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Komatsu WA380-3 Avance Loader Wheel Loader Shop Manual SEBM006104 – PDF DOWNLOAD
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Komatsu WA380-3 Avance Loader Wheel Loader Shop Manual
SERIAL NUMBERS WA380-3 – 50001 and up
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Description
Komatsu WA380-3 Avance Loader Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA380-3 Avance Loader Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA380-3 Avance Loader
Serial Number: 50001 and up
Book Code: SEBM006104
Language: English
Pages: 802
File Format: Portable Document Format (PDF)
KOMATSU WA380-3 AVANCE LOADER WHEEL LOADER SHOP MANUAL SEBM006104 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu WA380-3 Avance Loader Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- 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 chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” 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.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA380-3 Avance Loader Wheel Loader Shop Manual
MAIN MENU...................................................................................................................................................... 0 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 BREAK PIPING...............................................................................................................................................111 BRAKE HYDRAULIC CIRCUIT DIAGRAM ...........................................................................................................................112 BRAKE VALVE ...............................................................................................................................................113 ACCUMULATOR CHARGE VALVE...................................................................................................................................118 ACCUMULATOR (FOR BRAKE) ...................................................................................................................................124 BRAKE......................................................................................................................................................126 PARKING BRAKE CONTROL .....................................................................................................................................128 PARKING BRAKE .............................................................................................................................................129 PARKING BRAKE SOLENOID VALVE ..............................................................................................................................130 PARKING BRAKE VALVE .......................................................................................................................................131 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE ............................................................................................................132 HYDRAULIC PIPING...........................................................................................................................................133 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....................................................................................................................134 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................135 WORK EQUIPMENT LEVER LINKAGE ..............................................................................................................................139 HYDRAULIC TANK ............................................................................................................................................140 PPC VALVE .................................................................................................................................................142 PPC RELIEF VALVE...........................................................................................................................................147 ACCUMULATOR (FOR PPC VALVE) ..............................................................................................................................148 MAIN CONTROL VALVE ........................................................................................................................................149 WORK EQUIPMENT LINKAGE ....................................................................................................................................164 BUCKET ....................................................................................................................................................166 BUCKET POSITIONER AND BOOM KICK-OUT .....................................................................................................................167 CAB........................................................................................................................................................173 ROPS CAB ..................................................................................................................................................175 AIR CONDITIONER ...........................................................................................................................................176 ELECTRIC CIRCUIT DIAGRAM ..................................................................................................................................187 MACHINE MONITOR SYSTEM ....................................................................................................................................188 MAIN MONITOR ..............................................................................................................................................189 MAINTENANCE MONITOR ......................................................................................................................................194 WORK EQUIPMENT CONTROL SYSTEM .............................................................................................................................197 E.C.S.S. (Electronically Controlled Suspension System) ..................................................................................................204 SENSORS ...................................................................................................................................................208 ENGINE STARTING CIRCUIT ...................................................................................................................................212 ENGINE STOP CIRCUIT .......................................................................................................................................213 PREHEATING CIRCUIT.........................................................................................................................................214 ELECTRIC TRANSMISSION CONTROL ............................................................................................................................215 KICK-DOWN SWITCH ..........................................................................................................................................218 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM ........................................................................................................................219 TRANSMISSION CUT-OFF SWITCH ..............................................................................................................................224 TRANSMISSION CUT-OFF FUNCTION ............................................................................................................................225 ELECTRIC PARKING BRAKE CONTROL ............................................................................................................................227 20 TESTING AND ADJUSTING ......................................................................................................................................239 STANDARD VALUE TABLE FOR ENGINE ...........................................................................................................................240 STANDARD VALUE TABLE FOR CHASSIS ..........................................................................................................................241 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ................................................................................................................245 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING .........................................................................................................249 ADJUSTING VALVE CLEARANCE .................................................................................................................................250 MEASURING COMPRESSION PRESSURE ............................................................................................................................251 MEASURING BLOW-BY PRESSURE ..............................................................................................................................252 TESTING AND ADJUSTING FUEL INJECTION TIMING ...............................................................................................................253 MEASURING EXHAUST COLOR ...................................................................................................................................255 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ...........................................................................................................256 MEASURING EXHAUST GAS TEMPERATURE .........................................................................................................................257 MEASURING ENGINE OIL PRESSURE ............................................................................................................................258 MEASURING ENGINE SPEED ....................................................................................................................................259 TESTING AND ADJUSTING FAN BELT TENSION ....................................................................................................................260 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE .............................................................................................................261 MEASURING ACCELERATOR PEDAL ..............................................................................................................................263 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER ..........................................................................................................265 MEASURING STALL SPEED .....................................................................................................................................266 MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE ......................................................................................268 METHOD OF OPERATING EMERGENCY MANUALSPOOL .................................................................................................................270 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL ................................................................................................................272 TESTING AND ADJUSTING STEERING WHEEL ......................................................................................................................273 TESTING AND ADJUSTING STEERING CONTROL ....................................................................................................................276 MEASURING STEERING OIL PRESSURE ...........................................................................................................................277 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL .........................................................................................................279 MEASURING BRAKE PERFORMANCE ...............................................................................................................................280 TESTING BRAKE OIL PRESSURE ................................................................................................................................281 TESTING FOR BRAKE DISC WEAR ...............................................................................................................................282 BLEEDING AIR FROM BRAKE SYSTEM ...........................................................................................................................283 MEASURING PARKING BRAKE PERFORMANCE ......................................................................................................................284 MANUAL RELEASE METHOD FOR PARKING BRAKE ...................................................................................................................285 TESTING WEAR OF PARKING BRAKE DISC ........................................................................................................................286 MEASURING WORK EQUIPMENT CONTROL LEVER ....................................................................................................................287 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE ...............................................................................................................289 MEASURING PPC VALVE PRESSURE ..............................................................................................................................291 MEASURING WORK EQUIPMENT .................................................................................................................................293 TESTING AND ADJUSTING BUCKET POSITIONER .................................................................................................................295 TESTING AND ADJUSTING BOOM KICK-OUT .....................................................................................................................296 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) ..............................................................................................................298 ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER ..............................................................................................................299 TROUBLESHOOTING............................................................................................................................................300 POINTS TO REMEMBER WHEN TROUBLESHOOTING ...............................................................................................................301 SEQUENCE OF EVENTS IN TROUBLESHOOTING .................................................................................................................302 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE .............................................................................................................303 HANDLING CONNECTORS ...................................................................................................................................310 CHECKS BEFORE TROUBLESHOOTING .........................................................................................................................311 METHOD OF USING TROUBLESHOOTING CHARTS ................................................................................................................312 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................................320 CONNECTOR PIN ARRANGEMENT DIAGRAM......................................................................................................................321 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ............................................................................................................326 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) .............................................................................................................333 S-1 Starting performance is poor (Starting always takes time) ....................................................................................334 S-2 Engine does not start .........................................................................................................................335 (1) Engine does not turn.......................................................................................................................335 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).....................................................................336 (3) Exhaust gas comes out but engine does not start (Fuel is being injected)...................................................................337 S-3 Engine does not pick up smoothly (Follow-up is poor) ..........................................................................................338 S-4 Engine stops during operations ................................................................................................................339 S-5 Engine does not rotate smoothly (hunting) .....................................................................................................340 S-6 Engine lacks output (no power) ................................................................................................................341 S-7 Exhaust gas is black (incomplete combustion) ..................................................................................................342 S-8 Oil consumption is excessive (or exhaust gas is blue) .........................................................................................343 S-9 Oil becomes contaminated quickly ..............................................................................................................344 S-10 Fuel consumption is excessive ................................................................................................................345 S-11 Oil is in cooling water, or water spurts back, or water level goes down.......................................................................346 S-12 Oil pressure lamp lights up (drop in oil pressure) ...........................................................................................347 S-13 Oil level rises ..............................................................................................................................348 S-14 Water temperature becomes too high (overheating) ............................................................................................349 S-15 Abnormal noise is made........................................................................................................................350 S-16 Vibration is excessive........................................................................................................................351 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) .......................................................................................................352 TROUBLE DATA DISPLAY ..............................................................................................................................354 M-1 Main monitor does not work.....................................................................................................................356 M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up ...............................................357 M-3 Speedometer display does not work properly ....................................................................................................358 M-4 Abnormality in shift indicator ................................................................................................................359 (a) Stays at N even when directional lever is at F.............................................................................................359 (b) Stays at N even when directional lever is at R.............................................................................................359 (c) Does not display N even when directional lever is at N and displays R when directional lever is at F.......................................359 (d) Does not display N even when directional lever is at N and displays F when directional lever is at R.......................................360 (e) Does not display lst, 4th..................................................................................................................360 (f) Does not display 3rd, 4th..................................................................................................................360 (g) Does not display 2nd, 3rd..................................................................................................................361 (h) Does not display 1st, 2nd..................................................................................................................361 M-5 High beam does not light up ...................................................................................................................362 M-6 Turn signal display does not light up .........................................................................................................363 (a) L.H. turn signal does not light up.........................................................................................................363 (b) R.H. turn signal does not light up.........................................................................................................363 M-7 Abnormality in parking display ................................................................................................................364 (a) Parking lamp does not light up.............................................................................................................364 (b) Parking lamp stays lighted up..............................................................................................................364 M-8 Abnormality in preheating system (QGS) ........................................................................................................365 (a) Does not carry out preheating..............................................................................................................365 (b) Always carries out preheating for 1 minute.................................................................................................366 (c) Preheating stays on........................................................................................................................366 (d) Preheating time becomes shorter, or there is variation.....................................................................................367 M-9 Night lighting does not light up ..............................................................................................................368 M-10 Abnormality in front working lamp ............................................................................................................369 (a) Neither monitor display nor front working lamp light up....................................................................................369 (b) Working lamp lights up but monitor display does not light up...............................................................................369 (c) Monitor lights up but working lamp does not light up.......................................................................................369 M-11 Abnormality in rear working lamp..............................................................................................................370 (a) Neither monitor display nor rear working lamp light up.....................................................................................370 (b) Working lamp lights up but monitor display does not light up...............................................................................370 (c) Monitor lights up but working lamp does not light up.......................................................................................370 M-12 Abnormality in transmission cut-off...........................................................................................................372 (a) When monitor switch is pressed, cut-off function is not switched and display is not given..................................................372 (b) Monitor display goes out but cut-off function stays on.....................................................................................372 (c) Monitor display lights up but cut-off function is not actuated.............................................................................373 M-13 Abnormality in parking brake dragging warning.................................................................................................374 (a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, and caution lamp flashes................374 (b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po...............374 M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated.....................375 (a) Actuated continuously......................................................................................................................375 (b) Not actuated...............................................................................................................................375 M-15 Abnormality in buzzer.........................................................................................................................376 (a) Buzzer does not sound when starting switch is turned ON (during self-check)................................................................376 (b) Buzzer always sounds.......................................................................................................................376 M-16 Condition of monitor switches is not stored in memory.........................................................................................377 M-17 Abnormality in failure display mode...........................................................................................................378 (a) Does not enter failure display mode........................................................................................................378 (b) Time for time elapsed since failure on failure display mode does not advance...............................................................378 M-18 Abnormality in emergency steering normal display..............................................................................................379 (a) Emergency steering normal display does not light up........................................................................................379 (b) Emergency steering normal display stays lighted up.........................................................................................379 M-19 Abnormality in emergency steering actuation display...........................................................................................380 (a) Emergency steering actuation display does not light up.....................................................................................380 (b) Emergency steering actuation display stays lighted up......................................................................................380 M-20 Abnormality in auto-greasing system...........................................................................................................381 (a) Forced greasing cannot be carried out......................................................................................................381 (b) Monitor display flashes rapidly (2 times/sec)..............................................................................................381 (c) When no more grease remains, monitor display flashes rapidly (2 times/sec).................................................................381 (d) Monitor display flashes slowly (1 time/sec)................................................................................................382 (e) Monitor display goes out...................................................................................................................382 M-21 Abnormality in ECSS system....................................................................................................................383 (a) Display does not change when switch is pressed.............................................................................................383 (b) Monitor display lights up but ECSS function does not work..................................................................................383 M-22 Buzzer does not sound when auto-leveling switch is actuated...................................................................................383 M-23 Failure code is not sent to main monitor (abnormality in network).............................................................................384 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) ................................................................................................385 K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec., maintenance monitor does not...................386 (a) All lamps on maintenance monitor do not light up for 3 seconds.............................................................................386 (b) Some lamps do not light up.................................................................................................................387 K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out ...............................................387 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 ....388 K-4 When starting switch is turned ON (engine stopped), CHECK items flash ........................................................................389 (a) Engine oil level display flashes...........................................................................................................389 (b) Engine water level display flashes.........................................................................................................390 K-5 When starting switch is turned ON (engine started), CAUTION items flash ......................................................................391 (a) Engine oil pressure display flashes........................................................................................................391 (b) Battery charge level display flashes.......................................................................................................392 (c) Brake oil pressure display flashes.........................................................................................................393 (d) Air cleaner display flashes................................................................................................................394 K-6 CAUTION items are flashing but alarm buzzer does not sound ....................................................................................395 K-7 There is no abnormality in monitor display but alarm buzzer sounds ...........................................................................396 K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up .....................................................397 (a) CHECK lamp.................................................................................................................................397 (b) CAUTION lamp...............................................................................................................................397 K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up .................................398 (a) CHECK lamp.................................................................................................................................398 (b) CAUTION lamp...............................................................................................................................398 K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) .....................399 K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up ......................................................400 K-12 Service meter does not work ..................................................................................................................401 K-13 Service meter is running even when engine is stopped..........................................................................................401 K-14 Abnormality in gauge items ...................................................................................................................402 (a) Abnormality in fuel gauge..................................................................................................................402 (b) Abnormality in engine water temperature gauge..............................................................................................403 (c) Abnormality in torque converter oil temperature gauge......................................................................................404 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) .........................................................................................................405 E-1 Engine does not start .........................................................................................................................406 (a) Starting motor does not turn...............................................................................................................406 (b) Starting motor turns.......................................................................................................................410 E-2 Engine does not stop ..........................................................................................................................412 E-3 Engine stops when machine is traveling ........................................................................................................412 E-4 Parking brake does not work ...................................................................................................................413 (a) Parking brake has no effect when parking brake switch is turned ON (parking)...............................................................413 (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)...................................................413 E-5 Parking brake is applied when machine is traveling ............................................................................................414 E-6 Parking brake is released when starting switch is turned ON ...................................................................................416 E-7 Transmission does when parking brake is applied (but parking brake works normally) ..........................................................416 E-8 Transmission does not work normally ...........................................................................................................417 (a) Problem in common circuit for transmission (always stays in 2nd)...........................................................................419 (b) Problem in H-L circuit.....................................................................................................................419 (c) Problem in speed circuit...................................................................................................................420 (d) Problem in 4th circuit (does not enter 4th)................................................................................................420 (e) Contact in H-L circuit.....................................................................................................................421 (f) Contact in speed circuit...................................................................................................................423 (g) Contact in 4th circuit (always stays in 4th)...............................................................................................425 (h) Problem in FORWARD circuit (REVERSE is normal).............................................................................................426 (i) Problem in REVERSE circuit (FORWARD is normal).............................................................................................428 (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal).......................................430 (k) Contact in FORWARD circuit.................................................................................................................432 (I) Contact in REVERSE circuit.................................................................................................................434 (m) Problem in common circuit for FORWARD and REVERSE..........................................................................................436 E-9 Kick-down switch does not work (the regular F1 to F4 shifts normally).........................................................................437 E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function) .................439 E-11 Kick-down operation cannot be canceled .......................................................................................................439 (a) Not canceled even when directional lever is moved from F to N or R.........................................................................439 (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th).......................................................440 E-12 Kick-down switch is actuated by mistake when traveling in 2nd ................................................................................442 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) .........................................................................443 POWER TRAIN .......................................................................................................................................444 T-1 Machine does not start ....................................................................................................................444 T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes .....................................................................446 T-3 Excessive shock when starting machine or shifting gear ....................................................................................448 T-4 Excessive time lag when starting machine or shifting gear .................................................................................449 T-5 Torque converter oil temperature is high ..................................................................................................450 STEERING SYSTEM ...................................................................................................................................451 T-6 Steering does not turn ....................................................................................................................451 T-7 Steering wheel is heavy ...................................................................................................................452 T-8 Steering wheel wobbles or there is excessive shock .......................................................................................453 T-9 Machine steers to one side when traveling ................................................................................................453 T-10 Turning radius to left and right is different ...........................................................................................453 BRAKE SYSTEM ......................................................................................................................................454 T-11 Brakes do not work or braking effect is poor .............................................................................................454 T-12 Brakes are not released or brakes drag ...................................................................................................455 T-13 Parking brake is not released or brake drags .............................................................................................456 WORK EQUIPMENT ....................................................................................................................................457 T-14 Boom does not rise .......................................................................................................................457 T-15 Boom movement is slow or boom lacks lifting power ........................................................................................458 T-16 When boom is raised, it moves slowly at a certain height .................................................................................459 T-17 Bucket cannot be pushed with cylinder (bucket floats) ....................................................................................459 T-18 Excessive hydraulic drift of boom ........................................................................................................459 T-19 Boom shakes during operation .............................................................................................................459 T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ................................................................460 T-21 Bucket does not tilt back ................................................................................................................461 T-22 Bucket movement is slow or tilt-back lacks power .........................................................................................462 T-23 Bucket movement becomes slow during tilt-back operation ..................................................................................463 T-24 Bucket cannot be pushed with bucket cylinder .............................................................................................463 T-25 Excessive hydraulic drift of bucket ......................................................................................................463 T-26 Bucket shakes during loading operation (Main control valve at HOLD) .....................................................................464 T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ...............................................................464 T-28 Boom, bucket control levers are heavy or do not move smoothly ............................................................................465 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) ........................................................................466 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM ..................................................................................................467 D-1 ECSS does not work ............................................................................................................................468 (a) Error code [d0] is displayed...............................................................................................................469 (b) Error code [d1] is displayed...............................................................................................................469 (c) Error code [d2] is displayed...............................................................................................................470 (d) Error code [d3] is displayed...............................................................................................................470 (e) Error code [d4] is displayed...............................................................................................................471 (f) No abnormality display is given............................................................................................................471 D-2 ECSS cannot be canceled .......................................................................................................................475 D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h) ...........................................................476 D-4 Output is turned ON when transmission..........................................................................................................476 D-5 Output is turned ON when transmission is in 4th ...............................................................................................477 D-6 Controller LED code is not displayed ..........................................................................................................478 D-7 ECSS is abnormal but main monitor does not give abnormality display ..........................................................................478 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) ..........................................................................................479 OUTLINE ...........................................................................................................................................481 1. Function........................................................................................................................................481 2. When carrying out troubleshooting...............................................................................................................481 3. Failure code table..............................................................................................................................481 4. Table of troubleshooting modes and causes.......................................................................................................482 W-1 Failure code [40] Abnormality in bucket dump solenoid system ..................................................................................484 W-2 Failure code [41] Short circuit in power source when bucket DUMP, TILT solenoids are OFF .....................................................485 W-3 Failure code [42] Abnormality in bucket tilt solenoid system ..................................................................................486 W-4 Failure code [43] Abnormality in damping solenoid system ......................................................................................487 W-5 Failure code [44]Short circuit in power source at hot end of damping solenoid ................................................................488 W-6 Failure code [45]Short circuit in power source at return end of damping solenoid .............................................................488 W-7 Failure code [48] Abnormality in bucket lever kick-out relay system ..........................................................................489 W-8 Failure code [49] Abnormality in boom lever kick-out relay system .............................................................................491 W-9 Failure code [50] Abnormality in auto-leveler relay system ....................................................................................492 W-10 Failure code [51] Disconnection in boom RAISE, LOWER detection pressure switch ..............................................................493 W-11 Failure code [52] Abnormality in boom angle potentiometer system ............................................................................494 W-12 Failure code [53] Abnormality in bucket angle potentiometer system ..........................................................................494 W-13 Failure code [54] Abnormality in model selection wiring harness ..............................................................................496 W-14 Sensor cannot be adjusted ....................................................................................................................497 W-15 Does not carry out auto-leveling .............................................................................................................498 (a) Auto-leveler switch system.................................................................................................................498 (b) Auto-leveler LED system....................................................................................................................498 (c) Bucket lever neutral switch system.........................................................................................................499 (d) Engine speed signal system.................................................................................................................500 W-16 Auto-leveler cannot be set ...................................................................................................................501 (a) Auto-leveler set switch system.............................................................................................................501 (b) Auto-leveler set LED system................................................................................................................501 W-17 Remote positioner RAISE, LOWER LEDs do not light up ..........................................................................................502 (a) Remote positioner switch system............................................................................................................502 (b) Remote positioner LED system...............................................................................................................502 W-18 Remote positioner set LEDs do not flash ......................................................................................................503 (a) Remote positioner switch system............................................................................................................503 (b) Remote positioner LED system...............................................................................................................503 W-19 Bucket does not tilt immediately at boom FLOAT detent when remote positioner is at RAISE and auto mode is ON ................................504 W-20 Buzzer for switch operation does not sound ...................................................................................................505 W-21 Bucket correction, boom stop response are slow ...............................................................................................506 W-22 Bucket (lever) control .......................................................................................................................507 (a) Bucket kick-out does not work even when bucket is at maximum tilt..........................................................................507 (b) Lever is not held by detent................................................................................................................508 W-23 Failure code is not displayed on main monitor ................................................................................................510 W-24 Maintenance monitor check ....................................................................................................................511 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................512 METHOD OF USING MANUAL ....................................................................................................................................514 PRECAUTIONS WHEN CARRYING OUT OPERATION ...................................................................................................................515 SPECIAL TOOL LIST .........................................................................................................................................517 STARTING MOTOR ............................................................................................................................................519 REMOVAL AND INSTALLATION...............................................................................................................................519 ALTERNATOR ................................................................................................................................................520 REMOVAL AND INSTALLATION...............................................................................................................................520 ENGINE OIL COOLER .........................................................................................................................................521 REMOVAL AND INSTALLATION...............................................................................................................................521 FUEL INJECTION PUMP .......................................................................................................................................522 REMOVAL................................................................................................................................................522 INSTALLATION...........................................................................................................................................523 WATER PUMP ................................................................................................................................................524 REMOVAL AND INSTALLATION...............................................................................................................................524 TURBOCHARGER...............................................................................................................................................526 REMOVAL AND INSTALLATION...............................................................................................................................526 NOZZLE HOLDER ............................................................................................................................................527 REMOVAL AND INSTALLATION...............................................................................................................................527 THERMOSTAT ................................................................................................................................................528 REMOVAL AND INSTALLATION...............................................................................................................................528 CYLINDER HEAD..............................................................................................................................................529 REMOVAL................................................................................................................................................529 INSTALLATION...........................................................................................................................................534 RADIATOR...................................................................................................................................................536 REMOVAL................................................................................................................................................536 INSTALLATION...........................................................................................................................................539 ENGINE.....................................................................................................................................................540 REMOVAL................................................................................................................................................540 INSTALLATION...........................................................................................................................................545 TORQUE CONVERTER CHARGING PUMP.............................................................................................................................546 REMOVAL................................................................................................................................................546 INSTALLATION...........................................................................................................................................547 TORQUE CONVERTER, TRANSMISSION.............................................................................................................................548 REMOVAL................................................................................................................................................548 INSTALLATION...........................................................................................................................................552 TORQUE CONVERTER...........................................................................................................................................553 DISASSEMBLY............................................................................................................................................553 ASSEMBLY...............................................................................................................................................555 TRANSMISSION...............................................................................................................................................558 DISASSEMBLY............................................................................................................................................558 ASSEMBLY...............................................................................................................................................568 TRANSMISSION CLUTCH PACK...................................................................................................................................582 DISASSEMBLY............................................................................................................................................582 ASSEMBLY...............................................................................................................................................588 TRANSMISSION CONTROL VALVE.................................................................................................................................600 REMOVAL................................................................................................................................................600 INSTALLATION...........................................................................................................................................602 DISASSEMBLY............................................................................................................................................603 ASSEMBLY...............................................................................................................................................605 TRANSMISSION ACCUMULATOR VALVE.............................................................................................................................608 DISASSEMBLY............................................................................................................................................608 ASSEMBLY...............................................................................................................................................609 TRANSMISSION MODULATING VALVE..............................................................................................................................610 DISASSEMBLY............................................................................................................................................610 ASSEMBLY...............................................................................................................................................611 DRIVE SHAFT................................................................................................................................................612 DISASSEMBLY............................................................................................................................................612 ASSEMBLY...............................................................................................................................................615 FRONT AXLE.................................................................................................................................................617 REMOVAL................................................................................................................................................617 INSTALLATION...........................................................................................................................................619 REAR AXLE..................................................................................................................................................620 REMOVAL................................................................................................................................................620 INSTALLATION...........................................................................................................................................624 DIFFERENTIAL...............................................................................................................................................626 DISASSEMBLY............................................................................................................................................626 ASSEMBLY...............................................................................................................................................631 AXLE HOUSING...............................................................................................................................................641 DISASSEMBLY............................................................................................................................................641 ASSEMBLY...............................................................................................................................................648 CENTER HINGE PIN...........................................................................................................................................658 REMOVAL................................................................................................................................................658 INSTALLATION...........................................................................................................................................662 STEERING VALVE.............................................................................................................................................665 REMOVAL................................................................................................................................................665 INSTALLATION...........................................................................................................................................667 DISASSEMBLY............................................................................................................................................668 ASSEMBLY...............................................................................................................................................672 ORBIT-ROLL VALVE...........................................................................................................................................675 REMOVAL................................................................................................................................................675 INSTALLATION...........................................................................................................................................676 DISASSEMBLY............................................................................................................................................677 ASSEMBLY...............................................................................................................................................680 STEERING CYLINDER..........................................................................................................................................685 REMOVAL................................................................................................................................................685 INSTALLATION...........................................................................................................................................686 BRAKE VALVE................................................................................................................................................687 REMOVAL................................................................................................................................................687 INSTALLATION ..........................................................................................................................................688 RIGHT BRAKE VALVE (TANDEM) ..............................................................................................................................689 DISASSEMBLY............................................................................................................................................689 ASSEMBLY ..............................................................................................................................................690 LEFT BRAKE VALVE (SINGLE) ................................................................................................................................691 DISASSEMBLY............................................................................................................................................691 ASSEMBLY ..............................................................................................................................................692 PARKING BRAKE DISC ........................................................................................................................................693 REMOVAL................................................................................................................................................693 INSTALLATION...........................................................................................................................................695 HYDRAULIC TANK.............................................................................................................................................696 REMOVAL................................................................................................................................................696 INSTALLATION...........................................................................................................................................698 HYDRAULIC FILTER...........................................................................................................................................699 REMOVAL AND INSTALLATION...............................................................................................................................699 HYDRAULIC, STEERING, SWITCH, PPC PUMP..................................................................................................................700 REMOVAL................................................................................................................................................700 INSTALLATION...........................................................................................................................................703 MAIN CONTROL VALVE.........................................................................................................................................704 REMOVAL................................................................................................................................................704 INSTALLATION ..........................................................................................................................................706 DISASSEMBLY............................................................................................................................................707 ASSEMBLY...............................................................................................................................................709 PPC VALVE .................................................................................................................................................712 REMOVAL................................................................................................................................................712 INSTALLATION...........................................................................................................................................714 DISASSEMBLY............................................................................................................................................715 ASSEMBLY ..............................................................................................................................................716 BUCKET CYLINDER............................................................................................................................................717 REMOVAL................................................................................................................................................717 INSTALLATION...........................................................................................................................................719 BOOM CYLINDER .............................................................................................................................................720 REMOVAL................................................................................................................................................720 INSTALLATION...........................................................................................................................................721 HYDRAULIC CYLINDER ........................................................................................................................................722 DISASSEMBLY............................................................................................................................................722 ASSEMBLY...............................................................................................................................................725 WORK EQUIPMENT............................................................................................................................................728 REMOVAL................................................................................................................................................728 INSTALLATION ..........................................................................................................................................731 COUNTERWEIGHT .............................................................................................................................................733 REMOVAL AND INSTALLATION...............................................................................................................................733 FUEL TANK .................................................................................................................................................734 REMOVAL................................................................................................................................................734 INSTALLATION ..........................................................................................................................................736 CAB, FLOOR FRAME..........................................................................................................................................737 REMOVAL................................................................................................................................................737 INSTALLATION...........................................................................................................................................740 CAB........................................................................................................................................................741 REMOVAL................................................................................................................................................741 INSTALLATION...........................................................................................................................................742 MAIN MONITOR...............................................................................................................................................743 REMOVAL................................................................................................................................................743 INSTALLATION...........................................................................................................................................744 MAINTENANCE MONITOR........................................................................................................................................745 REMOVAL AND INSTALLATION...............................................................................................................................745 AIR CONDITIONER UNIT ......................................................................................................................................746 REMOVAL................................................................................................................................................746 INSTALLATION ..........................................................................................................................................751 AIR CONDITIONER CONDENSER..................................................................................................................................752 REMOVAL................................................................................................................................................752 INSTALLATION...........................................................................................................................................753 DRY RECEIVER...............................................................................................................................................754 REMOVAL AND INSTALLATION...............................................................................................................................754 AIR CONDITIONER CONDENSER COMPRESSOR ......................................................................................................................755 REMOVAL AND INSTALLATION...............................................................................................................................755 40 MAINTENANCE STANDARD .......................................................................................................................................756 ENGINE MOUNT, TRANSMISSION MOUNT ..........................................................................................................................757 TORQUE CONVERTER CHARGING PUMP ............................................................................................................................758 TORQUE CONVERTER ..........................................................................................................................................759 TRANSMISSION...............................................................................................................................................760 TRANSMISSION CONTROL VALVE ................................................................................................................................768 MODULATION VALVE ASSEMBLY .................................................................................................................................772 ACCUMULATOR VALVE ........................................................................................................................................773 DRIVE SHAFT ...............................................................................................................................................774 DIFFERENTIAL ..............................................................................................................................................775 FINAL DRIVE ...............................................................................................................................................778 AXLE MOUNT ................................................................................................................................................780 CENTER HINGE PIN ..........................................................................................................................................781 STEERING COLUMN ...........................................................................................................................................783 STEERING VALVE ............................................................................................................................................784 STEERING CYLINDER MOUNT ...................................................................................................................................785 BRAKE .....................................................................................................................................................786 BRAKE VALVE ...............................................................................................................................................787 PARKING BRAKE .............................................................................................................................................790 HYDRAULIC PUMP.............................................................................................................................................791 MAIN CONTROL VALVE ........................................................................................................................................792 PPC VALVE .................................................................................................................................................796 HYDRAULIC CYLINDER ........................................................................................................................................797 WORK EQUIPMENT LINKAGE ...................................................................................................................................798 BUCKET ....................................................................................................................................................800 BUCKET POSITIONER AND BOOM KICK-OUT .......................................................................................................................801
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