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Komatsu WA320 -6, WA320PZ-6 Wheel Loader Service Repair Manual – PDF Download
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- Komatsu WA320 -6, WA320PZ-6 Wheel Loader Service Repair Manual
- PUBLICATION NUMBER:SEN03911-03
- SERIAL NUMBERS : WA320- 70001 and up
WA320PZ-70001 and up
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Description
Komatsu WA320 -6, WA320PZ-6 Wheel Loader Service Repair Manual
KOMATSU WA320 -6, WA320PZ-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
Komatsu WA320 -6, WA320PZ-6 Wheel Loader Service Repair Manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA320 -6, WA320PZ-6 Wheel Loader Service Repair Manual
COVER ................................................................................................................................ 1 00 Index and foreword................................................................................................................. 0 100 Index......................................................................................................................... 2 Composition of shop manual.................................................................................................... 3 Table of contents............................................................................................................. 5 200 Foreword and general information.............................................................................................. 16 Safety notice................................................................................................................. 17 How to read the shop manual................................................................................................... 22 Explanation of terms for maintenance standard................................................................................. 24 Handling of electric equipment and hydraulic component........................................................................ 26 Handling of connectors newly used for engines................................................................................. 35 How to read electric wire code................................................................................................ 38 Precautions when carrying out operation....................................................................................... 41 Method of disassembling and connecting push-pull type coupler................................................................. 44 Standard tightening torque table.............................................................................................. 47 Conversion table.............................................................................................................. 51 01 Specification...................................................................................................................... 0 100 Specification and technical data.............................................................................................. 58 Specification dimension drawing............................................................................................... 60 Specifications................................................................................................................ 61 Weight table.................................................................................................................. 65 Table of fuel, coolant and lubricants......................................................................................... 67 10 Structure, function and maintenance standard....................................................................................... 0 100 Engine and cooling system..................................................................................................... 70 Engine mount and transfer mount............................................................................................... 71 Damper........................................................................................................................ 72 Cooling system................................................................................................................ 73 Cooling system hydraulic piping diagram....................................................................................... 74 Cooling fan motor............................................................................................................. 76 200 Power train................................................................................................................... 86 Power train................................................................................................................... 88 Power train system diagram.................................................................................................... 89 Drive shaft................................................................................................................... 91 HST hydraulic piping diagram.................................................................................................. 92 HST pump...................................................................................................................... 93 HST motor..................................................................................................................... 101 Transfer...................................................................................................................... 107 Clutch solenoid valve......................................................................................................... 118 Axle.......................................................................................................................... 119 Differential.................................................................................................................. 121 Torque proportioning differential............................................................................................. 126 Limited slip differential..................................................................................................... 129 Final drive................................................................................................................... 133 300 Steering system............................................................................................................... 138 Steering piping diagram....................................................................................................... 140 Steering column............................................................................................................... 141 Priority valve................................................................................................................ 142 Orbit-roll valve.............................................................................................................. 145 Cushion valve................................................................................................................. 153 Steering cylinder............................................................................................................. 154 Emergency steering piping diagram............................................................................................. 156 Emergency steering valve...................................................................................................... 157 Steering relief valve......................................................................................................... 160 400 Brake system.................................................................................................................. 162 Brake piping diagram.......................................................................................................... 164 Charge valve.................................................................................................................. 165 Brake valve................................................................................................................... 169 Inching valve................................................................................................................. 173 Accumulator (for brake)....................................................................................................... 174 Slack adjuster................................................................................................................ 175 Brake......................................................................................................................... 177 Parking brake control......................................................................................................... 182 Parking brake................................................................................................................. 183 500 Undercarriage and frame....................................................................................................... 186 Axle mount and center hinge pin............................................................................................... 187 Tires......................................................................................................................... 192 600 Hydraulic system.............................................................................................................. 194 Work equipment hydraulic piping diagram....................................................................................... 195 Work equipment control lever linkage.......................................................................................... 199 Hydraulic tank................................................................................................................ 203 4-gear pump................................................................................................................... 205 Work equipment control valve.................................................................................................. 207 Cut-off valve................................................................................................................. 233 PPC valve..................................................................................................................... 236 Lock valve.................................................................................................................... 251 Accumulator (for PPC circuit)................................................................................................. 252 ECSS valve.................................................................................................................... 254 Accumulator (for ECSS)........................................................................................................ 256 700 Work equipment................................................................................................................ 258 Work equipment linkage........................................................................................................ 259 Bucket........................................................................................................................ 263 Bucket positioner and boom kick-out........................................................................................... 267 Work equipment cylinder....................................................................................................... 279 800 Cab and its attachments....................................................................................................... 282 Cab........................................................................................................................... 284 Air conditioner............................................................................................................... 285 910 Electrical system, Part 1..................................................................................................... 298 Machine monitor system........................................................................................................ 299 Machine monitor............................................................................................................... 303 920 Electrical system, Part 2..................................................................................................... 326 Electrical system (HST controller system)..................................................................................... 327 HST controller................................................................................................................ 343 ECSS system................................................................................................................... 345 KOMTRAX system................................................................................................................ 347 Engine starting circuit....................................................................................................... 349 Engine stopping circuit....................................................................................................... 351 Preheating circuit............................................................................................................ 352 Engine output derating function............................................................................................... 353 Automatic warm-up function.................................................................................................... 353 Parking brake circuit......................................................................................................... 355 Coupler plunger control system................................................................................................ 357 Multi-function knob........................................................................................................... 358 Max. traction switch.......................................................................................................... 359 Sensor........................................................................................................................ 360 20 Standard value table............................................................................................................... 0 100 Standard service value table.................................................................................................. 368 Standard service value table for engine....................................................................................... 369 Standard service value table for chassis...................................................................................... 370 30 Testing and adjusting.............................................................................................................. 0 110 Testing and adjusting, Part 1................................................................................................. 378 Tools for testing, adjusting, and troubleshooting............................................................................. 380 Measuring engine speed........................................................................................................ 385 Measuring exhaust gas color................................................................................................... 387 Adjusting valve clearance..................................................................................................... 389 Measuring compression pressure................................................................................................ 391 Measuring blow-by pressure.................................................................................................... 394 Measuring engine oil pressure................................................................................................. 395 Measuring intake air (boost) pressure......................................................................................... 396 Handling fuel system equipment................................................................................................ 398 Releasing residual pressure in fuel system.................................................................................... 398 Measuring fuel pressure....................................................................................................... 399 Measuring fuel return rate and leakage........................................................................................ 401 Bleeding air from fuel circuit................................................................................................ 405 Checking leakage in fuel system............................................................................................... 406 Handling cylinder cut-out mode operation...................................................................................... 407 Handling no-injection cranking operation...................................................................................... 407 Handling controller voltage circuit........................................................................................... 408 Check of muffler and muffler stack for looseness and damage................................................................... 408 Check of muffler function..................................................................................................... 409 Check of installed condition of cylinder head and manifolds................................................................... 409 Check of engine piping for damage and looseness............................................................................... 410 Testing and adjusting air conditioner compressor belt tension................................................................. 410 Replacing alternator belt..................................................................................................... 411 120 Testing and adjusting, Part 2................................................................................................. 414 Checking operating force of accelerator pedal................................................................................. 416 Checking directional lever.................................................................................................... 417 Testing and adjusting HST oil pressure........................................................................................ 418 Testing clutch control pressure............................................................................................... 422 Testing and adjusting steering wheel.......................................................................................... 423 Testing and adjusting steering oil pressure................................................................................... 425 Bleeding air from steering circuit............................................................................................ 427 Testing hydraulic fan......................................................................................................... 428 Measuring brake pedal......................................................................................................... 430 Testing and adjusting brake pedal linkage..................................................................................... 431 Measuring brake performance................................................................................................... 432 Testing and adjusting accumulator charge pressure............................................................................. 433 Testing wheel brake oil pressure.............................................................................................. 435 Testing wear of brake disc.................................................................................................... 438 Bleeding air from wheel brake circuit......................................................................................... 439 Releasing residual pressure in brake accumulator circuit...................................................................... 440 Testing parking brake performance............................................................................................. 441 Testing and adjusting parking brake control cable............................................................................. 442 Measuring and adjusting work equipment control lever.......................................................................... 443 Testing and adjusting worke quipment hydraulic pressure....................................................................... 444 Testing work equipment PPC oil pressure....................................................................................... 445 Bleeding air from hydraulic circuit........................................................................................... 447 Releasing remaining pressure in hydraulic circuit............................................................................. 448 Testing and adjusting bucket positioner....................................................................................... 449 Testing and adjusting of boom kick-out switch................................................................................. 450 Checking proximity switch operation pilot lamp................................................................................ 451 Procedure for testing diodes.................................................................................................. 452 Preparation work for troubleshooting for electric system...................................................................... 453 Starting KOMTRAX terminal operations.......................................................................................... 457 Indicator lamps of KOMTRAX terminal........................................................................................... 461 130 Testing and adjusting, Part 3................................................................................................. 466 Adjusting machine monitor..................................................................................................... 467 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................ 468 Special functions of machine monitor (EMMS)................................................................................... 470 Pm clinic inspection chart.................................................................................................... 525 40 Troubleshooting.................................................................................................................... 0 100 Failure code table and fuse locations......................................................................................... 528 Failure codes table........................................................................................................... 529 Fuse locations................................................................................................................ 535 200 General information on troubleshooting........................................................................................ 540 Points to remember when troubleshooting....................................................................................... 541 Sequence of events in troubleshooting......................................................................................... 542 Testing before troubleshooting................................................................................................ 543 Classification and procedures of troubleshooting.............................................................................. 544 Information contained in troubleshooting table................................................................................ 547 Connection table for connector pin numbers.................................................................................... 549 T- branch box and T- branch adapter table..................................................................................... 585 310 Troubleshooting by failure code (Display of code), Part 1..................................................................... 590 Failure code [2G40ZG] Brake: Oil pressure reduction........................................................................... 591 Failure code [6091NX] HST filter: Clogging.................................................................................... 593 Failure code [989FN1] Travel speed: Overrun alarm............................................................................. 595 Failure code [AA1ANX] Air cleaner: Clogging................................................................................... 597 Failure code [AB00L6] Alternator R system: Hot short.......................................................................... 599 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage...................................... 601 Failure code [B@BAZG] Engine: Oil pressure reduction.......................................................................... 603 Failure code [B@BAZK] Engine oil: Low level................................................................................... 604 Failure code [B@BCNS] Engine: Overheat........................................................................................ 605 Failure code [B@BCZK] Engine: Low coolant level............................................................................... 607 Failure code [B@C6NS] Front brake: High oil temperature....................................................................... 609 Failure code [B@CRNS] HST: High oil temperature............................................................................... 610 320 Troubleshooting by failure code (Display of code), Part 2..................................................................... 612 Failure code [CA111] Abnormality in engine controller......................................................................... 614 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................... 615 Failure code [CA122] Charge pressure sensor high error........................................................................ 617 Failure code [CA123] Charge pressure sensor low error......................................................................... 619 Failure code [CA131] Throttle sensor high error............................................................................... 621 Failure code [CA132] Throttle sensor low error................................................................................ 623 Failure code [CA144] Coolant sensor high error................................................................................ 625 Failure code [CA145] Coolant sensor low error................................................................................. 627 Failure code [CA153] Charge temperature sensor high error..................................................................... 629 Failure code [CA154] Charge temperature sensor low error...................................................................... 631 Failure code [CA155] Derating of speed by abnormally high charge temperature.................................................. 633 Failure code [CA187] Sensor power supply 2 low error.......................................................................... 635 Failure code [CA221] Atmospheric pressure sensor high error................................................................... 637 Failure code [CA222] Atmospheric sensor low error............................................................................. 639 Failure code [CA227] Sensor power supply 2 high error......................................................................... 641 Failure code [CA234] Engine overspeed......................................................................................... 642 Failure code [CA238] Ne speed sensor power supply error....................................................................... 643 Failure code [CA271] IMV (IMA) Short circuit.................................................................................. 644 Failure code [CA272] IMV (IMA) Disconnection.................................................................................. 645 Failure code [CA322] Injector #1 open/short error............................................................................. 647 Failure code [CA323] Injector #5 open/short error............................................................................. 649 Failure code [CA324] Injector #3 open/short error............................................................................. 651 Failure code [CA325] Injector #6 open/short error............................................................................. 653 Failure code [CA331] Injector #2 open/short error............................................................................. 655 Failure code [CA332] Injector #4 open/short error............................................................................. 657 Failure code [CA342] Calibration code inconsistency........................................................................... 659 Failure code [CA351] Injectors drive circuit error............................................................................ 661 Failure code [CA352] Sensor power supply 1 low error.......................................................................... 663 Failure code [CA386] Sensor power supply 1 high error......................................................................... 665 330 Troubleshooting by failure code (Display of code), Part 3..................................................................... 668 Failure code [CA428] Abnormally high level in water sensor.................................................................... 671 Failure code [CA429] Abnormally low level in water sensor..................................................................... 673 Failure code [CA431] Idle validation switch error............................................................................. 675 Failure code [CA432] Idle validation action error............................................................................. 679 Failure code [CA435] Engine oil pressure switch error......................................................................... 683 Failure code [CA441] Battery voltage low error................................................................................ 684 Failure code [CA442] Battery voltage high error............................................................................... 687 Failure code [CA449] Common rail pressure high error 2........................................................................ 689 Failure code [CA451] Common rail pressure sensor high error................................................................... 691 Failure code [CA452] Common rail pressure sensor low error.................................................................... 693 Failure code [CA488] Derating of torque by abnormally high charge temperature................................................. 695 Failure code [CA553] Common rail pressure high error 1........................................................................ 696 Failure code [CA559] Supply pump pressure very low error...................................................................... 697 Failure code [CA689] Engine Ne speed sensor error............................................................................. 699 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 701 Failure code [CA757] All continuous data lost error........................................................................... 702 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 705 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 707 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 711 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 713 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 715 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 717 Failure code [CA2555] Intake heater relay disconnection error................................................................. 719 Failure code [CA2556] Intake heater relay short circuit error................................................................. 721 340 Troubleshooting by failure code (Display of code), Part 4..................................................................... 724 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short............................................................ 725 Failure code [D192KY] ECSS solenoid relay: Hot short.......................................................................... 727 Failure code [D1B0KA] HST safety relay: Disconnection......................................................................... 729 Failure code [D1B0KB] HST safety relay: Ground fault.......................................................................... 731 Failure code [D1B0KY] HST safety relay: Hot short............................................................................. 733 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection................................................................ 735 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection........................................................... 737 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection........................................................... 739 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................................ 743 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality............................................................. 745 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault.............................................. 747 Failure code [DAJ1L6] HST controller main power line: Hot short............................................................... 749 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage........................................................... 751 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness.............................. 753 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............................... 755 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range............................................................. 757 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals................................. 759 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection............................................................ 760 Failure code [DAJRMA] HST controller: Disagreement in option selection........................................................ 766 350 Troubleshooting by failure code (Display of code), Part 5..................................................................... 768 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line................................................. 769 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality........................................................ 775 Failure code [DD1NLD] Fan reverse switch signal: Abnormality.................................................................. 777 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short.................................................. 779 Failure code [DDB6KB] Parking brake indicator signal: Ground fault............................................................ 781 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble.... 783 Failure code [DDB6L0] Parking brake reminder signal: Ground fault............................................................. 785 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short................................................. 787 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault............................................ 789 Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................................. 791 Failure code [DDE5MA] Emergency steering operation switch: Disconnection...................................................... 793 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short.................................................... 795 Failure code [DDK3KB] Directional selector switch: Ground fault............................................................... 797 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 799 Failure code [DDK6KY] FNR lever: Hot short.................................................................................... 803 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)............................................ 805 360 Troubleshooting by failure code (Display of code), Part 6..................................................................... 808 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.......................................... 809 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 813 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 815 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................................. 816 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short................................................... 817 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault..................................................... 819 Failure code [DHH1KY] HST oil pressure sensor: Hot short...................................................................... 821 Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................................... 823 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 825 Failure code [DLT3KX] Travel speed sensor B: Abnormality...................................................................... 827 Failure code [DLT4KX] Travel speed sensor A: Abnormality...................................................................... 831 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality.................................................................. 833 Failure code [DV00KY] Alarm buzzer: Hot short................................................................................. 835 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault............................................................ 837 Failure code [DW26KY] Motor 2 solenoid: Hot short............................................................................. 839 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................. 841 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault................................................ 843 370 Troubleshooting by failure code (Display of code), Part 7..................................................................... 846 Failure code [DX16KA] Fan EPC solenoid: Disconnection......................................................................... 847 Failure code [DX16KB] Fan EPC solenoid: Ground fault.......................................................................... 848 Failure code [DX16KY] Fan EPC solenoid: Hot short............................................................................. 849 Failure code [DX19KA] Motor 1 solenoid: Disconnection......................................................................... 851 Failure code [DX19KB] Motor 1 solenoid: Ground fault.......................................................................... 853 Failure code [DX19KY] Motor 1 solenoid: Hot short............................................................................. 855 Failure code [DX20KA] Clutch EPC solenoid: Disconnection...................................................................... 857 Failure code [DX20KB] Clutch EPC solenoid: Ground fault....................................................................... 859 Failure code [DX20KY] Clutch EPC solenoid: Hot short.......................................................................... 861 Failure code [DXH7KB] Reverse solenoid: Ground fault.......................................................................... 863 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................... 865 Failure code [DXH8KB] Forward solenoid: Ground fault.......................................................................... 867 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................... 869 Failure code [J141N1] Steering pump: Overrun alarm............................................................................ 871 Failure code [M100N1] HST pump: Overrun alarm................................................................................. 871 Failure code [M400N1] Motor 1: Overrun alarm.................................................................................. 872 400 Troubleshooting of electrical system (E-mode)................................................................................. 874 E-1 Engine does not start..................................................................................................... 877 E-2 Preheater does not operate normally....................................................................................... 885 E-3 Travel speed is low or high............................................................................................... 889 E-4 ECSS does not operate..................................................................................................... 895 E-5 ECSS keeps operating...................................................................................................... 898 E-6 Defective boom kick-out function and cancellation......................................................................... 901 E-7 Defective bucket positioner function and cancellation..................................................................... 905 E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 909 E-9 Travel direction selection system does not function....................................................................... 913 E-10 Fan does not reverse..................................................................................................... 917 E-11 Fan keeps rotating in reverse............................................................................................ 921 E-12 Wiper does not operate................................................................................................... 923 E-13 Windshield washer does not operate....................................................................................... 927 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off......................................................... 931 E-15 Working lamp does not light up or go off................................................................................. 939 E-16 Turn signal lamp and hazard lamp do not light up or go off............................................................... 945 E-17 Brake lamp does not light or it keeps lighting up........................................................................ 951 E-18 Backup lamp does not light or it keeps lighting up....................................................................... 953 E-19 Backup alarm does not sound or it keeps sounding......................................................................... 956 E-20 Horn does not sound or it keeps sounding................................................................................. 959 E-21 Alarm buzzer does not sound or it keeps sounding......................................................................... 961 E-22 Air conditioner does not operate or stop................................................................................. 963 E-23 The KOMTRAX system does not work properly................................................................................ 967 500 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................... 970 Method of using troubleshooting chart......................................................................................... 972 Failure code and cause table.................................................................................................. 975 H-1 The machine does not start................................................................................................ 977 H-2 The travel speed is slow.................................................................................................. 978 H-3 The traction force is weak................................................................................................ 979 H-4 Engine stalls when traveling or engine speed drops excessively............................................................ 980 H-5 Shift range is not shifted................................................................................................ 981 H-6 The steering wheel does not turn.......................................................................................... 982 H-7 The steering wheel is heavy............................................................................................... 983 H-8 Steering wheel shakes or jerks............................................................................................ 984 H-9 Machine deviates naturally to one side when traveling..................................................................... 984 H-10 The brake does not work or does not work well............................................................................ 985 H-11 The brake is not released or is dragged.................................................................................. 986 H-12 The lift arm does not rise or lower...................................................................................... 987 H-13 The lift arm moves slowly or the lift arm rising force is insufficient................................................... 988 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 989 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).......................................... 989 H-16 Hydraulic drifts of the lift arm occur often............................................................................. 989 H-17 The lift arm wobbles during operation.................................................................................... 989 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily................................ 990 H-19 The bucket does not tilt back............................................................................................ 991 H-20 The bucket moves slowly or the tilting-back force is insufficient........................................................ 992 H-21 The bucket comes to operate slowly in the midst of tilting-back.......................................................... 993 H-22 The bucket cylinder cannot hold down the bucket.......................................................................... 993 H-23 Hydraulic drifts of the bucket occur often............................................................................... 993 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)................................... 993 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily................................... 994 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy............................................. 994 H-27 The ECSS does not operate and machine pitches and bounces................................................................ 995 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................................. 996 600 Troubleshooting of engine (S-mode)............................................................................................ 998 Method of using troubleshooting charts........................................................................................ 999 S-1 Starting performance is poor..............................................................................................1003 S-2 Engine does not start.....................................................................................................1005 S-3 Engine does not pick up smoothly..........................................................................................1008 S-4 Engine stops during operations............................................................................................1009 S-5 Engine does not rotate smoothly...........................................................................................1010 S-6 Engine lacks output (or lacks power)......................................................................................1011 S-7 Exhaust smoke is black (incomplete combustion)............................................................................1012 S-8 Oil consumption is excessive (or exhaust smoke is blue)...................................................................1013 S-9 Oil becomes contaminated quickly..........................................................................................1014 S-10 Fuel consumption is excessive............................................................................................1015 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....................................................1016 S-12 Oil pressure drops.......................................................................................................1017 S-13 Oil level rises (Entry of coolant or fuel)...............................................................................1018 S-14 Coolant temperature becomes too high (overheating).......................................................................1019 S-15 Abnormal noise is made...................................................................................................1020 S-16 Vibration is excessive...................................................................................................1021 50 Disassembly and assembly........................................................................................................... 0 100 General information on disassembly and assembly...............................................................................1024 How to read this manual.......................................................................................................1025 Coating materials list........................................................................................................1027 Special tool list.............................................................................................................1030 Sketches of special tools.....................................................................................................1034 200 Engine and cooling system.....................................................................................................1042 Removal and installation of fuel supply pump assembly.........................................................................1043 Removal and installation of fuel injector assembly............................................................................1045 Removal and installation of cylinder head assembly............................................................................1053 Removal and installation of engine hood assembly..............................................................................1065 Removal and installation of radiator..........................................................................................1068 Removal and installation of air aftercooler...................................................................................1071 Removal and installation of hydraulic oil cooler assembly.....................................................................1073 Removal and installation of engine assembly...................................................................................1075 Removal and installation of engine front oil seal assembly....................................................................1081 Removal and installation of engine rear oil seal assembly.....................................................................1084 Removal and installation of cooling fan and fan motor assembly................................................................1087 Removal and installation of fuel tank assembly................................................................................1090 310 Power train, Part 1...........................................................................................................1094 Removal and installation of transfer..........................................................................................1095 Disassembly and assembly of transfer assembly.................................................................................1098 Removal and installation of parking brake assembly............................................................................1117 Disassembly and assembly of parking brake assembly............................................................................1118 320 Power train, Part 2...........................................................................................................1124 Removal and installation of front axle assembly...............................................................................1125 Removal and installation of rear axle assembly................................................................................1127 Disassembly and assembly of axle housing assembly.............................................................................1130 Disassembly and assembly of differential assembly.............................................................................1142 400 Undercarriage and frame.......................................................................................................1166 Removal and installation of center hinge pin..................................................................................1167 Removal and installation of counterweight.....................................................................................1177 500 Hydraulic system..............................................................................................................1180 Removal and installation of HST pump and 4-gear pump assembly.................................................................1181 Disassembly and assembly of HST pump assembly.................................................................................1184 Removal and installation of HST motor 1 assembly..............................................................................1211 Removal and installation of HST motor 2 assembly..............................................................................1213 Disassembly and assembly of HST motor assembly................................................................................1215 Removal and installation of work equipment control valve assembly.............................................................1231 Removal and installation of hydraulic tank assembly...........................................................................1233 Disassembly and assembly of hydraulic cylinder assembly.......................................................................1235 600 Work equipment................................................................................................................1244 Removal and installation of work equipment assembly...........................................................................1245 700 Cab and its attachments.......................................................................................................1252 Removal and installation of operator's cab and floor frame assembly...........................................................1253 Removal and installation of operator's cab glass (Stuck glass)................................................................1259 Disassembly and assembly of operator's seat assembly..........................................................................1267 Removal and installation of air conditioner unit..............................................................................1277 800 Electrical system.............................................................................................................1282 Removal and installation of monitor panel.....................................................................................1283 Removal and installation of engine controller assembly........................................................................1285 Removal and installation of HST controller assembly...........................................................................1286 Removal and installation of KOMTRAX terminal assembly.........................................................................1287 90 Diagrams and drawings.............................................................................................................. 0 100 Hydraulic diagrams and drawings...............................................................................................1290 Automatic greasing circuit diagram............................................................................................1291 Hydraulic circuit diagram.....................................................................................................1294 200 Electrical diagrams and drawings..............................................................................................1298 Common electrical circuit diagram.............................................................................................1300 Connector list and stereogram.................................................................................................1313
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