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KOMATSU WA420-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up) – PDF DOWNLOAD
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- KOMATSU WA420-3MC WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A31001 and up
- PUBLICATION NUMBER:CEBM003502
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Description
KOMATSU WA420-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up)
KOMATSU WA420-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 AND UP) – PDF DOWNLOAD:
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KOMATSU WA420-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE 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, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU WA420-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up)
MAIN MENU........................................................................................................................................ 0 COVER............................................................................................................................................ 1 CONTENTS......................................................................................................................................... 3 FOREWORD......................................................................................................................................... 15 01 GENERAL....................................................................................................................................... 29 SPECIFICATION DRAWINGS....................................................................................................................... 30 SPECIFICATIONS............................................................................................................................... 32 WEIGHT TABLE................................................................................................................................. 35 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................................................................. 36 ENGINE OIL SPECIFICATIONS................................................................................................................ 37 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS..................... 38 FINAL DRIVE OIL SPECIFICATIONS........................................................................................................... 38 DRIVE AXLE OIL SPECIFICATIONS............................................................................................................ 38 DIESEL FUEL SPECIFICATIONS............................................................................................................... 38 COOLANT SPECIFICATIONS................................................................................................................... 39 10 STRUCTURE AND FUNCTION........................................................................................................................ 45 POWER TRAIN.................................................................................................................................. 47 POWER TRAIN SYSTEM........................................................................................................................... 48 TORQUE CONVERTER, TRANSMISSION PIPING........................................................................................................ 50 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM........................................................................................................ 52 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....................................................................................................... 53 TORQUE CONVERTER............................................................................................................................. 54 TORQUE CONVERTER OIL FILTER.................................................................................................................. 57 TRANSMISSION................................................................................................................................. 58 FORWARD, REVERSE CLUTCH.................................................................................................................. 60 REVERSE, 2ND CLUTCH...................................................................................................................... 61 3RD, 4TH CLUTCH.......................................................................................................................... 61 FORWARD 1ST.............................................................................................................................. 63 FORWARD 2ND.............................................................................................................................. 64 FORWARD 3RD.............................................................................................................................. 65 FORWARD 4TH.............................................................................................................................. 66 REVERSE 1ST.............................................................................................................................. 67 TRANSMISSION CONTROL VALVE................................................................................................................... 68 UPPER VALVE.............................................................................................................................. 69 LOWER VALVE.............................................................................................................................. 70 TRANSMISSION SOLENOID VALVE.............................................................................................................. 71 FLOW VALVE............................................................................................................................... 73 ACCUMULATOR VALVE........................................................................................................................ 74 DIRECTIONAL SELECTOR VALVE............................................................................................................... 76 EMERGENCY MANUAL SPOOL................................................................................................................... 77 PRIORITY VALVE........................................................................................................................... 78 TORQUE CONVERTER OUTLET PORT VALVE....................................................................................................... 79 PILOT REDUCING VALVE..................................................................................................................... 80 PROPORTIONAL SOLENOID VALVE.............................................................................................................. 81 TRANSMISSION SOLENOID VALVE.............................................................................................................. 81 ELECTRONIC CONTROL MODULATION VALVE (ECMV)............................................................................................... 82 PILOT OIL FILTER......................................................................................................................... 85 DRIVE SHAFT.................................................................................................................................. 86 FRONT AXLE................................................................................................................................... 87 REAR AXLE.................................................................................................................................... 88 DIFFERENTIAL................................................................................................................................. 89 FRONT DIFFERENTIAL....................................................................................................................... 89 REAR DIFFERENTIAL........................................................................................................................ 90 TORQUE PROPORTIONING DIFFERENTIAL........................................................................................................ 92 LIMITED SLIP DIFFERENTIAL (OPTION)....................................................................................................... 93 FINAL DRIVE.................................................................................................................................. 96 AXLE MOUNT, CENTER HINGE PIN................................................................................................................. 97 STEERING PIPING.............................................................................................................................. 98 STEERING COLUMN.............................................................................................................................. 99 STEERING VALVE...............................................................................................................................100 OPERATION OF DEMAND VALVE................................................................................................................101 STEERING SPOOL OPERATED..................................................................................................................102 FLOW AMP.................................................................................................................................104 OPERATION OF STEERING VALVE..................................................................................................................107 TURNING RIGHT............................................................................................................................108 TURNING LEFT.............................................................................................................................109 STEERING RELIEF VALVE....................................................................................................................110 OPERATION OF RELIEF VALVE................................................................................................................111 SAFETY VALVE (WITH SUCTION)..............................................................................................................112 ORBIT-ROLL VALVE.............................................................................................................................114 CONNECTION BETWEEN HAND PUMP AND SLEEVE..................................................................................................116 STOP VALVE...................................................................................................................................118 GROUND DRIVEN STEERING PUMP (option).........................................................................................................119 DIVERTER VALVE (option)......................................................................................................................120 OPERATION................................................................................................................................121 FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING.....................................................................................122 BRAKE PIPING.................................................................................................................................124 BRAKE CIRCUIT DIAGRAM........................................................................................................................125 BRAKE VALVE..................................................................................................................................126 BRAKE VALVE (RIGHT)......................................................................................................................126 BRAKE VALVE (LEFT).......................................................................................................................127 OPERATION................................................................................................................................128 ACCUMULATOR CHARGE VALVE.....................................................................................................................131 ACCUMULATOR (for brake)......................................................................................................................135 SLACK ADJUSTER...............................................................................................................................136 BRAKE........................................................................................................................................139 PARKING BRAKE CONTROL........................................................................................................................141 PARKING BRAKE................................................................................................................................142 PARKING BRAKE SOLENOID VALVE.................................................................................................................143 PARKING BRAKE VALVE..........................................................................................................................144 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE...............................................................................................145 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM......................................................................................................146 HYDRAULIC PIPING.............................................................................................................................148 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................151 WORK EQUIPMENT LEVER LINKAGE.................................................................................................................152 HYDRAULIC TANK...............................................................................................................................153 BREATHER.................................................................................................................................154 PPC VALVE....................................................................................................................................155 OPERATION OF PPC VALVE...................................................................................................................157 FUNCTION OF PPC VALVE....................................................................................................................158 PPC RELIEF VALVE.............................................................................................................................160 ACCUMULATOR (FOR PPC VALVE)..................................................................................................................161 MAIN CONTROL VALVE...........................................................................................................................162 RELIEF VALVE.............................................................................................................................164 SAFETY VALVE (WITH SUCTION)..............................................................................................................165 SUCTION VALVE............................................................................................................................166 OPERATION OF CUT-OFF VALVE...............................................................................................................167 MAIN CONTROL VALVE OPERATION.................................................................................................................169 BOOM AND BUCKET SPOOL HOLD POSITION......................................................................................................169 BOOM SPOOL AT RAISE POSITION.............................................................................................................170 BOOM SPOOL AT LOWER POSITION.............................................................................................................171 BOOM SPOOL AT FLOAT POSITION.............................................................................................................172 BUCKET SPOOL AT DUMP POSITION............................................................................................................173 BUCKET SPOOL AT TILT POSITION............................................................................................................174 WORK EQUIPMENT LINKAGE.......................................................................................................................175 BUCKET.......................................................................................................................................177 BUCKET POSITIONER AND BOOM KICK-OUT..........................................................................................................178 ROPS CAB.....................................................................................................................................184 AIR CONDITIONER..............................................................................................................................185 AIR CONDITIONER PIPING...................................................................................................................185 ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................186 ELECTRIC CIRCUIT DIAGRAM ECSS................................................................................................................187 MACHINE MONITOR SYSTEM.......................................................................................................................188 OUTLINE..................................................................................................................................188 MAIN MONITOR.................................................................................................................................189 MAIN MONITOR DISPLAY FUNCTION............................................................................................................190 MAIN MONITOR SWITCH FUNCTION.............................................................................................................191 TROUBLE DATA DISPLAY MODE................................................................................................................192 MAINTENANCE MONITOR..........................................................................................................................193 MAINTENANCE MONITOR DISPLAY FUNCTION.....................................................................................................194 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.......................................................................................................195 SYSTEM STRUCTURE DIAGRAM.................................................................................................................195 SHIFT CONTROL SYSTEM FUNCTION............................................................................................................196 GEAR SHIFT CHARACTERISTICS...............................................................................................................198 SAFETY FUNCTION..........................................................................................................................199 TRANSMISSION CONTROLLER..................................................................................................................200 ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)...........................................................................................201 CONNECTOR SIGNALS........................................................................................................................204 SENSORS......................................................................................................................................205 ENGINE OIL LEVEL SENSOR..................................................................................................................205 RADIATOR WATER LEVEL SENSORS.............................................................................................................206 ENGINE WATER TEMPERATURE SENSOR TORQUE CONVERTER OIL TEMPERATURE SENSOR..................................................................206 FUEL LEVEL SENSOR........................................................................................................................207 ENGINE SPEED SENSOR......................................................................................................................208 ENGINE OIL PRESSURE SENSOR...............................................................................................................208 ENGINE STARTING CIRCUIT......................................................................................................................209 ENGINE STOP CIRCUIT..........................................................................................................................210 ETHER START CIRCUIT..........................................................................................................................211 ELECTRIC TRANSMISSION CONTROL................................................................................................................212 COMBINATION SWITCH.......................................................................................................................213 KICK-DOWN, HOLD SWITCH.......................................................................................................................215 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM...........................................................................................................216 NORMAL OPERATION.........................................................................................................................216 KICK-DOWN SWITCH OPERATED................................................................................................................217 CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE I).........................................................................................218 CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE II)........................................................................................219 TRANSMISSION CUT-OFF SWITCH..............................................................................................................220 TRANSMISSION CUT-OFF FUNCTION................................................................................................................221 ELECTRIC PARKING BRAKE CONTROL...............................................................................................................223 PARKING BRAKE EMERGENCY RELEASE SWITCH...................................................................................................225 EMERGENCY BRAKE SWITCH...................................................................................................................225 PARKING BRAKE SAFETY RELAY...............................................................................................................226 NEUTRALIZER RELAY........................................................................................................................226 FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY..............................................................................................234 20 TESTING, ADJUSTING, AND TROUBLESHOOTING.......................................................................................................235 STANDARD VALUE TABLE FOR CHASSIS.............................................................................................................237 SERVICE TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.....................................................................................244 MEASURING ENGINE SPEEDS......................................................................................................................246 MEASURING INTAKE MANIFOLD PRESSURE...........................................................................................................246 MEASURING INTAKE AIR RESTRICTION.............................................................................................................246 MEASURING ENGINE LUBRICATING OIL PRESSURE....................................................................................................247 MEASURING FUEL INLET RESTRICTION.............................................................................................................247 MEASURING BLOW-BY PRESSURE...................................................................................................................247 MEASURING EXHAUST BACK PRESSURE..............................................................................................................247 MEASURING COOLANT TEMPERATURE................................................................................................................248 MEASURING AND ADJUSTING VALVE CLEARANCE......................................................................................................248 MEASURING WASTEGATE ACTUATOR CALIBRATION.....................................................................................................248 MEASURING EXHAUST COLOR......................................................................................................................249 MEASURING ACCELERATOR PEDAL..................................................................................................................250 OPERATING ANGLE OF ACCELERATOR PEDAL.........................................................................................................251 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER.............................................................................................252 MEASURING STALL SPEEDS.......................................................................................................................253 MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE.........................................................................255 METHOD OF OPERATING EMERGENCY MANUAL SPOOL...................................................................................................256 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL...................................................................................................257 TESTING AND ADJUSTING STEERING WHEEL.........................................................................................................258 TESTING AND ADJUSTING STEERING CONTROL.......................................................................................................260 MEASURING STEERING OIL PRESSURE..............................................................................................................261 METHOD OF MEASURING MAIN RELIEF PRESSURE.....................................................................................................261 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL............................................................................................262 MEASURING BRAKE PERFORMANCE..................................................................................................................263 TESTING BRAKE OIL PRESSURE...................................................................................................................264 MEASURING BRAKE DISC WEAR....................................................................................................................265 BLEEDING AIR FROM BRAKE SYSTEM...............................................................................................................266 MEASURING PARKING BRAKE PERFORMANCE..........................................................................................................267 MANUAL RELEASE OF PARKING BRAKE..............................................................................................................268 MEASURING PARKING BRAKE DISC WEAR............................................................................................................269 MEASURING WORK EQUIPMENT CONTROL LEVER.......................................................................................................270 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE..................................................................................................272 MEASURING WORK EQUIPMENT.....................................................................................................................276 MEASURING HYDRAULIC DRIFT WORK EQUIPMENT.....................................................................................................277 TESTING AND ADJUSTING BUCKET POSITIONER......................................................................................................278 TESTING AND ADJUSTING BOOM KICKOUT...........................................................................................................279 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)..................................................................................................281 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR................................................................................................282 TROUBLESHOOTING..............................................................................................................................284 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................285 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................286 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................................................287 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.....................................................................................292 HANDLING CONNECTORS......................................................................................................................294 CHECKS BEFORE TROUBLESHOOTING............................................................................................................295 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................297 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................................................................................305 CONNECTOR AND PIN IDENTIFICATION.........................................................................................................311 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)................................................................................................318 S-1 STARTING PERFORMANCE IS POOR.....................................................................................................319 S-2 ENGINE DOES NOT START............................................................................................................320 S-3 ENGINE DOES NOT ACCELERATE SMOOTHLY (POOR THROTTLE RESPONSE).....................................................................323 S-4 ENGINE STOPS DURING OPERATIONS...................................................................................................324 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................325 S-6 ENGINE LACKS OUTPUT (NO POWER)...................................................................................................326 S-7 EXHAUST IS BLACK (INCOMPLETE COMBUSTION).........................................................................................327 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................................................328 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................329 S-10 FUEL CONSUMPTION IS EXCESSIVE...................................................................................................330 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.........................................................331 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................................................................332 S-13 OIL LEVEL RISES.................................................................................................................333 S-14 WATER TEMPERATURE BECOMES TOO HIGH..............................................................................................334 S-15 ABNORMAL NOISE IS MADE..........................................................................................................335 S-16 VIBRATION IS EXCESSIVE..........................................................................................................336 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)..........................................................................................338 TROUBLE DATA DISPLAY.................................................................................................................340 M-1 MAIN MONITOR DOES NOT WORK.......................................................................................................342 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT..........................................343 M-3 SPEEDOMETER DISPLAYS DOES NOT WORK PROPERLY......................................................................................344 M-4 ABNORMALITY IN SHIFT INDICATOR...................................................................................................345 A) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F................................................................................345 B) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R................................................................................345 C) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F..........................345 D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R..........................346 E) DOES NOT DISPLAY 1ST, 4TH.....................................................................................................346 F) DOES NOT DISPLAY 3RD, 4TH.....................................................................................................347 G) DOES NOT DISPLAY 2ND, 3RD.....................................................................................................347 H) DOES NOT DISPLAY 1ST, 2ND.....................................................................................................348 M-5 HIGH BEAM DOES NOT LIGHT UP......................................................................................................349 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................................................350 A) L. H. TURN SIGNAL DOES NOT LIGHT UP...........................................................................................350 B) R. H. TURN SIGNAL DOES NOT LIGHT UP...........................................................................................350 M-7 ABNORMALITY IN PARKING DISPLAY...................................................................................................351 A) PARKING LAMP DOES NOT LIGHT UP................................................................................................351 B) PARKING LAMP STAYS LIT........................................................................................................351 M-8 NOT USED.........................................................................................................................351 M-9 NIGHT LIGHTING DOES NOT LIGHT UP.................................................................................................352 M-10 ABNORMALITY IN FRONT WORKING LAMP...............................................................................................353 A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT..........................................................................353 B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP..................................................................353 C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP..........................................................................353 M-11 ABNORMALITY IN REAR WORKING LAMP................................................................................................354 A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT..........................................................................354 B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP..................................................................354 C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP..........................................................................354 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.............................................................................................356 A) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN.....................................356 B) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON........................................................................356 C) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED................................................................357 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...................................................................................358 A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHE....358 B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT ....358 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATE........359 A) ACTUATED CONTINUOUSLY.........................................................................................................359 B) NOT ACTUATED..................................................................................................................359 M-15 ABNORMALITY IN BUZZER...........................................................................................................360 A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF CHECK)...................................................360 B) BUZZER ALWAYS SOUNDS..........................................................................................................360 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...........................................................................361 M-17 ABNORMALITY IN FAILURE DISPLAY MODE.............................................................................................362 A) DOES NOT ENTER FAILURE DISPLAY MODE...........................................................................................362 B) TIME DOES NOT ADVANCE FOR "TIME ELAPSED SINCE FAILURE" ON FAILURE DISPLAY MODE................................................362 M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY................................................................................363 A) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP...........................................................................363 B) EMERGENCY STEERING NORMAL DISPLAY STAYS LIT...................................................................................363 M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY.............................................................................364 A) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP........................................................................364 B) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIT................................................................................364 M-20 NOT USED........................................................................................................................364 M-21 ABNORMALITY IN E.C.S.S. SYSTEM..................................................................................................365 A) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED................................................................................365 B) MONITOR DISPLAY LIGHTS, BUT E.C.S.S. FUNCTION DOES NOT WORK...................................................................365 M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED.....................................................................365 M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...............................................................366 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...................................................................................368 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO........369 A) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR THREE SECONDS............................................................369 B) SOME LAMPS DO NOT LIGHT.......................................................................................................370 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT...................................370 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITO........371 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH.............................................................372 A) ENGINE OIL LEVEL DISPLAY FLASHES..............................................................................................372 B) ENGINE WATER LEVEL DISPLAY FLASHES............................................................................................373 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH..........................................................374 A) ENGINE OIL PRESSURE DISPLAY FLASHES...........................................................................................374 B) BATTERY CHARGE LEVEL DISPLAY FLASHES..........................................................................................375 C) BRAKE OIL PRESSURE DISPLAY FLASHES............................................................................................376 D) AIR CLEANER DISPLAY FLASHES...................................................................................................377 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.......................................................................378 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS...............................................................379 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP AND/OR CAUTION LAMP) DOES NOT LIGHT UP...................................380 A) CHECK LAMP....................................................................................................................380 B) CAUTION LAMP..................................................................................................................380 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP.............................381 A) CHECK LAMP....................................................................................................................381 B) CAUTION LAMP..................................................................................................................381 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP).........382 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP..........................................383 K-12 SERVICE METER DOES NOT WORK.....................................................................................................384 K-13 SERVICE METER RUNS EVEN WHEN ENGINE IS STOPPED..................................................................................384 K-14 ABNORMALITY IN GAUGE ITEMS......................................................................................................385 A) ABNORMALITY IN FUEL GAUGE.....................................................................................................385 B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE ................................................................................386 C) ABNORMALITY IN TORQUE CONVERTER TEMPERATURE GAUGE ............................................................................387 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)............................................................................................388 E-1 ENGINE DOES NOT START............................................................................................................389 E-2 ENGINE DOES NOT STOP.............................................................................................................393 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING...........................................................................................394 E-4 PARKING BRAKE DOES NOT WORK......................................................................................................395 E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...............................................................................397 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON......................................................................399 E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY).........................399 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T-MODE)............................................................400 POWER TRAIN..........................................................................................................................401 T-1 MACHINE DOES NOT MOVE........................................................................................................401 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.........................................................403 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS......................................................................405 T-4 EXCESSIVE TIME LAG WHEN STARTING TO MOVE MACHINE OR AFTER SHIFTING GEARS.....................................................406 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.....................................................................................407 STEERING SYSTEM......................................................................................................................408 T-6 STEERING WHEEL DOES NOT TURN.................................................................................................408 T-7 STEERING IS HEAVY............................................................................................................409 T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK............................................................................410 T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING....................................................................................410 T-10 TURNING RADIUS TO LEFT AND TO RIGHT IS DIFFERENT............................................................................410 BRAKE SYSTEM.........................................................................................................................411 T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR................................................................................411 T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG......................................................................................412 T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS................................................................................413 WORK EQUIPMENT.......................................................................................................................414 T-14 BOOM DOES NOT RISE..........................................................................................................414 T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER...........................................................................415 T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT....................................................................416 T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)..................................................................416 T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM...........................................................................................416 T-19 BOOM SHAKES DURING OPERATION................................................................................................416 T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....................................................417 T-21 BUCKET DOES NOT TILT BACK...................................................................................................418 T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER............................................................................419 T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.....................................................................420 T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER................................................................................420 T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.........................................................................................420 T-26 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD).........................................................421 T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT...................................................421 T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY...............................................................422 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D-MODE)...........................................................424 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.....................................................................................425 D-1 ECSS DOES NOT WORK...............................................................................................................426 A) ERROR CODE (d0) IS DISPLAYED..................................................................................................427 B) ERROR CODE (d1) IS DISPLAYED..................................................................................................427 C) ERROR CODE (d2) IS DISPLAYED..................................................................................................428 D) ERROR CODE (d3) IS DISPLAYED..................................................................................................428 E) ERROR CODE (d4) IS DISPLAYED..................................................................................................429 F) NO ABNORMALITY DISPLAY IS GIVEN ..............................................................................................429 D-2 ECSS CANNOT BE CANCELED..........................................................................................................433 D-3 OUTPUT IS TURNED ON (DOES NOT MAINTAIN 5 KM/H TRAVEL SPEED) (VARIES AROUND 5 KM/H)...............................................434 D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST..................................................................................434 D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH..................................................................................435 D-6 CONTROLLER LED CODE IS NOT DISPLAYED.............................................................................................436 D-7 ECSS ABNORMALITY NOT DISPLAYED ON MAIN MONITOR...................................................................................436 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE)...............................................................................438 OUTLINE..............................................................................................................................439 1. FUNCTION..........................................................................................................................439 2. WHEN CARRYING OUT TROUBLESHOOTING.................................................................................................439 3. FAILURE CODE TABLE................................................................................................................439 4. TABLE OF TROUBLESHOOTING MODES AND CAUSES.........................................................................................440 A-1 TROUBLESHOOTING CODE [10] MODULATION VALVE SOLENOID SYSTEM (DISCONNECTION, SHORT CIRCUIT)........................................441 A-2 TROUBLESHOOTING CODE [11] SHORT CIRCUIT IN POWER SOURCE FOR MODULATION VALVE SOLENOID SYSTEM.....................................442 A-3 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM...............................................................................443 A-4 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM...............................................................................443 A-5 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM..............................................................444 A-6 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM............................................................445 A-7 TROUBLESHOOTING CODE [17] BRAKE OUTPUT SIGNAL....................................................................................446 A-8 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM.........................................................447 A-9 TROUBLESHOOTING CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM...............................................................448 A-10 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM.............................................................449 A-11 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM.............................................................450 A-12 HOLD SWITCH SIGNAL SYSTEM.......................................................................................................451 A-13 KICK-DOWN SWITCH SYSTEM.........................................................................................................451 A-14 KICK-DOWN OUTPUT SIGNAL SYSTEM..................................................................................................452 A-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM..............................................................................................453 A-16 NEUTRALIZER SIGNAL SYSTEM.......................................................................................................454 A-17 BUZZER SIGNAL SYSTEM............................................................................................................455 A-18 NETWORK SIGNAL SYSTEM...........................................................................................................456 A-19 CONTROLLER POWER SOURCE SYSTEM..................................................................................................457 A-20 ABNORMALITY IN MODEL SELECTION WIRING HARNESS...................................................................................458 30 DISASSEMBLY AND ASSEMBLY.....................................................................................................................460 METHOD OF USING MANUAL.......................................................................................................................466 REMOVAL AND INSTALLATION PROCEDURES......................................................................................................466 GENERAL PRECAUTIONS......................................................................................................................466 SPECIAL TOOLS............................................................................................................................466 PRECAUTIONS WHEN CARRYING OUT THESE OPERATIONS...........................................................................................467 PRECAUTIONS FOR REMOVAL PROCEDURES...................................................................................................467 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK......................................................................................468 PRECAUTIONS WHEN COMPLETING THE OPERATIONS...........................................................................................469 SPECIAL TOOL LIST............................................................................................................................470 STARTING MOTOR...............................................................................................................................472 REMOVAL..................................................................................................................................472 INSTALLATION.............................................................................................................................472 ALTERNATOR...................................................................................................................................473 REMOVAL..................................................................................................................................473 INSTALLATION.............................................................................................................................473 ENGINE.......................................................................................................................................474 ENGINE OIL COOLER ASSEMBLY...............................................................................................................474 AFTERCOOLER CORE ASSEMBLY................................................................................................................474 FUEL INJECTION PUMP ASSEMBLY.............................................................................................................474 WATER PUMP ASSEMBLY......................................................................................................................474 TURBOCHARGER ASSEMBLY....................................................................................................................474 NOZZLE HOLDER ASSEMBLY...................................................................................................................474 THERMOSTAT ASSEMBLY......................................................................................................................474 CYLINDER HEAD ASSEMBLY...................................................................................................................474 RADIATOR.....................................................................................................................................475 REMOVAL..................................................................................................................................475 INSTALLATION.............................................................................................................................477 ENGINE.......................................................................................................................................478 REMOVAL..................................................................................................................................478 INSTALLATION.............................................................................................................................483 TORQUE CONVERTER CHARGING PUMP...............................................................................................................485 REMOVAL..................................................................................................................................485 INSTALLATION.............................................................................................................................485 TORQUE CONVERTER & TRANSMISSION..............................................................................................................486 REMOVAL..................................................................................................................................486 INSTALLATION.............................................................................................................................494 TORQUE CONVERTER.............................................................................................................................496 DISASSEMBLY..............................................................................................................................496 ASSEMBLY.................................................................................................................................498 TRANSMISSION.................................................................................................................................501 DISASSEMBLY..............................................................................................................................501 TORQUE CONVERTER.....................................................................................................................502 TRANSMISSION.........................................................................................................................504 ASSEMBLY.................................................................................................................................506 TRANSMISSION CLUTCH PACK.....................................................................................................................512 DISASSEMBLY..............................................................................................................................512 FORWARD, 2ST CLUTCH ASSEMBLY.........................................................................................................512 REVERSE, 2ND CLUTCH ASSEMBLY.........................................................................................................515 3RD, 4TH CLUTCH ASSEMBLY.............................................................................................................518 ASSEMBLY.................................................................................................................................521 FORWARD, 1ST CLUTCH ASSEMBLY.........................................................................................................521 REVERSE, 2ND CLUTCH ASSEMBLY.........................................................................................................525 3RD, 4TH CLUTCH ASSEMBLY.............................................................................................................529 PARKING BRAKE................................................................................................................................533 DISASSEMBLY..............................................................................................................................533 ASSEMBLY.................................................................................................................................535 TRANSMISSION CONTROL VALVE...................................................................................................................538 REMOVAL..................................................................................................................................538 INSTALLATION.............................................................................................................................541 DISASSEMBLY..............................................................................................................................542 ASSEMBLY.................................................................................................................................547 TRANSMISSION ACCUMULATOR VALVE...............................................................................................................553 DISASSEMBLY..............................................................................................................................553 ASSEMBLY.................................................................................................................................553 DRIVE SHAFT..................................................................................................................................554 DISASSEMBLY..............................................................................................................................554 ASSEMBLY.................................................................................................................................556 FRONT AXLE...................................................................................................................................558 REMOVAL..................................................................................................................................558 INSTALLATION.............................................................................................................................559 REAR AXLE....................................................................................................................................560 REMOVAL..................................................................................................................................560 INSTALLATION.............................................................................................................................562 FRONT DIFFERENTIAL...........................................................................................................................564 REMOVAL..................................................................................................................................564 INSTALLATION.............................................................................................................................567 REAR DIFFERENTIAL............................................................................................................................568 REMOVAL..................................................................................................................................568 INSTALLATION.............................................................................................................................571 DIFFERENTIAL.................................................................................................................................572 DISASSEMBLY..............................................................................................................................572 ASSEMBLY.................................................................................................................................575 FINAL DRIVE..................................................................................................................................583 DISASSEMBLY..............................................................................................................................583 ASSEMBLY.................................................................................................................................586 CENTER HINGE PIN.............................................................................................................................590 REMOVAL..................................................................................................................................590 INSTALLATION.............................................................................................................................599 STEERING VALVE (ORBIT ROLL)..................................................................................................................605 REMOVAL..................................................................................................................................605 INSTALLATION.............................................................................................................................606 STEERING VALVE...............................................................................................................................607 DISASSEMBLY..............................................................................................................................607 DISASSEMBLY OF ROTOR.................................................................................................................607 DISASSEMBLY OF CONTROL SIDE..........................................................................................................608 ASSEMBLY.................................................................................................................................610 ASSEMBLY OF CONTROL SIDE.............................................................................................................610 ASSEMBLY OF ROTOR....................................................................................................................612 REMOVAL..................................................................................................................................615 INSTALLATION.............................................................................................................................616 STEERING DEMAND VALVE........................................................................................................................617 DISASSEMBLY..............................................................................................................................617 ASSEMBLY.................................................................................................................................621 STEERING, SWITCH PUMP........................................................................................................................625 REMOVAL..................................................................................................................................625 INSTALLATION.............................................................................................................................628 STEERING CYLINDER............................................................................................................................629 REMOVAL..................................................................................................................................629 INSTALLATION.............................................................................................................................630 BRAKE VALVE..................................................................................................................................631 REMOVAL..................................................................................................................................631 INSTALLATION.............................................................................................................................632 RIGHT BRAKE VALVE (TANDEM)...................................................................................................................633 DISASSEMBLY..............................................................................................................................633 ASSEMBLY.................................................................................................................................634 LEFT BRAKE VALVE (SINGLE)....................................................................................................................635 DISASSEMBLY..............................................................................................................................635 ASSEMBLY.................................................................................................................................636 SLACK ADJUSTER...............................................................................................................................637 REMOVAL..................................................................................................................................637 INSTALLATION.............................................................................................................................638 DISASSEMBLY..............................................................................................................................639 ASSEMBLY.................................................................................................................................640 BRAKE........................................................................................................................................641 DISASSEMBLY..............................................................................................................................641 ASSEMBLY.................................................................................................................................647 PARKING BRAKE DISC...........................................................................................................................655 REMOVAL..................................................................................................................................655 INSTALLATION.............................................................................................................................657 HYDRAULIC TANK...............................................................................................................................658 REMOVAL..................................................................................................................................658 INSTALLATION.............................................................................................................................660 WORK EQUIPMENT, PPC PUMP.....................................................................................................................661 REMOVAL..................................................................................................................................661 INSTALLATION.............................................................................................................................664 PPC VALVE....................................................................................................................................665 REMOVAL..................................................................................................................................665 INSTALLATION.............................................................................................................................666 DISASSEMBLY..............................................................................................................................667 ASSEMBLY.................................................................................................................................668 MAIN CONTROL VALVE...........................................................................................................................669 REMOVAL..................................................................................................................................669 INSTALLATION.............................................................................................................................671 DISASSEMBLY (2 SPOOL VALVE)..............................................................................................................673 ASSEMBLY (2 SPOOL VALVE).................................................................................................................677 DISASSEMBLY (3 SPOOL VALVE)..............................................................................................................681 ASSEMBLY (3 SPOOL VALVE).................................................................................................................685 BUCKET CYLINDER..............................................................................................................................688 REMOVAL..................................................................................................................................688 INSTALLATION.............................................................................................................................689 BOOM CYLINDER................................................................................................................................690 REMOVAL..................................................................................................................................690 INSTALLATION.............................................................................................................................691 HYDRAULIC CYLINDER...........................................................................................................................692 DISASSEMBLY..............................................................................................................................692 ASSEMBLY.................................................................................................................................695 WORK EQUIPMENT...............................................................................................................................698 REMOVAL..................................................................................................................................698 INSTALLATION.............................................................................................................................701 COUNTERWEIGHT................................................................................................................................703 REMOVAL..................................................................................................................................703 INSTALLATION.............................................................................................................................703 FUEL TANK....................................................................................................................................704 REMOVAL..................................................................................................................................704 INSTALLATION.............................................................................................................................706 CAB..........................................................................................................................................707 REMOVAL..................................................................................................................................707 INSTALLATION.............................................................................................................................708 MAIN MONITOR.................................................................................................................................709 REMOVAL..................................................................................................................................709 INSTALLATION.............................................................................................................................710 MAINTENANCE MONITOR..........................................................................................................................711 REMOVAL..................................................................................................................................711 INSTALLATION.............................................................................................................................711 AIR CONDITIONER UNIT.........................................................................................................................712 REMOVAL..................................................................................................................................712 INSTALLATION.............................................................................................................................717 AIR CONDITIONER CONDENSER....................................................................................................................718 REMOVAL..................................................................................................................................718 INSTALLATION.............................................................................................................................719 DRY RECEIVER.................................................................................................................................720 REMOVAL..................................................................................................................................720 INSTALLATION.............................................................................................................................721 AIR CONDITIONER COMPRESSOR...................................................................................................................722 REMOVAL..................................................................................................................................722 INSTALLATION.............................................................................................................................723 40 MAINTENANCE STANDARD..........................................................................................................................724 ENGINE MOUNT, TRANSMISSION MOUNT.............................................................................................................725 TORQUE CONVERTER.............................................................................................................................726 TRANSMISSION.................................................................................................................................727 FORWARD, 1ST CLUTCH......................................................................................................................731 2ND, REVERSE CLUTCH......................................................................................................................733 3RD, 4TH CLUTCH..........................................................................................................................734 TRANSMISSION CONTROL VALVE...................................................................................................................735 UPPER VALVE ASSEMBLY.....................................................................................................................735 LOWER VALVE ASSEMBLY.....................................................................................................................737 DRIVE SHAFTS.................................................................................................................................739 DIFFERENTIAL.................................................................................................................................741 LIMITED SLIP DIFFERENTIAL (OPTIONAL).........................................................................................................743 FINAL DRIVE..................................................................................................................................744 AXLE MOUNT...................................................................................................................................745 STEERING COLUMN..............................................................................................................................746 STEERING VALVE...............................................................................................................................747 STEERING CYLINDER MOUNT......................................................................................................................748 GROUND DRIVEN STEERING PUMP (optional).......................................................................................................749 SLACK ADJUSTER...............................................................................................................................750 BRAKE VALVE..................................................................................................................................751 BRAKE VALVE (LEFT).......................................................................................................................751 BRAKE VALVE (RIGHT)......................................................................................................................753 BRAKE........................................................................................................................................755 PARKING BRAKE................................................................................................................................756 TORQUE CONVERTER, TRANSMISSION PUMP..........................................................................................................757 HYDRAULIC PUMP (STEERING, SWITCH PUMP).......................................................................................................758 HYDRAULIC, PPC PUMP..........................................................................................................................759 PPC VALVE....................................................................................................................................760 CUT-OFF VALVE................................................................................................................................761 MAIN CONTROL VALVE...........................................................................................................................763 2-SPOOL VALVE............................................................................................................................763 3-SPOOL VALVE (OPTIONAL).................................................................................................................765 HYDRAULIC CYLINDER...........................................................................................................................767 CENTER HINGE PIN.............................................................................................................................769 WORK EQUIPMENT LINKAGE.......................................................................................................................771 BUCKET.......................................................................................................................................773 BUCKET POSITIONER AND BOOM KICK-OUT..........................................................................................................774 90 OTHER.........................................................................................................................................776 ELECTRICAL CIRCUIT DIAGRAM (1 OF 4) WA320-3MC, WA380-3MC, WA420-3MC..........................................................................777 ELECTRICAL CIRCUIT DIAGRAM (2 OF 4) WA320-3MC, WA380-3MC, WA420-3MC..........................................................................778 ELECTRICAL CIRCUIT DIAGRAM (3 OF 4) WA420-3MC................................................................................................779 ELECTRICAL CIRCUIT DIAGRAM (4 OF 4) WA420-3MC................................................................................................780
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