Komatsu WA380-3 Avance Loader Shop Manual SEBM006105 PDF

COVER 1
CONTENTS 2
01 GENERAL 24
GENERAL ASSEMBLY DRAWING 25
SPECIFICATIONS 27
WEIGHT TABLE 30
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
POWER TRAIN 35
POWER TRAIN SYSTEM 36
TORQUE CONVERTER, TRANSMISSION PIPING 38
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 39
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 40
TORQUE CONVERTER 41
TORQUE CONVERTER OIL FILTER 43
TRANSMISSION 44
TRANSMISSION CONTROL VALVE 54
DRIVE SHAFT 76
AXLE 77
DIFFERENTIAL 79
FINAL DRIVE 83
AXLE MOUNT, CENTER HINGE PIN 84
STEERING PIPING 86
STEERING COLUMN 87
STEERING VALVE 88
ORBIT-ROLL VALVE 102
STOP VALVE 106
EMERGENCY STEERING PUMP 107
DIVERTER VALVE 108
BRAKE PIPING 111
BRAKE HYDRAULIC CIRCUIT DIAGRAM 112
BRAKE VALVE 114
ACCUMULATOR CHARGE VALVE 119
ACCUMULATOR (FOR BRAKE) 125
BRAKE 127
PARKING BRAKE CONTROL 129
PARKING BRAKE 130
PARKING BRAKE SOLENOID VALVE 131
PARKING BRAKE VALVE 132
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 133
HYDRAULIC PIPING 134
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 135
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 136
WORK EQUIPMENT LEVER LINKAGE 140
HYDRAULIC TANK 141
PPC VALVE 143
PPC RELIEF VALVE 148
ACCUMULATOR (FOR PPC VALVE) 149
MAIN CONTROL VALVE 150
WORK EQUIPMENT LINKAGE 165
BUCKET 167
BUCKET POSITIONED AND BOOM KICK-OUT 168
CAB 174
ROPS CAB 176
AIR CONDITIONER 177
ELECTRIC CIRCUIT DIAGRAM 178
MACHINE MONITOR SYSTEM 189
MAIN MONITOR 190
MAINTENANCE MONITOR 195
WORK EQUIPMENT CONTROL SYSTEM 198
E C S S (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) 205
SENSORS 209
ENGINE STARTING CIRCUIT 213
ENGINE STOP CIRCUIT 214
PREHEATING CIRCUIT 215
ELECTRIC TRANSMISSION CONTROL 216
KICK-DOWN SWITCH 219
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 220
TRANSMISSION CUT-OFF SWITCH 225
TRANSMISSION CUT-OFF FUNCTION 226
ELECTRIC PARKING BRAKE CONTROL 228
20 TESTING AND ADJUSTING 240
STANDARD VALUE TABLE FOR ENGINE 241
STANDARD VALUE TABLE FOR CHASSIS 242
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 246
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 250
ADJUSTING VALVE CLEARANCE 251
MEASURING COMPRESSION PRESSURE 252
MEASURING BLOW-BY PRESSURE 253
TESTING AND ADJUSTING FUEL INJECTION TIMING 254
MEASURING EXHAUST COLOR 256
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 257
MEASURING EXHAUST GAS TEMPERATURE 258
MEASURING ENGINE OIL PRESSURE 259
MEASURING ENGINE SPEED 260
TESTING AND ADJUSTING FAN BELT TENSION 261
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 262
MEASURING ACCELERATOR PEDAL 264
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 266
MEASURING STALL SPEED 267
MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE 269
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 271
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL 273
TESTING AND ADJUSTING STEERING WHEEL 274
TESTING AND ADJUSTING STEERING CONTROL 277
MEASURING STEERING OIL PRESSURE 278
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 280
MEASURING BRAKE PERFORMANCE 281
TESTING BRAKE OIL PRESSURE 282
TESTING FOR BRAKE DISC WEAR 283
BLEEDING AIR FROM BRAKE SYSTEM 284
MEASURING PARKING BRAKE PERFORMANCE 285
MANUAL RELEASE METHOD FOR PARKING BRAKE 286
TESTING WEAR OF PARKING BRAKE DISC 287
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 288
MEASURING WORK EQUIPMENT CONTROL LEVER 289
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 291
MEASURING PPC VALVE PRESSURE 293
MEASURING WORK EQUIPMENT 295
TESTING AND ADJUSTING BUCKET POSITIONER 297
TESTING AND ADJUSTING BOOM KICK-OUT 298
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 300
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER 301
TROUBLESHOOTING 302
POINTS TO REMEMBER WHEN TROUBLESHOOTING 303
SEQUENCE OF EVENTS IN TROUBLESHOOTING 304
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 305
HANDLING CONNECTORS 312
CHECKS BEFORE TROUBLESHOOTING 313
METHOD OF USING TROUBLESHOOTING CHARTS 314
CONNECTOR TYPES AND MOUNTING LOCATIONS 322
CONNECTOR PIN ARRANGEMENT DIAGRAM 323
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 328
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 335
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 336
S-2 ENGINE DOES NOT START 337
(1) ENGINE DOES NOT TURN 337
(2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 338
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 339
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 340
S-4 ENGINE STOPS DURING OPERATIONS 341
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 342
S-6 ENGINE LACKS OUTPUT (NO POWER) 343
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 344
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 345
S-9 OIL BECOMES CONTAMINATED QUICKLY 346
S-10 FUEL CONSUMPTION IS EXCESSIVE 347
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 348
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 349
S-13 OIL LEVEL RISES 350
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 351
S-15 ABNORMAL NOISE IS MADE 352
S-16 VIBRATION IS EXCESSIVE 353
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 354
TROUBLE DATA DISPLAY 356
M-1 MAIN MONITOR DOES NOT WORK 358
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP 359
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 360
M-4 ABNORMALITY IN SHIFT INDICATOR 361
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 361
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 361
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F 361
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R 362
(e) DOES NOT DISPLAY 1ST,4TH 362
(f) DOES NOT DISPLAY 3RD,4TH 362
(g) DOES NOT DISPLAY 2ND,3RD 363
(h) DOES NOT DISPLAY 1ST,2ND 363
M-5 HIGH BEAM DOES NOT LIGHT UP 364
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 365
(a) L H TURN SIGNAL DOES NOT LIGHT UP 365
(b) R H TURN SIGNAL DOES NOT LIGHT UP 365
M-7 ABNORMALITY IN PARKING DISPLAY 366
(a) PARKING LAMP DOES NOT LIGHT UP 366
(b) PARKING LAMP STAYS LIGHTED UP 366
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS) 367
(a) DOES NOT CARRY OUT PREHEATING 367
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE 368
(c) PREHEATING STAYS ON 368
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION 369
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 370
M-10 ABNORMALITY IN FRONT WORKING LAMP 371
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 371
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 371
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 371
M-11 ABNORMALITY IN REAR WORKING LAMP 372
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 372
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 372
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 372
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 374
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 374
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON 374
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED 375
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 376
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES 376
(b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N 376
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED 377
(a) ACTUATED CONTINUOUSLY 377
(b) NOT ACTUATED 377
M-15 ABNORMALITY IN BUZZER 378
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 378
(b) BUZZER ALWAYS SOUNDS 378
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 379
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 380
(a) DOES NOT ENTER FAILURE DISPLAY MODE 380
(b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 380
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY 381
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP 381
(b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP 381
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY 382
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP 382
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP 382
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM 383
(a) FORCED GREASING CANNOT BE CARRIED OUT 383
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 383
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 383
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) 384
(e) MONITOR DISPLAY GOES OUT 384
M-21 ABNORMALITY IN ECSS SYSTEM 385
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED 385
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK 385
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED 385
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 386
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 387
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK 388
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 388
(b) SOME LAMPS DO NOT LIGHT UP 389
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT 389
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT 390
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 391
(a) ENGINE OIL LEVEL DISPLAY FLASHES 391
(b) ENGINE WATER LEVEL DISPLAY FLASHES 392
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 393
(a) ENGINE OIL PRESSURE DISPLAY FLASHES 393
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES 394
(c) BRAKE OIL PRESSURE DISPLAY FLASHES 395
(d) AIR CLEANER DISPLAY FLASHES 396
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 397
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 398
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP 399
(a) CHECK LAMP 399
(b) CAUTION LAMP 399
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP)LIGHTS UP 400
(a) CHECK LAMP 400
(b) CAUTION LAMP 400
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) 401
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP 402
K-12 SERVICE METER DOES NOT WORK 403
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 403
K-14 ABNORMALITY IN GAUGE ITEMS 404
(a) ABNORMALITY IN FUEL GAUGE 404
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 405
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 406
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 407
E-1 ENGINE DOES NOT START 408
(a) STARTING MOTOR DOES NOT TURN 408
(b) STARTING MOTOR TURNS 412
E-2 ENGINE DOES NOT STOP 414
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 414
E-4 PARKING BRAKE DOES NOT WORK 415
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON 415
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS 415
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 416
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 418
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED 418
E-8 TRANSMISSION DOES NOT WORK NORMALLY 419
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND) 421
(b) PROBLEM IN H-L CIRCUIT 421
(c) PROBLEM IN SPEED CIRCUIT 422
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH) 422
(e) CONTACT IN H-L CIRCUIT 423
(f) CONTACT IN SPEED CIRCUIT 425
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH) 427
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL) 428
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL) 430
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL) 432
(k) CONTACT IN FORWARD CIRCUIT 434
(l) CONTACT IN REVERSE CIRCUIT 436
(m) PROBLEM IN COMMON CIRCUIT FOE FORWARD AND REVERSE 438
E-9 KICK-DOWN SWITCH DOES NOT WORK 439
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION) (SELF-HOLDING FUNCTION)) 441
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED 441
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R 441
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH) 442
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND 444
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) 445
POWER TRAIN 446
T-1 MACHINE DOES NOT START 446
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 448
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 450
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 451
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 452
STEERING SYSTEM 453
T-6 STEERING DOES NOT TURN 453
T-7 STEERING WHEEL IS HEAVY 454
T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK 455
T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING 455
T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT 455
BRAKE SYSTEM 456
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 456
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG 457
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 458
WORK EQUIPMENT 459
T-14 BOOM DOES NOT RISE 459
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 460
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 461
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 461
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM 461
T-19 BOOM SHAKES DURING OPERATION 461
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 462
T-21 BUCKET DOES NOT TILT BACK 463
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 464
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 465
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 465
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 465
T-26 BUCKET SHAKES DURING LOADING OPERATION 466
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 466
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 467
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) 468
JUDGMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM 469
D-1 ECSS DOES NOT WORK 470
(a) ERROR CODE [d0] IS DISPLAYED 471
(b) ERROR CODE [d1] IS DISPLAYED 471
(c) ERROR CODE [d2] IS DISPLAYED 472
(d) ERROR CODE [d3] IS DISPLAYED 472
(e) ERROR CODE [d4] IS DISPLAYED 473
(f) NO ABNORMALITY DISPLAY IS GIVEN 473
D-2 ECSS CANNOT BE CANCELED 477
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 km/h) (DEVIATES AROUND 5 km/h) 478
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST 478
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH 479
D-6 CONTROLLER LED CODE IS NOT DISPLAYED 480
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY 480
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) 481
OUTLINE 483
1 FUNCTION 483
2 WHEN CARRYING OUT TROUBLESHOOTING 483
3 FAILURE COED TABLE 483
4 TABLE OF TROUBLESHOOTING MODES AND CAUSES 484
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM 486
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF 487
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM 488
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM 489
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID 490
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID 490
W-7 FAILURE CODE [48] ABNORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM 491
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM 493
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM 494
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH 495
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIOMETER SYSTEM 496
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM 496
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS 498
W-14 SENSOR CANNOT BE ADJUSTED 499
W-15 DOES NOT CARRY OUT AUTO-LEVELING 500
(a) AUTO-LEVELER SWITCH SYSTEM 500
(b) AUTO-LEVELER LED SYSTEM 500
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM 501
(d) ENGINE SPEED SIGNAL SYSTEM 502
W-16 AUTO-LEVELER CANNOT BE SET 503
(a) AUTO-LEVELER SET SWITCH SYSTEM 503
(b) AUTO-LEVELER SET LED SYSTEM 503
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP 504
(a) REMOTE POSITIONED SWITCH SYSTEM 504
(b) REMOTE POSITIONED LED SYSTEM 504
W-18 REMOTE POSITIONED SET LEDS DO NOT FLASH 505
(a) REMOTE POSITIONED SWITCH SYSTEM 505
(b) REMOTE POSITIONED LED SYSTEM 505
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONED IS AT RAISE AND AUTO MODE IS ON 506
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND 507
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW 508
W-22 BUCKET (LEVER) CONTROL 509
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT 509
(b) LEVER IS NOT HELD BY DETENT 510
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR 512
W-24 MAINTENANCE MONITOR CHECK 513
30 DISASSEMBLY AND ASSEMBLY 514
METHOD OF USING MANUAL 516
PRECAUTIONS WHEN CARRYING OUT OPERATION 517
SPECIAL TOOL LIST 519
STARTING MOTOR 521
REMOVAL AND INSTALLATION 521
ALTERNATOR 522
REMOVAL AND INSTALLATION 522
ENGINE OIL COOLER 523
REMOVAL AND INSTALLATION 523
FUEL INJECTION PUMP 524
REMOVAL 524
INSTALLATION 525
WATER PUMP 526
REMOVAL AND INSTALLATION 526
TURBOCHARGER 528
REMOVAL AND INSTALLATION 528
NOZZLE HOLDER 529
REMOVAL AND INSTALLATION 529
THERMOSTAT 530
REMOVAL AND INSTALLATION 530
CYLINDER HEAD 531
REMOVAL 531
INSTALLATION 536
RADIATOR 538
REMOVAL 538
INSTALLATION 541
ENGINE 542
REMOVAL 542
INSTALLATION 547
TORQUE CONVERTER CHARGING PUMP 548
REMOVAL 548
INSTALLATION 549
TORQUE CONVERTER, TRANSMISSION 550
REMOVAL 550
INSTALLATION 554
TORQUE CONVERTER 555
DISASSEMBLY 555
ASSEMBLY 557
TRANSMISSION 560
DISASSEMBLY 560
ASSEMBLY 570
TRANSMISSION CLUTCH PACK 584
DISASSEMBLY 584
ASSEMBLY 590
TRANSMISSION CONTROL VALVE 602
REMOVAL 602
INSTALLATION 604
DISASSEMBLY 605
ASSEMBLY 607
TRANSMISSION ACCUMULATOR VALVE 610
DISASSEMBLY 610
ASSEMBLY 611
TRANSMISSION MODULATING VALVE 612
DISASSEMBLY 612
ASSEMBLY 613
DRIVE SHAFT 614
DISASSEMBLY 614
ASSEMBLY 617
FRONT AXLE 619
REMOVAL 619
INSTALLATION 621
REAR AXLE 622
REMOVAL 622
INSTALLATION 626
DIFFERENTIAL 628
DISASSEMBLY 628
ASSEMBLY 633
AXLE HOUSING 643
DISASSEMBLY 643
ASSEMBLY 650
CENTER HINGE PIN 660
REMOVAL 660
INSTALLATION 664
STEERING VALVE 667
REMOVAL 667
INSTALLATION 669
DISASSEMBLY 670
ASSEMBLY 674
ORBIT-ROLL VALVE 677
REMOVAL 677
INSTALLATION 678
DISASSEMBLY 679
ASSEMBLY 682
STEERING CYLINDER 687
REMOVAL 687
INSTALLATION 688
BRAKE VALVE 689
REMOVAL 689
INSTALLATION 690
RIGHT BRAKE VALVE (TANDEM) 691
DISASSEMBLY 691
ASSEMBLY 692
LEFT BRAKE VALVE (SINGLE) 693
DISASSEMBLY 693
ASSEMBLY 694
PARKING BRAKE DISC 695
REMOVAL 695
INSTALLATION 697
ACCUMULATOR CHARGE VALVE 698
REMOVAL AND INSTALLATION 698
DISASSEMBLY 699
ASSEMBLY 701
HYDRAULIC TANK 703
REMOVAL 703
INSTALLATION 705
HYDRAULIC FILTER 706
REMOVAL AND INSTALLATION 706
HYDRAULIC, STEERING, SWITCH, PPC PUMP 707
REMOVAL 707
INSTALLATION 710
MAIN CONTROL VALVE 711
REMOVAL 711
INSTALLATION 713
DISASSEMBLY 714
ASSEMBLY 716
PPC VALVE 719
REMOVAL 719
INSTALLATION 721
DISASSEMBLY 722
ASSEMBLY 723
BUCKET CYLINDER 724
REMOVAL 724
INSTALLATION 726
BOOM CYLINDER 727
REMOVAL 727
INSTALLATION 728
HYDRAULIC CYLINDER 729
DISASSEMBLY 729
ASSEMBLY 732
WORK EQUIPMENT 735
REMOVAL 735
INSTALLATION 738
COUNTERWEIGHT 740
REMOVAL AND INSTALLATION 740
FUEL TANK 741
REMOVAL 741
INSTALLATION 743
CAB, FLOOR FRAME 744
REMOVAL 744
INSTALLATION 747
CAB 748
REMOVAL 748
INSTALLATION 749
MAIN MONITOR 750
REMOVAL 750
INSTALLATION 751
MAINTENANCE MONITOR 752
REMOVAL AND INSTALLATION 752
AIR CONDITIONER UNIT 753
REMOVAL 753
INSTALLATION 758
AIR CONDITIONER CONDENSER 759
REMOVAL 759
INSTALLATION 760
DRY RECEIVER 761
REMOVAL AND INSTALLATION 761
AIR CONDITIONER CONDENSER COMPRESSOR 762
REMOVAL AND INSTALLATION 762
40 MAINTENANCE STANDARD 763
ENGINE MOUNT, TRANSMISSION MOUNT 764
TORQUE CONVERTER CHARGING PUMP 765
TORQUE CONVERTER 766
TRANSMISSION 767
TRANSMISSION CONTROL VALVE 775
MODULATION VALVE ASSEMBLY 779
ACCUMULATOR VALVE 780
DRIVE SHAFT 781
DIFFERENTIAL 782
FINAL DRIVE 785
AXLE MOUNT 787
CENTER HINGE PIN 788
STEERING COLUMN 790
STEERING VALVE 791
STEERING CYLINDER MOUNT 792
BRAKE 793
BRAKE VALVE 794
PARKING BRAKE 797
HYDRAULIC PUMP 798
MAIN CONTROL VALVE 799
PPC VALVE 803
HYDRAULIC CYLINDER 804
WORK EQUIPMENT LINKAGE 805
BUCKET 807
BUCKET POSITIONED AND BOOM KICK-OUT 808

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

● Always wear safety glasses when hitting parts with a hammer.

● Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.

5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.

8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.

13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.