Komatsu WA470-3 Avance Loader Shop Manual SEBM006307 PDF

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Komatsu WA470-3 Avance Loader Shop Manual SEBM006307 – PDF DOWNLOAD

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Komatsu WA470-3 Avance Loader Shop Manual SEBM006307 – PDF DOWNLOAD 

Language : English
Pages : 879
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA470-3 Avance Loader Shop Manual SEBM006307 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
WA470-3                   50001 and up

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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu WA470-3 Avance Loader Shop Manual SEBM006307 – PDF DOWNLOAD

MACHINE MODEL   SERIAL NUMBER
WA470-3                   50001 and up

COVER 1
CONTENTS 2
01 GENERAL 28
GENERAL ASSEMBLY DRAWING 29
SPECIFICATIONS 31
WEIGHT TABLE 34
LIST OF LUBRICANT AND WATER 36
10 STRUCTURE AND FUNCTION 39
POWER TRAIN 40
POWER TRAIN SYSTEM 41
TORQUE CONVERTER, TRANSMISSION PIPING 43
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 44
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 45
TORQUE CONVERTER 47
TRANSMISSION 50
TRANSMISSION CONTROL VALVE 60
TRANSMISSION SOLENOID VALVE 88
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 90
PILOT OIL FILTER 93
DRIVE SHAFT 94
AXLE 95
DIFFERENTIAL 97
LIMITED SLIP DIFFERENTIAL 101
FINAL DRIVE 105
AXLE MOUNT, CENTER HINGE PIN 106
STEERING PIPING 107
STEERING COLUMN 108
STEERING VALVE 109
ORBIT-ROLL VALVE 123
STOP VALVE 127
EMERGENCY STEERING PUMP 128
DIVERTER VALVE 129
BRAKE PIPING 132
BRAKE HYDRAULIC CIRCUIT DIAGRAM 133
BRAKE VALVE 135
CHARGE VALVE 140
ACCUMULATOR (FOR BRAKE) 146
SLACK ADJUSTER 147
BRAKE 150
PARKING BRAKE CONTROL 152
PARKING BRAKE 153
PARKING BRAKE SOLENOID VALVE 154
PARKING BRAKE VALVE 155
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 156
HYDRAULIC PIPING 157
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 158
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 159
WORK EQUIPMENT LEVER LINKAGE 161
HYDRAULIC TANK 162
PPC VALVE 164
PPC RELIEF VALVE 169
ACCUMULATOR (FOR PPC VALVE) 170
CUT-OFF VALVE 171
MAIN CONTROL VALVE 174
WORK EQUIPMENT LINKAGE 188
BUCKET 190
BUCKET POSITIONER AND BOOM KICK-OUT 191
CAB 197
ROPS CAB 200
AIR CONDITIONER 202
ELECTRIC CIRCUIT DIAGRAM 203
MACHINE MONITOR SYSTEM 223
MAIN MONITOR 224
MAINTENANCE MONITOR 229
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 232
WORK EQUIPMENT CONTROL SYSTEM 246
E C S S (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)(OPTION) 253
E C S S SYSTEM(OPTION) 257
SENSORS 261
ENGINE STARTING CIRCUIT 266
ENGINE STOP CIRCUIT 267
PREHEATING CIRCUIT 268
ELECTRIC TRANSMISSION CONTROL 269
KICK-DOWN SWITCH 272
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 273
TRANSMISSION CUT-OFF SWITCH 282
TRANSMISSION CUT-OFF FUNCTION 283
ELECTRIC PARKING BRAKE CONTROL 287
20 TESTING AND ADJUSTING 300
STANDARD VALUE TABLE FOR ENGINE 301
STANDARD VALUE TABLE FOR CHASSIS 302
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 305
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 310
MEASUREING ENGINE SPEED 311
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 312
ADJUSTING VALVE CLEARANCE 313
MEASURING EXHAUST COLOR 314
MEASURING EXHAUST GAS TEMPERATURE 315
MEASURING BLOW-BY PRESSURE 316
MEASURING COMPRESSION PRESSURE 317
MEASURING ENGINE OIL PRESSURE 318
TESTING AND ADJUSTING FUEL INJECTION TIMING 319
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 321
TESTING AND ADJUSTING FAN BELT TENSION 323
MEASURING ACCELERATOR PEDAL 324
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 326
MEASURING STALL SPEED 327
MEASURING TORQUE CONVERTER, TRANSMISSION,PARKING BRAKE OIL PRESSURE 329
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 331
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL 333
TESTING AND ADJUSTING STEERING WHEEL 334
TESTING AND ADJUSTING STEERING CONTROL 337
MEASURING STEERING OIL PRESSURE 338
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 340
TESTING BRAKE OIL PRESSURE 341
MEASURING BRAKE PERFORMANCE 342
MEASURING BRAKE DISC WEAR 343
BLEEDING AIR FROM BRAKE SYSTEM 344
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 345
MEASURING PARKING BRAKE PERFORMANCE 346
MANUAL RELEASE METHOD FOR PARKING BRAKE 347
TESTING WEAR OF PARKING BRAKE DISC 348
MEASURING WORK EQUIPMENT CONTROL LEVER 349
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 351
MEASURING WORK EQUIPMENT 355
TESTING AND ADJUSTING BUCKET POSITIONER 357
TESTING AND ADJUSTING BOOM KICK-OUT 358
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 360
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR 361
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER 362
TROUBLESHOOTING 363
POINTS TO REMEMBER WHEN TROUBLESHOOTING 364
SEQUENCE OF EVENTS IN TROUBLESHOOTING 365
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 366
HANDLING CONNECTORS 373
CHECKS BEFORE TROUBLESHOOTING 374
METHOD OF USING TROUBLESHOOTING CHARTS 375
CONNECTOR TYPES AND MOUNTING LOCATIONS 383
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 388
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 395
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 396
S-2 ENGINE DOES NOT START 397
(1) ENGINE DOES NOT TURN 397
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 398
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 399
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 400
S-4 ENGINE STOPS DURING OPERATIONS 401
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 402
S-6 ENGINE LACKS OUTPUT (NO POWER) 403
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 404
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 405
S-9 OIL BECOMES CONTAMINATED QUICKLY 406
S-10 FUEL CONSUMPTION IS EXCESSIVE 407
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 408
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 409
S-13 OIL LEVEL RISES 410
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 411
S-15 ABNORMAL NOISE IS MADE 412
S-16 VIBRATION IS EXCESSIVE 413
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 414
TROUBLE DATA DISPLAY 416
M-1 MAIN MONITOR DOES NOT WORK 419
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP 420
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 421
M-4 ABNORMALITY IN SHIFT INDICATOR 422
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 422
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 422
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F 422
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R 423
(e) DOES NOT DISPLAY 1ST, 4TH 423
(f) DOES NOT DISPLAY 3RD, 4TH 424
(g) DOES NOT DISPLAY 2ND, 3RD 424
(h) DOES NOT DISPLAY 1ST, 2ND 425
M-5 HIGH BEAM DOES NOT LIGHT UP 426
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 427
(a) L H TURN SIGNAL DOES NOT LIGHT UP 427
(b) R H TURN SIGNAL DOES NOT LIGHT UP 427
M-7 ABNORMALITY IN PARKING DISPLAY 428
(a) PARKING LAMP DOES NOT LIGHT UP 428
(b) PARKING LAMP STAYS LIGHTED UP 428
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS) 429
(a) DOES NOT CARRY OUT PREHEATING 429
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE 430
(c) PREHEATING STAYS ON 430
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION 431
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 432
M-10 ABNORMALITY IN FRONT WORKING LAMP 433
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 433
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 433
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 433
M-11 ABNORMALITY IN REAR WORKING LAMP 434
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 434
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 434
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 434
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 436
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 436
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON 436
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED 437
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 438
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES 438
(b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N 438
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED 439
(a) ACTUATED CONTINUOUSLY 439
(b) NOT ACTUATED 439
M-15 ABNORMALITY IN BUZZER 440
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 440
(b) BUZZER ALWAYS SOUNDS 440
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 441
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 442
(a) DOES NOT ENTER FAILURE DISPLAY MODE 442
(b) TIMES FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 442
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY 443
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP 443
(b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP 443
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY 444
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP 444
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP 444
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM 445
(a) FORCED GREASING CANNOT BE CARRIED OUT 445
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 445
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 445
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) 446
(e) MONITOR DISPLAY GOES OUT 446
M-21 ABNORMALITY IN ECSS SYSTEM 447
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED 447
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK 447
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED 447
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 448
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 449
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK 450
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 450
(b) SOME LAMPS DO NOT LIGHT UP 451
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT 451
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 452
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 453
(a) ENGINE OIL LEVEL DISPLAY FLASHES 453
(b) ENGINE WATER LEVEL DISPLAY FLASHES 454
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 455
(a) ENGINE OIL PRESSURE DISPLAY FLASHES 455
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES 456
(c) BRAKE OIL PRESSURE DISPLAY FLASHES 457
(d) AIR CLEANER DISPLAY FLASHES 458
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 459
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 460
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP 461
(a) CHECK LAMP 461
(b) CAUTION LAMP 461
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP 462
(a) CHECK LAMP 462
(b) CAUTION LAMP 462
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) 463
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP 464
K-12 SERVICE METER DOES NOT WORK 465
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 465
K-14 ABNORMALITY IN GAUGE ITEMS 466
(a) ABNORMALITY IN FUEL GAUGE 466
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 467
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 468
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 469
E-1 ENGINE DOES NOT START 470
(a) STARTING MOTOR DOES NOT TURN 470
(b) STARTING MOTOR TURNS 474
E-2 ENGINE DOES NOT STOP 476
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 476
E-4 PARKING BRAKE DOES NOT WORK 477
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (PARKING) 477
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE) 477
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 478
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 480
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY) 480
E-8 TRANSMISSION DOES NOT WORK NORMALLY 481
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND) 483
(b) PROBLEM IN H-L CIRCUIT 483
(c) PROBLEM IN SPEED CIRCUIT 484
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH) 484
(e) CONTACT IN H-L CIRCUIT 485
(f) CONTACT IN SPEED CIRCUIT 487
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH) 489
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL) 490
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL) 492
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL) 494
(k) CONTACT IN FORWARD CIRCUIT 496
(l) CONTACT IN REVERSE CIRCUIT 498
(m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE 500
E-9 KICK-DOWN SWITCH DOES NOT WORK (THE REGULAR F1 TO F4 SHIFTS NORMALLY) 501
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION (SELF-HOLDING FUNCTION)) 503
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED 503
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R 503
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH) 504
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND 506
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)(T MODE) 507
POWER TRAIN 508
T-1 MACHINE DOES NOT START 508
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 510
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 512
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 513
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 514
STEERING SYSTEM 515
T-6 STEERING DOES NOT TURN 515
T-7 STEERING WHEEL IS HEAVY 516
T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK 517
T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING 517
T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT 517
BRAKE SYSTEM 518
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 518
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG 519
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 520
WORK EQUIPMENT 521
T-14 BOOM DOES NOT RISE 521
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 522
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 523
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 523
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM 523
T-19 BOOM SHAKES DURING OPERATION 523
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 524
T-21 BUCKET DOES NOT TILT BACK 525
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 526
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 527
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 527
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 527
T-26 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD) 528
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 528
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 529
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE) 530
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM) 531
D-1 ECSS DOES NOT WORK 532
(a) ERROR CODE [d0] IS DISPLAYED 533
(b) ERROR CODE [d1] IS DISPLAYED 533
(c) ERROR CODE [d2] IS DISPLAYED 534
(d) ERROR CODE [d3] IS DISPLAYED 534
(e) ERROR CODE [d4] IS DISPLAYED 535
(f) NO ABNORMALITY DISPLAY IS GIVEN 535
D-2 ECSS CANNOT BE CANCELED 539
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 KM/H)(DEVIATES AROUND 5 KM/H) 540
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST 540
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH 541
D-6 CONTROLLER LED CODE IS NOT DISPLAYED 542
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY 542
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) 543
OUTLINE 545
1 FUNCTION 545
2 WHEN CARRYING OUT TROUBLESHOOTING 545
3 FAILURE CODE TABLE 545
4 TABEL OF TROUBLESHOOTING MODES AND CAUSES 546
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM 548
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF 549
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM 550
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM 551
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID 552
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID 552
W-7 FAILURE CODE [48] ANMORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM 553
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM 555
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM 556
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH 557
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIONMETER SYSTEM 558
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM 558
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS 560
W-14 SENSOR CANNOT BE ADJUSTED 561
W-15 DOES NOT CARRY OUT AUTO-LEVELING 562
(a) AUTO-LEVELER SWITCH SYSTEM 562
(b) AUTO-LEVELER LED SYSTEM 562
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM 563
(d) ENGINE SPEED SIGNAL SYSTEM 564
W-16 AUTO-LEVELER CANNOT BE SET 565
(a) AUTO-LEVELER SET SWITCH SYSTEM 565
(b) AUTO-LEVELER SET LED SYSTEM 565
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP 566
(a) REMOTE POSITIONER SWITCH SYSTEM 566
(b) REMOTE POSITIONER LED SYSTEM 566
W-18 REMOTE POSITIONER SET LEDS DO NOT FLASH 567
(a) REMOTE POSITIONER SWITCH SYSTEM 567
(b) REMOTE POSITIONER LED SYSTEM 567
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONER IS AT RAISE AND AUTO MODE IS ON 568
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND 569
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW 570
W-22 BUCKET (LEVER) CONTROL 571
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT 571
(b) LEVER IS NOT HELD BY DETENT 572
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR 574
W-24 MAINTENANCE MONITOR CHECK 575
30 DISASSEMBLY AND ASSEMBLY 576
METHOD OF USING MANUAL 578
PRECAUTIONS WHEN CARRYING OUT OPERATION 579
SPECIAL TOOL LIST 581
STARTING MOTOR 583
REMOVAL 583
INSTALLATION 583
ALTERNATOR 584
REMOVAL 584
INSTALLATION 584
ENGINE OIL COOLER 585
REMOVAL 585
INSTALLATION 585
FUEL INJECTION PUMP 586
REMOVAL 586
INSTALLATION 587
WATER PUMP 588
REMOVAL 588
INSTALLATION 588
TURBOCHARGER 589
REMOVAL 589
INSTALLATION 589
NOZZLE HOLDER 590
REMOVAL 590
INSTALLATION 590
THERMOSTAT 591
REMOVAL 591
INSTALLATION 591
CYLINDER HEAD 592
REMOVAL 592
INSTALLATION 596
RADIATOR 598
REMOVAL 598
INSTALLATION 600
ENGINE 601
REMOVAL 601
INSTALLATION 606
TORQUE CONVERTER, TRANSMISSION 608
REMOVAL 608
INSTALLATION 615
TORQUE CONVERTER 617
DISASSEMBLY 617
ASSEMBLY 619
TRANSMISSION 622
DISASSEMBLY 622
ASSEMBLY 627
TRANSMISSION CLUTCH PACK 633
DISASSEMBLY 633
ASSEMBLY 642
PARKING BRAKE 654
DISASSEMBLY 654
ASSEMBLY 656
TRANSMISSION CONTROL VALVE 659
REMOVAL 659
INSTALLATION 661
DISASSEMBLY 662
ASSEMBLY 669
TRANSMISSION ACCUMULATOR VALVE 677
DISASSEMBLY 677
ASSEMBLY 678
DRIVE SHAFT 680
DISASSEMBLY 680
ASSEMBLY 682
FRONT AXLE 684
REMOVAL 684
INSTALLATION 686
REAR AXLE 687
REMOVAL 687
INSTALLATION 690
FRONT DIFFERENTIAL 692
REMOVAL 692
INSTALLATION 695
REAR DIFFERENTIAL 697
REMOVAL 697
INSTALLATION 700
DIFFERENTIAL 702
DISASSEMBLY 702
ASSEMBLY 705
FINAL DRIVE 713
DISASSEMBLY 713
ASSEMBLY 716
CENTER HINGE PIN 720
REMOVAL 720
INSTALLATION 729
STEERING VALVE(ORBIT ROLL) 735
REMOVAL 735
INSTALLATION 736
STEERING VALVE 737
DISASSEMBLY 737
ASSEMBLY 740
REMOVAL 745
INSTALLATION 746
STEERING DEMAND VALVE 747
DISASSEMBLY 747
ASSEMBLY 751
STEERING, SWITCH PUMP 755
REMOVAL 755
INSTALLATION 758
STEERING CYLINDER 759
REMOVAL 759
INSTALLATION 760
BRAKE VALVE 761
REMOVAL 761
INSTALLATION 762
RIGHT BRAKE VALVE (TANDEM) 763
DISASSEMBLY 763
ASSEMBLY 764
LEFT BRAKE VALVE (SINGLE) 765
DISASSEMBLY 765
ASSEMBLY 766
SLACK ADJUSTER 767
REMOVAL 767
INSTALLATION 768
BRAKE 771
DISASSEMBLY 771
ASSEMBLY 777
PARKING BRAKE DISC 785
REMOVAL 785
INSTALLATION 787
ACCUMULATOR CHARGE VALVE 788
REMOVAL 788
INSTALLATION 788
DISASSEMBLY 789
ASSEMBLY 791
HYDRAULIC TANK 793
REMOVAL 793
INSTALLATION 795
WORK EQUIPMENT, PPC PUMP 796
REMOVAL 796
INSTALLATION 799
PPC VALVE 800
REMOVAL 800
INSTALLATION 801
DISASSEMBLY 802
ASSEMBLY 803
MAIN CONTROL VALVE 804
REMOVAL 804
INSTALLATION 806
DISASSEMBLY 807
ASSEMBLY 809
BUCKET CYLINDER 811
REMOVAL 811
INSTALLATION 812
BOOM CYLINDER 813
REMOVAL 813
INSTALLATION 814
HYDRAULIC CYLINDER 815
DISASSEMBLY 815
ASSEMBLY 818
WORK EQUIPMENT 821
REMOVAL 821
INSTALLATION 824
COUNTERWEIGHT 826
REMOVAL 826
INSTALLATION 826
FUEL TANK 827
REMOVAL 827
INSTALLATION 828
CAB 829
REMOVAL 829
INSTALLATION 830
MAIN MONITOR 831
REMOVAL 831
INSTALLATION 832
MAINTENANCE MONITOR 833
REMOVAL 833
INSTALLATION 833
AIR CONDITIONER UNIT 834
REMOVAL 834
INSTALLATION 837
AIR CONDITIONER CONDENSER 840
REMOVAL 840
INSTALLATION 841
DRY RECEIVER 842
REMOVAL 842
INSTALLATION 842
AIR CONDITIONER COMPRESSOR 843
REMOVAL 843
INSTALLATION 844
40 MAINTENANCE STANDARD 845
ENGINE MOUNT, TRANSMISSION MOUNT 846
TORQUE CONVERTER 847
TRANSMISSION 848
TRANSMISSION CONTROL VALVE 855
FLOW VALVE 862
ACCUMULATOR VALVE 863
DRIVE SHAFT 865
DIFFERENTIAL 866
FINAL DRIVE 868
AXLE MOUNT 869
STEERING COLUMN 870
STEERING VALVE 871
STEERING CYLINDER MOUNT 872
SLACK ADJUSTER 873
BRAKE VALVE 874
BRAKE 877
PARKING BRAKE 879
TORQUE CONVERTER, TRANSMISSION PUMP 880
STEERING, SWITCH PUMP 881
HYDRAULIC, PPC PUMP 882
PPC VALVE 883
CUT-OFF VALVE 884
MAIN CONTROL VALVE 885
BOOM CYLINDER 890
BUCKET CYLINDER 891
CENTER HINGE PIN 892
WORK EQUIPMENT LINKAGE 894
BUCKET 896
BUCKET POSITIONER AND BOOM KICK-OUT 897

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24