCH CONTROLLER SYSTEM................................................................................................................................................1559 E-14 Ground fault or short circuit in boom raise/lower or bucket tilt/dump pressure switch system.............................................................................1559 E-15 Disconnection in F ECMV fill switch system...............................................................................................................................1560 E-16 Disconnection in R ECMV fill switch system...............................................................................................................................1561 E-17 Disconnection in RPM set switch..........................................................................................................................................1562 E-18 Electronic governor voltage command system abnormality...................................................................................................................1563 E-19 Transmission cut-off signal system abnormality...........................................................................................................................1564 E-20 Modulated clutch ECMV fill switch system abnormality.....................................................................................................................1565 E-21 Right brake pedal switch system abnormality..............................................................................................................................1566 E-22 Travel speed control ON/OFF switch system abnormality....................................................................................................................1567 E-23 RPM set ON/OFF switch system abnormality.................................................................................................................................1568 E-24 Engine speed output signal system abnormality............................................................................................................................1569 E-25 Modulated clutch controller power supply abnormality.....................................................................................................................1570 E-26 Network system abnormality...............................................................................................................................................1571 E-27 F1 (Forward 1st) input signal system abnormality.........................................................................................................................1571 WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER SYSTEM (JOYSTICK STEERING CONTROL SYSTEM).........................................................................................1572 E-28 Ground fault or short circuit in travel speed sensor system..............................................................................................................1572 E-29 Right and left steering speeds are different.............................................................................................................................1574 E-30 Console switch abnormality (Steering lever angle sensor or frame angle sensor cannot be adjusted)........................................................................1575 E-31 Power supply voltage abnormality.........................................................................................................................................1576 WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER SYSTEM (REMOTE BOOM POSITIONER CONTROL SYSTEM)....................................................................................1577 E-32 Remote positioner sensor cannot be adjusted..............................................................................................................................1577 E-33 Engine speed signal system abnormality...................................................................................................................................1578 E-34 Remote positioner "Raise"/"Lower" LED does not light.....................................................................................................................1579 E-35 Remote positioner "Raise" stop lamp (multi-monitor screen) does not blink (for 2.5 sec)..................................................................................1580 E-36 Remote positioner "Lower" stop lamp (multi-monitor screen) does not blink (for 2.5 sec)..................................................................................1580 E-37 Switch operation buzzer does not sound...................................................................................................................................1581 E-38 Boom stop shocks are made (Boom detent switch abnormality)...............................................................................................................1582 E-39 Short circuit in boom "Raise"/"Lower" sensor pressure switch.............................................................................................................1584 VHMS CONTROLLER SYSTEM............................................................................................................................................................1586 E-40 Disconnection or hot short in sensor power supply 24 V system............................................................................................................1586 E-41 Disconnection or hot short in sensor power supply 12V system.............................................................................................................1588 E-42 Disconnection or hot short in sensor power supply 5 V system.............................................................................................................1589 E-43 Disconnection or ground fault in buzzer output system....................................................................................................................1590 E-44 Disconnection or ground fault in check lamp system.......................................................................................................................1591 E-45 Disconnection or ground fault in blink synchronizing signal system.......................................................................................................1592 E-46 Hot short in boom bottom pressure sensor system..........................................................................................................................1593 E-47 Hot short in boom head pressure sensor system............................................................................................................................1594 E-48 Hot short in rear brake oil pressure sensor system.......................................................................................................................1595 E-49 Hot short in front brake oil pressure sensor system......................................................................................................................1596 E-50 Hot short in work equipment relief oil pressure sensor system............................................................................................................1597 E-51 Hot short in transmission main relief oil pressure sensor system.........................................................................................................1598 E-52 Hot short in steering relief oil pressure sensor system..................................................................................................................1599 E-53 Hot short in torque converter outlet oil pressure sensor system..........................................................................................................1600 E-54 Hot short in transmission modulated oil pressure sensor system...........................................................................................................1601 E-55 Disconnection or hot short in torque converter oil temperature sensor system.............................................................................................1602 E-56 Disconnection in hydraulic oil temperature sensor system.................................................................................................................1603 E-57 Disconnection in ambient temperature sensor system.......................................................................................................................1604 E-58 Hot short in main PPC oil pressure sensor system.........................................................................................................................1605 E-59 Ground fault in fuel level sensor........................................................................................................................................1606 E-60 Hot short in battery electrolyte level sensor [1] system.................................................................................................................1607 E-61 Hot short in battery electrolyte level sensor [2] system.................................................................................................................1608 E-62 Hot short in battery electrolyte level sensor [3] system.................................................................................................................1609 E-63 Ground fault or hot short in brake oil level sensor system...............................................................................................................1610 E-64 Hot short in coolant level sensor system.................................................................................................................................1611 E-65 Ground fault or hot short in transmission oil filter sensor system.......................................................................................................1612 E-66 Hot short in dust indicator relay [1] system.............................................................................................................................1613 E-67 Hot short in dust indicator relay [2] system.............................................................................................................................1614 E-68 Hot short in dust indicator relay [3] system.............................................................................................................................1615 E-69 Hot short in dust indicator relay [4] system.............................................................................................................................1616 E-70 Ground fault in alternator charge system.................................................................................................................................1617 MAIN MONITOR SYSTEM...............................................................................................................................................................1618 E-71 Main monitor does not operate............................................................................................................................................1618 E-72 All main monitor items keep lighting when engine is started (PRE-LUBE) just (within 3 sec) after starting switch is turned ON............................................1620 E-73 Speedometer does not indicate normally...................................................................................................................................1624 E-74 Gear shift indicator abnormality.........................................................................................................................................1625 E-75 Winker display does not light............................................................................................................................................1628 E-76 Parking display abnormality..............................................................................................................................................1629 E-77 Night lamp does not light................................................................................................................................................1630 E-78 Front working lamp abnormality...........................................................................................................................................1632 E-79 Rear working lamp abnormality............................................................................................................................................1634 E-80 Transmission cut-off function abnormality................................................................................................................................1636 E-81 Emergency steering normal display abnormality............................................................................................................................1639 E-82 Emergency steering operation display abnormality.........................................................................................................................1640 E-83 Parking brake dragging alarm abnormality.................................................................................................................................1641 E-84 Parking brake dragging alarm abnormality (Joystick steering mode)........................................................................................................1642 E-85 When parking brake dragging alarm is turned ON, buzzer and caution lamp operate continuously or do not operate at all....................................................1644 E-86 Caution buzzer abnormality...............................................................................................................................................1645 E-87 Monitor switch state is not saved........................................................................................................................................1647 E-88 Service meter does not advance or it advances while engine is stopped....................................................................................................1648 E-89 Transmission controller does not sound buzzer............................................................................................................................1650 E-90 Auto grease system abnormality...........................................................................................................................................1651 E-91 Failure code is not transferred to main monitor (Network abnormality)....................................................................................................1653 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................1655 How to read this manual...................................................................................................................................................................1657 Coating materials list....................................................................................................................................................................1659 Special tool list.........................................................................................................................................................................1662 Sketches of special tools.................................................................................................................................................................1667 Procedure for flushing work equipment and steering hydraulic circuit......................................................................................................................1713 Procedure for flushing brake hydraulic circuit............................................................................................................................................1718 Bleeding air from piston pump.............................................................................................................................................................1723 Bleeding air from work equipment circuit and steering circuit.............................................................................................................................1724 Bleeding air from brake circuit...........................................................................................................................................................1726 Removal and installation of DT connector pin..............................................................................................................................................1728 Removal and installation of HD connector pin..............................................................................................................................................1730 Repair procedure of HD connector pin harness..............................................................................................................................................1731 Removal and installation of engine assembly...............................................................................................................................................1732 Removal and installation of damper assembly...............................................................................................................................................1760 Disassembly and assembly of damper assembly...............................................................................................................................................1766 Removal and installation of radiator and hydraulic oil cooler assembly....................................................................................................................1774 Procedure for disassembly and assembly of MESABI oil cooler assembly .....................................................................................................................1786 Disassembly and assembly of MESABI oil cooler assembly....................................................................................................................................1789 Removal and installation of fuel cooler assembly..........................................................................................................................................1797 Removal and installation of torque converter and transmission oil cooler assembly.........................................................................................................1802 Removal and installation of bumper and fuel tank assembly.................................................................................................................................1805 Removal and installation of hood assembly.................................................................................................................................................1808 Removal and installation of bulkhead assembly.............................................................................................................................................1810 Disassembly and assembly of ECMV..........................................................................................................................................................1814 Removal and installation of torque converter and transmission assembly....................................................................................................................1821 Disconnection and connection of transmission assembly and torque converter assembly.......................................................................................................1859 Disconnection and connection of torque converter assembly and PTO • transfer assembly.....................................................................................................1868 Disassembly and assembly of torque converter assembly.....................................................................................................................................1871 Disassembly and assembly of modulated clutch assembly.....................................................................................................................................1882 Disassembly and assembly of PTO and transfer assembly.....................................................................................................................................1886 Disconnection and connection of transmission assembly and transfer • parking brake assembly...............................................................................................1900 Disassembly and assembly of transmission assembly.........................................................................................................................................1908 Disassembly and assembly of transfer assembly.............................................................................................................................................1932 Disassembly and assembly of parking brake assembly........................................................................................................................................1940 Removal and installation of parking brake assembly (from machine body)....................................................................................................................1943 Disassembly and assembly of drive shaft assembly..........................................................................................................................................1947 Removal and installation of front axle assembly...........................................................................................................................................1956 Removal and installation of front final drive assembly....................................................................................................................................1960 Removal and installation of rear axle assembly............................................................................................................................................1964 Disconnection and connection of differential assembly.....................................................................................................................................1980 Disassembly and assembly of differential assembly.........................................................................................................................................1982 Removal and installation of rear final drive assembly.....................................................................................................................................1993 Disassembly and assembly of final drive and brake assembly................................................................................................................................1998 Removal and installation of center support assembly.......................................................................................................................................2010 Disassembly and assembly of center support assembly.......................................................................................................................................2012 Removal and installation of steering demand valve assembly................................................................................................................................2016 Removal and installation of steering cylinder assembly....................................................................................................................................2019 Removal and installation of steering pump, control pump and PPC pump assembly.............................................................................................................2025 Removal and installation of switching pump assembly.......................................................................................................................................2032 Removal and installation of emergency diverter valve assembly.............................................................................................................................2035 Removal and installation of emergency steering pump assembly..............................................................................................................................2040 Removal and installation of brake accumulator charge valve assembly.......................................................................................................................2044 Removal and installation of brake oil cooler assembly.....................................................................................................................................2046 Removal and installation of brake oil tank assembly.......................................................................................................................................2049 Removal and installation of transmission, brake cooling and brake pump assembly...........................................................................................................2052 Disconnecting procedure for front frame and rear frame....................................................................................................................................2056 Removal and installation of center hinge pin..............................................................................................................................................2057 Removal and installation of work equipment control valve assembly.........................................................................................................................2074 Removal and installation of work equipment pump assembly (Right side).....................................................................................................................2092 Removal and installation of work equipment pump assembly (Left side)......................................................................................................................2096 Removal and installation of hydraulic tank and filter case assembly.......................................................................................................................2100 Removal and installation of bucket cylinder assembly......................................................................................................................................2106 Removal and installation of lift cylinder assembly........................................................................................................................................2120 Disassembly and assembly of hydraulic cylinder assembly...................................................................................................................................2138 Removal and installation of work equipment assembly.......................................................................................................................................2142 Run-in procedure for bucket pin...........................................................................................................................................................2223 Run-in procedure for lift arm pin.........................................................................................................................................................2225 Removal and installation of air conditioner unit assembly.................................................................................................................................2228 Removal and installation of operator's cab and floor assembly.............................................................................................................................2230 Removal and installation of operator's cab assembly.......................................................................................................................................2233 Disassembly and assembly of operator's seat assembly......................................................................................................................................2234 Removal and installation of controller assemblies.........................................................................................................................................2267 SERVICE KIT PARTS LIST....................................................................................................................................................................2269 40 MAINTENANCE STANDARD.......................................................................................................................................................................2333 ENGINE MOUNT..............................................................................................................................................................................2334 TRANSMISSION MOUNT .......................................................................................................................................................................2336 RADIATOR AND OIL COOLER...................................................................................................................................................................2338 DAMPER ...................................................................................................................................................................................2340 TORQUE CONVERTER, TRANSMISSION, BRAKE COOLING AND BRAKE PUMP .............................................................................................................................2341 INPUT TRANSFER. PTO ......................................................................................................................................................................2344 MODULATED CLUTCH ........................................................................................................................................................................2346 TORQUE CONVERTER .........................................................................................................................................................................2347 TRANSMISSION .............................................................................................................................................................................2348 TRANSFER .................................................................................................................................................................................2352 MAINRELIEF, TORQUE CONVERTER RELIEF VALVE ................................................................................................................................................2354 TORQUE CONVERTER REGULATOR VALVE .........................................................................................................................................................2356 BY-PASS FILL VALVE .......................................................................................................................................................................2357 BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE ...............................................................................................................................................2358 ECMV .....................................................................................................................................................................................2359 LUBRICATIONG OIL RELIEF VALVE ............................................................................................................................................................2361 DRIVE SHAFT ..............................................................................................................................................................................2362 CENTER SUPPORT ...........................................................................................................................................................................2363 DIFFERENTIAL .............................................................................................................................................................................2364 FINAL DRIVE...............................................................................................................................................................................2368 AXLE MOUNT ...............................................................................................................................................................................2372 CENTER HINGE PIN .........................................................................................................................................................................2374 STEERING PUMP ............................................................................................................................................................................2378 SWITCH PUMP ..............................................................................................................................................................................2379 STEERING DEMAND VALVE ....................................................................................................................................................................2380 DIVERTER VALVE ...........................................................................................................................................................................2382 STEERING CYLINDER MOUNT ..................................................................................................................................................................2383 EMERGENCY STEERING PUMP ..................................................................................................................................................................2386 BRAKE VALVE ..............................................................................................................................................................................2387 SLACK ADJUSTER ...........................................................................................................................................................................2389 BRAKE ....................................................................................................................................................................................2390 PARDING BRAKE ............................................................................................................................................................................2392 WORK EQUIPMENT PUMP NO.1 .................................................................................................................................................................2394 WORK EQUIPMENT PUMP NO.2 .................................................................................................................................................................2395 PPC VALVE ................................................................................................................................................................................2396 PPC RELIEF VALVE .........................................................................................................................................................................2398 PUMP CONTROL RELIEF VALVE ................................................................................................................................................................2399 MAIN CONTROL VALVE .......................................................................................................................................................................2400 HYDRAULIC CYLINDER .......................................................................................................................................................................2402 BUCKET POSITIONER AND REMOTE POSITIONER ..................................................................................................................................................2405 BUCKET LINKAGE ...........................................................................................................................................................................2406 90 OTHERS.....................................................................................................................................................................................2411 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................................................2412 BRAKE CIRCUIT DIAGRAM.....................................................................................................................................................................2414 WORK EUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/2) Serial No. : 50001 – 50084..................................................................................................................2417 WORK EUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/2) Serial No. : 50001 – 50084..................................................................................................................2419 WORK EUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/2) Serial No. : 50085 and up...................................................................................................................2421 WORK EUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/2) Serial No. : 50085 and up...................................................................................................................2423 ELECTRICAL CIRCUIT DIAGRAM (1/7) Serial No. : 50001 – 50038 (Standard specification machine)..............................................................................................2425 ELECTRICAL CIRCUIT DIAGRAM (1/7) Serial No. : 50001 – 50038 (Trainer seat specification machine)..........................................................................................2427 ELECTRICAL CIRCUIT DIAGRAM (2/7) Serial No. : 50001 – 50038...............................................................................................................................2429 ELECTRICAL CIRCUIT DIAGRAM (3/7) Serial No. : 50001 – 50038...............................................................................................................................2431 ELECTRICAL CIRCUIT DIAGRAM (4/7) Serial No. : 50001 – 50038...............................................................................................................................2433 ELECTRICAL CIRCUIT DIAGRAM (5/7) Serial No. : 50001 – 50038...............................................................................................................................2435 ELECTRICAL CIRCUIT DIAGRAM (6/7) Serial No. : 50001 – 50038...............................................................................................................................2437 ELECTRICAL CIRCUIT DIAGRAM (7/7) Serial No. : 50001 – 50038...............................................................................................................................2439 ELECTRICAL CIRCUIT DIAGRAM (1/7) Serial No. : 50039 – 50074...............................................................................................................................2441 ELECTRICAL CIRCUIT DIAGRAM (2/7) Serial No. : 50039 – 50074...............................................................................................................................2443 ELECTRICAL CIRCUIT DIAGRAM (3/7) Serial No. : 50039 – 50074...............................................................................................................................2445 ELECTRICAL CIRCUIT DIAGRAM (4/7) Serial No. : 50039 – 50074...............................................................................................................................2447 ELECTRICAL CIRCUIT DIAGRAM (5/7) Serial No. : 50039 – 50074...............................................................................................................................2449 ELECTRICAL CIRCUIT DIAGRAM (6/7) Serial No. : 50039 – 50074...............................................................................................................................2451 ELECTRICAL CIRCUIT DIAGRAM (7/7) Serial No. : 50039 – 50074...............................................................................................................................2453 ELECTRICAL CIRCUIT DIAGRAM (1/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2455 ELECTRICAL CIRCUIT DIAGRAM (2/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2457 ELECTRICAL CIRCUIT DIAGRAM (3/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2459 ELECTRICAL CIRCUIT DIAGRAM (4/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2461 ELECTRICAL CIRCUIT DIAGRAM (5/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2463 ELECTRICAL CIRCUIT DIAGRAM (6/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2465 ELECTRICAL CIRCUIT DIAGRAM (7/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2467 ELECTRICAL CIRCUIT DIAGRAM (8/8) Serial No. : 50075 – 50084, 50086, 50087.................................................................................................................2469 ELECTRICAL CIRCUIT DIAGRAM (1/11) Serial No. : 50085, 50088 and up........................................................................................................................2471 ELECTRICAL CIRCUIT DIAGRAM (2/11) Serial No. : 50085, 50088 and up........................................................................................................................2473 ELECTRICAL CIRCUIT DIAGRAM (3/11) Serial No. : 50085, 50088 and up........................................................................................................................2475 ELECTRICAL CIRCUIT DIAGRAM (4/11) Serial No. : 50085, 50088 and up........................................................................................................................2477 ELECTRICAL CIRCUIT DIAGRAM (5/11) Serial No. : 50085, 50088 and up........................................................................................................................2479 ELECTRICAL CIRCUIT DIAGRAM (6/11) Serial No. : 50085, 50088 and up........................................................................................................................2481 ELECTRICAL CIRCUIT DIAGRAM (7/11) Serial No. : 50085, 50088 and up........................................................................................................................2483 ELECTRICAL CIRCUIT DIAGRAM (8/11) Serial No. : 50085, 50088 and up........................................................................................................................2485 ELECTRICAL CIRCUIT DIAGRAM (9/11) Serial No. : 50085, 50088 and up........................................................................................................................2487 ELECTRICAL CIRCUIT DIAGRAM (10/11) Serial No. : 50085, 50088 and up.......................................................................................................................2489 ELECTRICAL CIRCUIT DIAGRAM (11/11) Serial No. : 50085, 50088 and up.......................................................................................................................2491
DESCRIPTION:
KOMATSU WA1200-3 SHOP MANUAL SEBM018237 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes, helmet and protective goggles. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
S.S 29/12/24
