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KOMATSU WA320PT-5L PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU WA320PT-5L PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM013602
- SERIAL NUMBERS WA320PT-5L A39001 and UP
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Description
KOMATSU WA320PT-5L PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL
KOMATSU WA320PT-5L PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA320PT-5L PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components. - GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
TABLE OF CONTENTS:
KOMATSU WA320PT-5L PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL
CEBM013602 - WA320PT-5L S/N A39001 and up............................................................ 1 CONTENTS............................................................................................. 2 REVISION PAGES....................................................................................... 3 01 GENERAL........................................................................................... 33 GENERAL INFORMATION.............................................................................. 34 Machine Specifications....................................................................... 35 Weight Table................................................................................. 41 LUBRICANTS....................................................................................... 42 Ambient Temperature Range.................................................................... 42 Recommended Lubricants....................................................................... 43 Addtional Lubricant Information.............................................................. 44 10 STRUCTURE AND FUNCTION............................................................................ 45 ENGINE AND DRIVE SYSTEM.......................................................................... 50 Mounting..................................................................................... 50 Drive Dampener............................................................................... 51 Outline...................................................................................... 51 Cooling System............................................................................... 52 Specification................................................................................ 52 Drive Line Componants........................................................................ 53 Drive Line Flow.............................................................................. 54 Power Flow Outline........................................................................... 55 Drive Shaft System........................................................................... 56 Drive Shaft Outline.......................................................................... 56 HST HYDRAULIC SYSTEM............................................................................. 57 Piping Diagram............................................................................... 57 HST Pump (Hydro-static Transmission)......................................................... 58 Specifications........................................................................... 58 Flow of Power............................................................................ 59 Flow of Oil.............................................................................. 59 High Pressure Relief Valve................................................................... 60 Function................................................................................. 60 Valve Operation.......................................................................... 61 Low Pressure Relief Valve.................................................................... 62 Function................................................................................. 62 Valve Operation.......................................................................... 62 HST Charge Pump.............................................................................. 63 Specifications........................................................................... 63 Pump Outline............................................................................. 63 Function................................................................................. 63 Speed Related Valve (DA Valve)............................................................... 64 Function................................................................................. 64 Valve Operation.......................................................................... 64 High Pressure Cut-off Valve.................................................................. 65 Function................................................................................. 65 Valve Operation.......................................................................... 65 HST MOTOR (HYDRO-STATIC TRANSMISSION)............................................................ 66 Motor 1...................................................................................... 66 Motor 1 Specifications....................................................................... 66 Motor 2...................................................................................... 67 Motor 2 Specifications....................................................................... 67 Principle.................................................................................... 68 Structure.................................................................................... 68 Operation.................................................................................... 68 PUMP VALVES...................................................................................... 69 EP Servo Valve............................................................................... 69 Function................................................................................. 69 Operation................................................................................ 69 HA Servo Valve............................................................................... 70 Function................................................................................. 70 Operation................................................................................ 70 Forward-Reverse Shuttle Valve................................................................ 71 Function................................................................................. 71 Operation................................................................................ 71 TRANSFER......................................................................................... 72 Outline...................................................................................... 73 Input Shaft.................................................................................. 75 Output Shaft................................................................................. 77 Clutch Operation............................................................................. 80 Low-Speed Mode............................................................................... 81 Operation.................................................................................... 81 High-Speed Mode.............................................................................. 82 Operation.................................................................................... 82 CLUTCH SOLENOID VALVE............................................................................ 83 Operation.................................................................................... 83 DRIVE AXLES...................................................................................... 84 Front Axle................................................................................... 84 Front Differential........................................................................... 85 Rear Axle.................................................................................... 88 Rear Differential............................................................................ 89 Outline...................................................................................... 92 Torque Proportioning Differential............................................................ 93 Outline.................................................................................. 93 LIMITED-SLIP DIFFERENTIALS....................................................................... 94 Front Differential........................................................................... 94 Operation of Limited-Slip Differential....................................................... 95 Final Drive.................................................................................. 98 Outline...................................................................................... 99 AXLE MOUNTING AND CENTER HINGE................................................................... 100 Outline...................................................................................... 101 Center Hinge................................................................................. 102 Axle Mount................................................................................... 104 STEERING SYSTEM.................................................................................. 105 Steering Piping.............................................................................. 105 Steering Column.............................................................................. 106 Priority Valve............................................................................... 107 Outline.................................................................................. 108 Operation................................................................................ 108 Orbit-Roll Valve............................................................................. 110 Outline.................................................................................. 111 Structure................................................................................ 111 Cushion Valve................................................................................ 117 Outline.................................................................................. 117 Function................................................................................. 117 Steering Cylinder............................................................................ 118 EMERGENCY STEERING............................................................................... 120 Steering Piping.............................................................................. 120 Steering Valve............................................................................... 121 BRAKING SYSTEM................................................................................... 125 Brake Piping................................................................................. 125 Brake Valve.................................................................................. 126 Outline.................................................................................. 127 Inching Valve................................................................................ 130 Outline.................................................................................. 130 Charge Valve................................................................................. 131 Function................................................................................. 132 Operation................................................................................ 133 Braking System Accumulator................................................................... 135 Function................................................................................. 135 Specifications........................................................................... 135 Slack Adjuster............................................................................... 136 Function................................................................................. 137 Operation................................................................................ 137 Braking Unit................................................................................. 138 Outline.................................................................................. 139 PARKING BRAKE.................................................................................... 140 Control...................................................................................... 140 Outline.................................................................................. 140 Parking Brake Unit........................................................................... 141 Outline.................................................................................. 141 WORK EQUIPMENT................................................................................... 142 Hydraulic Piping Layout WA320-5L............................................................. 142 Outline.................................................................................. 143 Hydraulic Piping Layout WA320PT-5L........................................................... 144 Outline.................................................................................. 145 Control Lever Linkage........................................................................ 146 WA320-5L 2-Lever Type.................................................................... 146 WA320PT-5L 3-Lever Type.................................................................. 147 Multi-Function Joystick Type (WA320-5L).................................................. 148 BASIC HYDRAULIC SYSTEM........................................................................... 150 Hydraulic Tank............................................................................... 150 Specifications........................................................................... 151 Vent......................................................................................... 151 4-gear Pump Unit............................................................................. 152 Outline.................................................................................. 152 Accumulator PPC Circuit...................................................................... 154 Outline.................................................................................. 154 Specifications........................................................................... 154 Lock Valve................................................................................... 155 Outline.................................................................................. 155 Bypass Valve................................................................................. 156 System Operation............................................................................. 157 Quick Coupler Solenoid Valve................................................................. 159 Outline...................................................................................... 159 E. C. S. S. Valve................................................................................ 160 ECSS Accumulator............................................................................. 162 Function..................................................................................... 162 Specifications............................................................................... 162 HYDRAULIC COOLING SYSTEM......................................................................... 163 Piping Layout................................................................................ 163 Outline...................................................................................... 163 Cooling Fan Motor............................................................................ 164 Specifications............................................................................... 164 Function..................................................................................... 165 Principle of Operation....................................................................... 165 WORK EQUIPMENT CONTROL VALVE..................................................................... 166 2-Spool Valve................................................................................ 166 3-Spool Valve................................................................................ 169 Relief Valve............................................................................. 172 Function................................................................................. 172 Operation................................................................................ 172 Safety-suction Valve..................................................................... 173 Function................................................................................. 173 Operation as Safety Valve................................................................ 173 Suction Valve............................................................................ 174 Function................................................................................. 174 Operation................................................................................ 174 Cut-Off Valve................................................................................ 175 Function................................................................................. 176 Operating Condition of Cut-Off Valve..................................................... 176 Work Equipment Controll Valve Operation...................................................... 179 WORK EQUIPMENT PPC VALVES........................................................................ 185 2-Lever Type Valve........................................................................... 185 Operation................................................................................ 187 Attachment Lever Valve....................................................................... 190 Operation................................................................................ 191 Joystick Lever Type.......................................................................... 194 Operation................................................................................ 196 WA320-5L MECHANICAL AND WORK EQUIPMENT........................................................... 200 Standard Work Equipment Bucket............................................................... 202 WA320PT-5L MECHANICAL AND WORK EQUIPMENT......................................................... 204 Optional Bucket.............................................................................. 206 Optional 1524 mm (60 inch) Construction Forks................................................ 208 Optional 1371.6 mm (54 inch) Utility Forks................................................... 209 Optional Extendable Boom..................................................................... 210 Hydraulic Quick Coupler Group................................................................ 211 BUCKET POSITIONER, BOOM KICK-OUT AND DUMP SPEED.................................................. 212 WA320-5L Related System...................................................................... 212 Outline.................................................................................. 213 Operation of Proximity Switch............................................................ 214 Function of Proximity Switch............................................................. 216 Function of Proximity Switch............................................................. 219 WA320PT-5L Related System.................................................................... 220 Outline.................................................................................. 221 Operation of Proximity Switch............................................................ 221 WORK EQUIPMENT CYLINDERS......................................................................... 230 WA320-5L..................................................................................... 230 Lift Cylinder............................................................................ 230 Bucket Cylinder.......................................................................... 230 WA320PT-5L................................................................................... 231 Lift Cylinder............................................................................ 231 Bucket Cylinder.......................................................................... 231 Coupler Plunger.......................................................................... 231 HEATING AND AIR CONDITIONER PIPING............................................................... 233 MACHINE MONITERING SYSTEM........................................................................ 234 Starting and Lighting Power Supply........................................................... 236 Speedometer Power Supply..................................................................... 238 Load Meter Power Supply...................................................................... 239 Sensor System Power Supply................................................................... 240 HST Safety Control Power Supply.............................................................. 241 Preheat System Power Supply.................................................................. 242 Load Meter Power Supply...................................................................... 243 MACHINE MONITOR.................................................................................. 244 Standard Speedometer Display................................................................. 244 Optional Load Meter.......................................................................... 245 LIST OF ITEMS DISPLAYED ON MONITOR............................................................... 246 Service Mode Functions....................................................................... 252 Outline.................................................................................. 252 Operating Method............................................................................. 254 Spedometer Specifications................................................................ 254 Load Meter Specifications................................................................ 255 Items Related to the Fault History of Electrical System...................................... 256 Items Related to the Fault History of Machine System......................................... 259 Real-Time Monitor Function Speedometer Specification..................................... 261 Real-Time Monitor Function Load Meter Specification...................................... 264 Real-Time Monitoring Items............................................................... 268 Tuning Function.......................................................................... 272 Maintenance Functions.................................................................... 274 Setting Required When Optional Device is Installed....................................... 278 Function of Selecting Optional Device.................................................... 278 Function of Selecting Optional Device.................................................... 280 Load Meter Function.......................................................................... 284 Outline.................................................................................. 284 Operating Method......................................................................... 284 Input/Ouput Signal....................................................................... 294 Speedometer Specification................................................................ 294 HST SYSTEM ELECTRICAL CONTROLLER................................................................. 301 System Diagram............................................................................... 301 Control Function............................................................................. 302 HST Controller............................................................................... 305 Input and Output Signals..................................................................... 305 Selecting Directional Selector Switch (If Equipped).......................................... 306 Outline.................................................................................. 306 Function................................................................................. 306 Operation................................................................................ 307 Engine Starting Circuit...................................................................... 308 Function................................................................................. 308 Operation................................................................................ 308 Engine Stop Circuit.......................................................................... 310 Operation................................................................................ 310 Automatic Preheating System.................................................................. 311 Outline.................................................................................. 311 Operation................................................................................ 311 Parking Brake Circuit........................................................................ 312 Operation................................................................................ 313 Electronically Controlled Suspension System.................................................. 315 Function................................................................................. 315 Sensors...................................................................................... 316 Engine Speed Sensor...................................................................... 316 Speed Sensor............................................................................. 316 Engine Oil Pressure Sensor............................................................... 317 Fuel Level Sensor........................................................................ 317 Coolant Temperature Sensor (For Monitor)................................................. 318 Coolant Temperature Sensor (For Preheating).............................................. 318 Axle Oil Temperature Sensor.............................................................. 319 HST Sensor for Load Meter (Load Meter Specification)..................................... 319 Emergency Steering Oil Pressure Sensor (If Equipped)..................................... 320 HST Oil Filter Clogging Sensor........................................................... 320 Coolant Level Sensor..................................................................... 321 Engine Oil Level Sensor.................................................................. 322 Air Cleaner Clogging Sensor.............................................................. 323 Lift Arm Angle Sensor (Load Meter Specification) (If Equipped)........................... 324 KOMTRAX SYSTEM................................................................................... 326 KOMTRAX Terminal System...................................................................... 326 KOMTRAX Terminal............................................................................. 327 Input and Output Signals..................................................................... 328 20 TESTING, ADJUSTING AND TROUBLESHOOTING............................................................ 329 STANDARD VALUE TABLE............................................................................. 331 Engine....................................................................................... 331 Chassis...................................................................................... 332 SPECIAL TOOLS.................................................................................... 337 ENGINE COMPONENTS................................................................................ 340 Measuring Exhaust Smoke...................................................................... 340 Measuring Exhaust Temperature................................................................ 340 Adjusting Valve Clearance.................................................................... 340 Measuring Compression Pressure............................................................... 340 Measuring Crankcase Pressure................................................................. 340 Measuring Engine Oil Pressure................................................................ 340 Measuring Boost Pressure..................................................................... 340 Measuring Fuel Pressure...................................................................... 340 Adjusting Engine Speed Sensor................................................................ 340 Bleeding Air From Fuel System................................................................ 340 Adjusting Engine Stop Solenoid............................................................... 340 Measuring Engine Speed....................................................................... 341 Measuring Low And High Idle.............................................................. 341 Measuring HST Stall Speed................................................................ 342 Measuring Hydraulic Stall................................................................ 342 Measuring Full Stall Speed............................................................... 342 ACCELERATOR PEDAL................................................................................ 343 Testing Pedal Force.......................................................................... 343 Operating Angle of Pedal..................................................................... 344 ADJUSTING ENGINE STOP SOLENOID................................................................... 345 ADJUSTING ENGINE SPEED SENSOR.................................................................... 346 REFRIGERENT COMPRESSOR BELT...................................................................... 347 DIRECTIONAL LEVER................................................................................ 348 HST OIL PRESSURE................................................................................. 349 Measuring.................................................................................... 349 Adjusting.................................................................................... 352 CLUTCH CONTROL PRESSURE.......................................................................... 354 STEERING WHEEL................................................................................... 355 Measuring Steering Wheel End Play............................................................ 355 Measuring Operating Force on Steering Wheel.................................................. 355 Measuring Operating Time for Steering Wheel.................................................. 356 STEERING OIL PRESSURE............................................................................ 357 Measuring Main Relief Pressure............................................................... 357 Adjusting Main Relief Pressure............................................................... 357 Bleeding Air From Steering Circuit........................................................... 358 HYDRAULIC FAN.................................................................................... 359 Measuring Fan Speed.......................................................................... 359 Measuring Oil Pressure....................................................................... 359 MEASURING BRAKE PEDAL............................................................................ 360 BRAKE PEDAL LINKAGE.............................................................................. 361 Testing...................................................................................... 361 Adjusting.................................................................................... 361 MEASURING BRAKE PERFORMANCE...................................................................... 362 ACCUMULATOR CHARGE PRESSURE...................................................................... 363 Measuring.................................................................................... 363 Adjusting.................................................................................... 363 BRAKE OIL PRESSURE............................................................................... 364 MEASURING WEAR OF BRAKE DISC..................................................................... 366 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................. 367 PARKING BRAKE PERFORMANCE........................................................................ 368 PARKING BRAKE LINKAGE............................................................................ 369 Testing...................................................................................... 369 Adjusting.................................................................................... 370 WORK EQUIPMENT CONTROL LEVER..................................................................... 371 WORK EQUIPMENT PRESSURE.......................................................................... 372 Measuring.................................................................................... 372 Adjusting.................................................................................... 372 WORK EQUIPMENT PPC OIL PRESSURE.................................................................. 374 Testing and Adjusting........................................................................ 374 Bleeding Air................................................................................. 376 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................ 377 BUCKET POSITIONER................................................................................ 378 Testing...................................................................................... 378 Adjusting.................................................................................... 378 BOOM KICK-OUT.................................................................................... 379 PROXIMITY SWITCH ACTUATION DISPLAY LAMP.......................................................... 380 PROCEDURE FOR CHECKING DIODE..................................................................... 382 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................. 383 FLOW OF MODES AND FUNCTIONS...................................................................... 384 SETTING MACHINE MONITOR (EMMS)................................................................... 400 REAL-TIME MONITORING ITEMS....................................................................... 409 PM CLINIC INSPECTION CHART....................................................................... 415 TROUBLESHOOTING (GENERAL)............................................................................ 417 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................... 418 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................ 420 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................ 421 Precautions When Handling Electric Equipment................................................. 421 Handling Control Box......................................................................... 426 Points To Remember When Troubleshooting Electric Circuits.................................... 427 Points To Remember When Handling Hydraulic Equipment......................................... 428 CHECKS BEFORE TROUBLESHOOTING.................................................................... 430 Using Troubleshooting Charts................................................................. 431 Phenomena Considered To Be Failures And Troubleshooting...................................... 432 TABLE FOR CONNECTOR PIN NUMBERS.................................................................. 435 T-ADAPTER TABLE.................................................................................. 458 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................... 461 CONNECTOR LAYOUT DRAWING......................................................................... 467 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).................................................. 473 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 474 Points To Remember If A Problem Returns To Normal............................................ 474 User Code Memory Retention Function.......................................................... 474 ERROR CODE AND POSSIBLE CAUSE TABLE.............................................................. 475 FUSE SYSTEM CHECK................................................................................ 477 Fuse Pannel Connection Table................................................................. 477 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 478 Code Key Table............................................................................... 479 [989F00]......................................................................................... 480 Transmission Protection Alert (00)........................................................... 480 [DHH1KX]......................................................................................... 482 HST Oil Pressure Signal Out Of Range......................................................... 482 [DLE2LC]......................................................................................... 484 Engine Speed Sensor Out Of Range............................................................. 484 [DW26KZ]......................................................................................... 486 Motor 2 Solenoid System Open Or Shorted...................................................... 486 [DX19KZ]......................................................................................... 490 Motor 1 Solenoid System Open Or Shorted...................................................... 490 Load Meter Specifications (If Equipped)...................................................... 492 [DX20KZ]......................................................................................... 495 Clutch Solenoid System Open Or Shorted....................................................... 495 Load Meter Specifications (If Equipped)...................................................... 498 [HST-1].......................................................................................... 502 Defective HST Power Controller Source........................................................ 502 [HST-2].......................................................................................... 506 Travel Speed Ranges Do Not Change............................................................ 506 [HST-3].......................................................................................... 510 Traction Control Inoperable.................................................................. 510 [HST-4].......................................................................................... 512 Travel Speed Cannot Be Changed When Gear Selector Is In 1st.................................. 512 [HST-5].......................................................................................... 515 Travel Speed Cannot Be Increased............................................................. 515 TROUBLESHOOTING OF TRAVEL DAMPENER SYSTEM (ECSS MODE)................................................ 517 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................... 518 Points To Remember If A Problem Returns To Normal............................................ 518 User Code Memory Retention Function.......................................................... 518 ECSS-1........................................................................................... 519 Travel Damper Dose Not Operate............................................................... 519 Travel Damper Does Not Reset................................................................. 522 TROUBLESHOOTING OF HST MONITOR SYSTEM (MON MODE)..................................................... 525 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................... 529 Points To Remember If A Problem Returns To Normal............................................ 529 User Code Memory Retention Function.......................................................... 529 ERROR CODE AND POSSIBLE CAUSE TABLE.............................................................. 530 FUSE SYSTEM CHECK................................................................................ 532 Fuse Pannel Connection Table................................................................. 532 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 533 Code Key Table............................................................................... 534 [15B0NX]......................................................................................... 535 HST Oil Filter Showing Clogged Condition..................................................... 535 HST Load Meter Specifications (If Equipped).................................................. 537 [2G42ZG]......................................................................................... 539 Low Accumulator Oil Pressure Indicated....................................................... 539 Load Meter Specifications (If Equipped)...................................................... 541 [989F00]......................................................................................... 543 Transmission Protection Caution Indicated.................................................... 543 [989FN1]......................................................................................... 544 HST Over-speed Condition..................................................................... 544 [AA1ANX]......................................................................................... 545 Clogged Air Cleaner Indicated (Standard)..................................................... 545 Load Meter Specifications (If Equipped)...................................................... 547 [AB00L6]......................................................................................... 549 Defective Battery Charging Circuit........................................................... 549 Load Meter Specifications (If Equipped)...................................................... 551 [AB00MA]......................................................................................... 553 Defective Battery Charging Circuit........................................................... 553 Load Meter Specifications (If Equipped)...................................................... 555 [B@BAZG]......................................................................................... 557 Abnormal Engine Oil Pressure Indicated....................................................... 557 Load Meter Specifications (If Equipped)...................................................... 559 [B@BAZK]......................................................................................... 561 Abnormal Engine Oil Level Indication......................................................... 561 Load Meter Specifications (If Equipped)...................................................... 563 [B@BCNS]......................................................................................... 564 Engine Coolant Indicating Overheat Condition................................................. 564 Load Meter Specifications (If Equipped)...................................................... 567 [B@BCZK]......................................................................................... 569 Abnormal Coolant Level Indication............................................................ 569 Load Meter Specifications (If Equipped)...................................................... 571 [B@C7NS]......................................................................................... 573 Brake Cooling Oil Indicating Overheating Condition........................................... 573 Load Meter Specifications (If Equipped)...................................................... 575 [B@CRNS]......................................................................................... 577 HST Oil Showing Overheating Condition........................................................ 577 Load Meter Specifications (If Equipped)...................................................... 579 [D5ZHL6]......................................................................................... 581 Ignition Switch “C” (Ign) Input Failure Indicated............................................ 581 Load Meter Specifications (If Equipped)...................................................... 583 [DAF3KK]......................................................................................... 586 With Ignition Switch On, Power Supply For Memory Is Off...................................... 586 [DAF5KP]......................................................................................... 588 Defective 5-V Power Supply Output (KP)....................................................... 588 [DAF6KP]......................................................................................... 590 Defective 24-V Power Supply Output (KP)...................................................... 590 [DAF0KT]......................................................................................... 592 Controller Internal Failure.................................................................. 592 [DAJ0KR]......................................................................................... 594 HST Controller Communication Failure......................................................... 594 Load Meter Specifications (If Equipped)...................................................... 596 [D182KZ]......................................................................................... 599 The Pre-heater Relay Coil Is Open Or Shorted................................................. 599 [D1B0KB]......................................................................................... 601 HST Safety (Transmission Cut-off) Relay Open Or Shorted (KB)................................. 601 [DD1CLD]......................................................................................... 603 Defective Subtotal Switch.................................................................... 603 [DD15LD]......................................................................................... 605 Monitor Panel Mode Selector Switch Will Not Set.............................................. 605 Load Meter Specifications (If Equipped)...................................................... 607 [DD16LD]......................................................................................... 609 Monitor Panel Mode Selector Switch Will Not Set.............................................. 609 Load Meter Specifications (If Equipped)...................................................... 611 [DD17LD]......................................................................................... 613 Monitor Panel Mode Selector Switch Will Not Set.............................................. 613 Load Meter Specifications (If Equipped)...................................................... 615 [DD18LD]......................................................................................... 617 Monitor Panel Mode Selector Switch Will Not Set.............................................. 617 Load Meter Specifications (If Equipped)...................................................... 619 [DDK3KB]......................................................................................... 621 Improper Input For Multiple Shift (FNR) Lever................................................ 621 Load Meter Specifications (If Equipped)...................................................... 624 [DDS5L6]......................................................................................... 628 Decreased Steering Oil Pressure.............................................................. 628 Load Meter Specifications (If Equipped)...................................................... 630 [DDY0LD]......................................................................................... 632 Defective Cancel Switch...................................................................... 632 [DGE2KX]......................................................................................... 634 Engine Coolant Temperature Sensor Out Of Range............................................... 634 Load Meter Specifications (If Equipped)...................................................... 636 [DGE3L6]......................................................................................... 638 Engine Coolant Temperature Sensor Out Of Range............................................... 638 Load Meter Specifications (If Equipped)...................................................... 640 [DGH1KX]......................................................................................... 642 HST Oil Showing Overheating Condition........................................................ 642 load Meter Specifications (If Equipped)...................................................... 644 [DGR4KA]......................................................................................... 646 Axle Oil Indicating Short Circuit............................................................ 646 Load Meter Specifications (If Equipped)...................................................... 648 [DGR4KX]......................................................................................... 650 Brake Cooling Oil Indicating Open Circuit.................................................... 650 Load Meter Specifications (If Equipped)...................................................... 652 [DHE4L6]......................................................................................... 654 Engine Oil Pressure Indicating A Short Or Open In The System................................. 654 Load Meter Specifications (If Equipped)...................................................... 656 [DHPCKX]......................................................................................... 658 Possible Defective Bottom Pressure Sensor.................................................... 658 [DHPDKX]......................................................................................... 660 Possible Defective Rod Pressure Sensor....................................................... 660 [DKA0KX]......................................................................................... 662 Possible Defective Boom Angle Sensor......................................................... 662 [DV00KB]......................................................................................... 664 Possible Short Or Open In Alarm Buzzer....................................................... 664 [MON-1].......................................................................................... 666 Parking Brake Indicator Lamp Does Not Work................................................... 666 Load Meter Specifications (If Equipped)...................................................... 670 [MON-2].......................................................................................... 675 Brake Oil Pressure Not Indicating Correctly.................................................. 675 Load Meter Specifications (If Equipped)...................................................... 677 [MON-3].......................................................................................... 679 Engine Coolant Sensor Not Indicating Correctly............................................... 679 Load Meter Specifications (If Equipped)...................................................... 681 [MON-4].......................................................................................... 683 HST Oil Temperature Not Indicating Correctly................................................. 683 [MON-5].......................................................................................... 687 Fuel Level Gauge Does Not Indicate Properly.................................................. 687 Load Meter Specifications (If Equipped)...................................................... 689 [MON-6].......................................................................................... 691 Abnormal Coolant Level Indication............................................................ 691 Load Meter Specifications (If Equipped)...................................................... 693 [MON-7].......................................................................................... 695 Steering Oil Pressure Not Reading Correctly.................................................. 695 Load Meter Specifications (If Equipped)...................................................... 697 [MON-8].......................................................................................... 699 Emergency Steering Oil Pressure Not Reading Correctly........................................ 699 Load Meter Specifications (If Equipped)...................................................... 701 [MON-9].......................................................................................... 703 Monitor Panel Mode Selector Switch Will Not Set Correctly.................................... 703 Load Meter Specifications (If Equipped)...................................................... 705 [MON-10]......................................................................................... 707 Monitor Panel Mode Selector Switch Will Not Set Correctly.................................... 707 Load Meter Specifications (If Equipped)...................................................... 709 [MON-11]......................................................................................... 711 Monitor Panel Mode Selector Switch Will Not Set Correctly.................................... 711 Load Meter Specifications (If Equipped)...................................................... 713 [MON-12]......................................................................................... 715 Monitor Panel Mode Selector Switch Will Not Set Correctly.................................... 715 Load Meter Specifications (If Equipped)...................................................... 717 [MON-13]......................................................................................... 719 Alarm Buzzer Does Not Stop Or Remains ON..................................................... 719 Load Meter Specifications (If Equipped)...................................................... 721 [MON-14]......................................................................................... 723 Abnormal Engine Oil Level Indication......................................................... 723 Load Meter Specifications (If Equipped)...................................................... 725 [MON-15]......................................................................................... 727 Clogged Air Cleaner Indicated................................................................ 727 Load Meter Specifications (If Equipped)...................................................... 729 [MON-16]......................................................................................... 731 Defective Cancel Switch...................................................................... 731 [MON-17]......................................................................................... 733 Defective Subtotal Switch.................................................................... 733 [MON-18]......................................................................................... 735 Possible Defective Bottom Pressure Sensor.................................................... 735 [MON-19]......................................................................................... 737 Possible Defective Rod Pressure Sensor....................................................... 737 [MON-20]......................................................................................... 739 Front Windshield Wiper Does Not Work......................................................... 739 Rear Windshield Wiper Does Not Work.......................................................... 741 [MON-21]......................................................................................... 743 Headlamps (Lo And High Beam) Does Not Function............................................... 743 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................ 747 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................... 749 Points To Remember If Abnormality Returns To Normal.......................................... 749 User Code Memory Retention Function.......................................................... 749 FUSE SYSTEM CHECK................................................................................ 750 Fuse Panel Connection Table.................................................................. 750 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 751 (E-1)............................................................................................ 753 Engine Will Not Crank........................................................................ 753 When Directional Selector Actuation Switch Is Turned OFF................................. 753 When Directional Selector Actuation Switch Is Turned ON...................................... 757 Defective Fuel Cut Solenoid System........................................................... 758 When Directional Selector Actuation Switch Is Turned ON (Load Meter Specification)........... 765 Defective Fuel Cut Solenoid System (Load Meter Specification)................................ 766 (E-2)............................................................................................ 770 The Engine Does Not Shut Down................................................................ 770 (E-3)............................................................................................ 773 Cold Start Pre-heater Does Not Work Properly................................................. 773 Preheating Does Not Work At All.......................................................... 773 Preheat Is Constant...................................................................... 775 Preheating Does Not Work At All (Load Meter Specification)............................... 778 Preheat Is Constant (Load Meter Specification............................................ 780 (E-4)............................................................................................ 782 Parking Brake Does Not Function Properly..................................................... 782 Parking Brake Dragging (Prevention Does Not Function).................................... 782 (E-5)............................................................................................ 792 Boom Kick-out Function Not Working Properly.................................................. 792 (E-6)............................................................................................ 795 Bucket Lever Function Not Working Properly................................................... 795 (E-7)............................................................................................ 798 Float Hold Function Not Working Properly..................................................... 798 (E-8)............................................................................................ 801 Travel Direction Does Not Change (“F” Machine Does Not Travel Forward)....................... 801 Travel Direction Does Not Change (“R” Machine Does Not Travel Reverse)....................... 803 (E-9)............................................................................................ 807 Front Windshield Wiper Does Not Work......................................................... 807 Rear Windshield Wiper Does Not Work.......................................................... 811 (E-10)........................................................................................... 813 The Window Washer Does Not Work.............................................................. 813 (E-11)........................................................................................... 815 Headlamps (Lo And High Beam) Does Not Function............................................... 815 Headlamps (Lo Beam) Do Not Function.......................................................... 820 Headlamps (Hi Beam) Do Not Function.......................................................... 824 Clearance Lamps Do Not Function.............................................................. 828 Turn Signals Do Not Function................................................................. 832 Work Lamps Do Not Function................................................................... 836 (E-12)........................................................................................... 840 Horn Does Not Sound.......................................................................... 840 (E-13)........................................................................................... 843 Air Conditioner System Does Not Work......................................................... 843 Air Does Not Flow From System And Cannot Be Adjusted......................................... 846 Air Does Not Cool Or Temperature Cannot Be Adjusted.......................................... 850 Cannot Switch Between Circulated And Vent Functions.......................................... 854 Cannot Switch Vent Functions................................................................. 856 DEFECTIVE COOLING (MECHANICAL)................................................................... 859 DEFECTIVE HEATING (MECHANICAL)................................................................... 860 ABNORMAL NOISE IS HEARD FROM SYSTEM (MECHANICAL)................................................. 861 WATER LEAKS FROM SYSTEM (MECHANICAL)............................................................. 862 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE).............................................. 863 METHOD OF USING TROUBLESHOOTING CHART............................................................ 865 FAILURE CODE AND CAUSE TABLE..................................................................... 868 (H-1)............................................................................................ 870 The Machine Does Not Start................................................................... 870 (H-2)............................................................................................ 871 The Travel Speed Is Slow..................................................................... 871 (H-3)............................................................................................ 872 The Thrust Force Is Weak..................................................................... 872 (H-4)............................................................................................ 873 Engine Stalls Or Engine Speed Drops Excessively.............................................. 873 (H-5)............................................................................................ 874 The Gears Do Not Change Speed Range.......................................................... 874 (H-6)............................................................................................ 875 The Steering Wheel Does Not Turn............................................................. 875 (H-7)............................................................................................ 876 Steering Wheel Movement Is Heavy............................................................. 876 (H-8)............................................................................................ 877 Steering Wheel Shakes Or Has Jerky Movement.................................................. 877 (H-10)........................................................................................... 878 Brakes Do Not Work Or Works Poorly........................................................... 878 (H-11)........................................................................................... 879 Brakes Is Not Releasing Or Dragged........................................................... 879 (H-12)........................................................................................... 880 The Lift Arm Does Not Rise Or Lower.......................................................... 880 (H-13)........................................................................................... 881 Lift Arm Moves Slow Or Rising Force Is Poor.................................................. 881 (H-14)........................................................................................... 882 When Rising Lift Arm, Arm Moves Slowly At Specific Heights................................... 882 (H-15)........................................................................................... 882 The Lift Arm Cylinder Will Not Hold Down The Bucket (The Bucket Rises)....................... 882 (H-16)........................................................................................... 882 Hydraulic Drift On The Lift Arm Occurs Often................................................. 882 (H-17)........................................................................................... 882 The Lift Arm Wobbles During Operation........................................................ 882 (H-18)........................................................................................... 883 When The Control Lever Is Switched From “Hold” To “Raise,” The Lift Arm Falls Temporarily.... 883 (H-19)........................................................................................... 884 The Bucket Does Not Tilt Back................................................................ 884 (H-20)........................................................................................... 885 Bucket Moves Slow Or The Tilting-back Force Is Insufficient.................................. 885 (H-21)........................................................................................... 886 The Bucket Operates Slowly In Tilting-back................................................... 886 (H-22)........................................................................................... 886 Bucket Cylinder Cannot Hold Down The Bucket.................................................. 886 (H-23)........................................................................................... 886 Hydraulic Drifts Of The Bucket Occurs Often.................................................. 886 (H-24)........................................................................................... 887 The Bucket Wobbles During Travel With Cargo (The Work Equipment Valve Is Set To “Hold”)...... 887 (H-25)........................................................................................... 887 When The Control Lever Is Switched From “Hold” To “Tilt,” The Bucket Falls Temporarily....... 887 (H-26)........................................................................................... 888 Control Levers For The Lift Arm And Bucket Do Not Move Smoothly.............................. 888 (H-27)........................................................................................... 889 Travel Damper Does Not Operate And Machine Pitches And Bounces............................... 889 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................ 891 METHOD OF USING TROUBLESHOOTING CHARTS........................................................... 892 (S-1) ENGINE STARTING PERFORMANCE IS POOR........................................................ 896 (S-2) ENGINE HAS STARTING PROBLEMS............................................................... 898 Engine Does Not Crank........................................................................ 898 Engine Cranks But No Exhaust Smoke Comes Out Of Stack........................................ 899 Smoke Comes Out Of Stack But Engine Does Not Start........................................... 900 (S-3) ENGINE DOES NOT RUN SMOOTHLY............................................................... 901 (S-4) ENGINE STOPS DURING OPERATIONS............................................................. 902 (S-5) ENGINE SPEED HUNTS......................................................................... 903 (S-6) ENGINE LACKS POWER......................................................................... 904 (S-7) EXHAUST SMOKE IS BLACK..................................................................... 905 (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE...................................... 906 (S-9) OIL BECOMES CONTAMINATED QUICKLY........................................................... 907 (S-10) FUEL CONSUMPTION IS EXCESSIVE............................................................. 908 (S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR..................................... 909 (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP....................................................... 910 (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)............................................ 911 (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)................................................ 912 (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG............................................ 913 (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING................................................ 914 30 DISASSEMBLY AND ASSEMBLY.......................................................................... 915 HOW TO USE THIS MANUAL........................................................................... 918 Removal And Installation Of Componants....................................................... 918 Special Tools............................................................................ 918 Overhaul Of Componants....................................................................... 919 Special Tools............................................................................ 919 Disassembly.............................................................................. 919 Assembly................................................................................. 919 PRECAUTIONS WHEN CARRYING OUT AN OPERATION....................................................... 920 SPECIAL TOOL LIST................................................................................ 922 Sketch Of Special Tools...................................................................... 926 CONNECTOR REPAIR PROCEDURES...................................................................... 931 Contact Terminal Removal (HD30 Type)......................................................... 931 Striping Insulation.......................................................................... 932 Crimping Contact Terminal (HD30 Type)........................................................ 933 Insertion Of Contact Terminal (HD30 Type).................................................... 934 Contact Terminal Removal (DT Type)........................................................... 935 Striping Insulation.......................................................................... 936 Crimping Contact Terminal (DT Type).......................................................... 937 Insertion Of Contact Terminal (DT Type)...................................................... 938 ENGINE ASSEMBLY.................................................................................. 939 Removal Procedures........................................................................... 939 Engine Installation.......................................................................... 946 RADIATOR AND AFTER-COOLER........................................................................ 948 Radiator Removal Procedures.................................................................. 948 Radiator Installation Procedures............................................................. 949 Aftercooler Removal Procedures............................................................... 950 Aftercooler Installation Procedures.......................................................... 951 Hydraulic Oil Cooler Removal Procedures...................................................... 952 COOLING FAN AND FAN MOTOR ASSEMBLY............................................................... 954 Removal Procedures........................................................................... 954 Installation Procedures...................................................................... 955 FUEL TANK ASSEMBLY............................................................................... 956 Removal Procedures........................................................................... 956 Installation Procedures...................................................................... 958 TRANSFER ASSEMBLY................................................................................ 959 Removal Procedures........................................................................... 959 Installation Procedures...................................................................... 961 TRANSFER ASSEMBLY OVERHAUL PROCEDURES............................................................ 962 Special Tools................................................................................ 962 Disassembly Procedures....................................................................... 962 Assembly Procedures.......................................................................... 973 PARKING BRAKE ASSEMBLY........................................................................... 988 Removal Procedures........................................................................... 988 Installation Procedures...................................................................... 989 PARKING BRAKE ASSEMBLY OVERHAUL PROCEDURES....................................................... 990 Special Tools................................................................................ 990 Disassembly Procedures....................................................................... 990 Assembly Procedures.......................................................................... 992 FRONT AXLE ASSEMBLY.............................................................................. 996 Removal Procedures........................................................................... 996 Installation Procedures...................................................................... 998 REAR AXLE ASSEMBLY...............................................................................1000 Removal Procedures...........................................................................1000 Installation Procedures......................................................................1002 FRONT AND REAR AXLE HOUSING OVERHAUL PROCEDURES..................................................1004 Special Tools................................................................................1004 Disassembly Procedures.......................................................................1004 Assembly Procedures..........................................................................1010 DIFFERENTIAL CARRIER OVERHAUL PROCEDURES.........................................................1018 Special Tools................................................................................1018 Dissembly Procedures.........................................................................1018 DISASSEMBLY OF STANDARD CARRIER..........................................................1024 Disassembly Of Anti-slip Differential....................................................1026 Assembly Procedures..........................................................................1030 Assembly Of Anti-slip Differential.......................................................1030 Assembly of Standard Differential Carrier................................................1035 HST AND 4-GEAR PUMP ASSEMBLY.....................................................................1046 Removal Procedures...........................................................................1046 Installation Procedures......................................................................1048 HST MOTOR 1 ASSEMBLY.............................................................................1050 Removal Procedures...........................................................................1050 Installation Procedures......................................................................1051 HST MOTOR 2 ASSEMBLY.............................................................................1052 Removal Procedures...........................................................................1052 Installation Procedures......................................................................1053 WORK EQUIPMENT CONTROL VALVE ASSEMBLY............................................................1054 Removal Procedures...........................................................................1054 Installation Procedures......................................................................1055 TRAVEL DAMPER VALVE ASSEMBLY.....................................................................1058 Removal Procedures...........................................................................1058 Installation Procedures......................................................................1059 HYDRAULIC TANK ASSEMBLY..........................................................................1060 Removal Procedures...........................................................................1060 Installation Procedures......................................................................1062 HST PUMP OVERHAUL PROCEDURES.....................................................................1064 Special Tools List...........................................................................1064 Disassembly Procedures.......................................................................1064 Assembly Procedures..........................................................................1077 HST MOTOR OVERHAUL PROCEDURES....................................................................1096 Special Tools List...........................................................................1096 Disassembly Procedures.......................................................................1096 Assembly Procedures..........................................................................1107 CYLINDERS........................................................................................1116 Bucket (Tilt) Cylinder.......................................................................1116 Removal..................................................................................1116 Installation.............................................................................1117 Boom (Lift) Cylinder.........................................................................1118 Removal..................................................................................1118 Installation.............................................................................1119 CYLINDER OVERHAUL PROCEDURES.....................................................................1120 Special Tools List...........................................................................1120 Disassembly Procedures.......................................................................1120 Assembly Procedures..........................................................................1123 WORK EQUIPMENT ASSEMBLY..........................................................................1128 Removal Procedures...........................................................................1128 Installation Procedure.......................................................................1132 Procedure For Installing Bucket Link Pin.................................................1132 Procedure For Installing Bucket Hinge Pin................................................1133 Procedure For Installing Bucket Cylinder Pin (On Rod Side)...............................1133 Procedure For Installing Boom Cylinder Pin (On Rod Side).................................1134 Procedure For Installing Boom Pin (On Frame Side)........................................1134 Procedure For Installing Bucket Link Pin.................................................1135 Procedure For Installing Bell Crank Center Pin...........................................1136 OPERATOR'S CAB ASSEMBLY..........................................................................1138 Special Tools................................................................................1138 Removal Procedures...........................................................................1138 Installation Procedures......................................................................1143 OPERATOR'S CAB GLASS.............................................................................1144 Special Tools................................................................................1144 Removal Procedures...........................................................................1144 Installation Procedures......................................................................1146 Coating Materials............................................................................1154 CENTER HINGE PIN.................................................................................1155 Special Tools................................................................................1155 Removal Procedures...........................................................................1155 Installation Procedures......................................................................1162 REAR COUNTERWEIGHT...............................................................................1168 Removal Procedures...........................................................................1168 Installation Procedures......................................................................1169 AIR CONDITIONER UNIT.............................................................................1170 Special Tools................................................................................1170 Removal Procedures...........................................................................1170 Load Meter Specification.................................................................1171 Installation Procedures......................................................................1173 REFRIGERENT COMPRESSOR ASSEMBLY..................................................................1174 Special Tools................................................................................1174 Removal Procedures...........................................................................1174 Installation Procedures......................................................................1175 MONITOR PANEL....................................................................................1176 Removal Procedures...........................................................................1176 Installation Procedures......................................................................1181 HST CONTROLLER...................................................................................1182 Removal Procedures...........................................................................1182 Installation Procedures......................................................................1183 KOMTRAX TERMINAL ASSEMBLY........................................................................1184 Removal......................................................................................1184 Installation.................................................................................1185 90 OTHER.............................................................................................1187 HYDRAULIC CIRCUIT DIAGRAM........................................................................1188 ELECTRICAL CIRCUIT DIAGRAM.......................................................................1190 STANDARD FLOOR HARNESS.......................................................................1190 LIGHT SWITCH AND FRONT WIPER.............................................................1190 MONITOR CONTROLLER.......................................................................1191 TO CAB HARNESS...........................................................................1192 TO REAR AND BULKHEAD HARNESS.............................................................1193 TO HST HARNESS...........................................................................1194 TO SHORT CONNECTOR.......................................................................1195 TO HST CONTROLLER........................................................................1196 AIR CONDITIONER RELAY HARNESS............................................................1197 JOINT CONNECTOR..........................................................................1198 FLOOR HARNESS FOR LOAD METER.................................................................1199 LIGHT SWITCH AND FRONT WIPER.............................................................1199 MONITOR CONTROLLER.......................................................................1200 TO CAB HARNESS...........................................................................1201 TO REAR AND BULKHEAD HARNESS.............................................................1202 TO HST HARNESS...........................................................................1203 TO KOMTRAX...............................................................................1204 HST CONTROLLER...........................................................................1205 AIR CONDITIONER RELAY HARNESS............................................................1206 JOINT CONNECTOR..........................................................................1207 HST AND BULK HEAD HARNESS....................................................................1208 GRILL HARNESS................................................................................1209 ENGINE AND POWER SUPPLY HARNESS..............................................................1210 CAB HARNESS..................................................................................1211 EMERGENCY STEERING AND MULTI-FUNCTION HARNESS................................................1212 LOAD METER AND PRINTER HARNESS...............................................................1213 FRONT HARNESS................................................................................1214
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