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Komatsu WA600-3L Wheel Loader Shop Manual A52001 and up – PDF DOWNLOAD
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Komatsu WA600-3L Wheel Loader Shop Manual
Book Code: CEBM002801
SERIAL NUMBERS WA600-3L – A52001 and up
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Description
Komatsu WA600-3L Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA600-3L Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA600-3L
Serial Number: A52001 and up
Book Code: CEBM002801
Language: English
Pages: 894
File Format: Portable Document Format (PDF)
KOMATSU WA600-3L WHEEL LOADER SHOP MANUAL A52001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA600-3L Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in thissection.
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 WA600-3L Wheel Loader Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 00 FOREWORD.................................................................................................................................. 11 SAFETY................................................................................................................................... 12 GENERAL.................................................................................................................................. 14 HOW TO READ THE SHOP MANUAL.............................................................................................................. 15 HOISTING INSTRUCTIONS.................................................................................................................... 16 COATING MATERIALS........................................................................................................................ 17 STANDARD TIGHTENING TORQUE............................................................................................................... 18 ELECTRIC WIRE CODE....................................................................................................................... 21 CONVERSIONS TABLES....................................................................................................................... 22 01 GENERAL................................................................................................................................... 29 GENERAL ASSEMBLY DRAWING................................................................................................................. 30 SPECIFICATIONS........................................................................................................................... 31 WEIGHT TABLE............................................................................................................................. 34 FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................................................ 35 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..................................................................................... 35 ENGINE OIL SPECIFICATIONS............................................................................................................ 36 NORMAL OPERATION................................................................................................................. 36 ARCTIC OPERATION................................................................................................................. 36 REAR MAIN FRAME, STEERING DRIVE, TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.............. 37 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS................. 37 FINAL DRIVE OIL SPECIFICATIONS....................................................................................................... 37 DRIVE AXLE OIL SPECIFICATIONS........................................................................................................ 37 DIESEL FUEL SPECIFICATIONS WARNING................................................................................................... 37 COOLANT SPECIFICATIONS............................................................................................................... 38 GENERAL.......................................................................................................................... 38 WATER............................................................................................................................ 38 ANTIFREEZE....................................................................................................................... 39 SUPPLEMENTAL COOLANT ADDITIVES................................................................................................... 40 10 STRUCTURE AND FUNCTION.................................................................................................................... 44 GENERAL POWER TRAIN...................................................................................................................... 48 POWER TRAIN SYSTEM....................................................................................................................... 49 RADIATOR, HYDRAULIC OIL COOLER........................................................................................................... 51 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................. 52 HYDRAULIC CIRCUIT FOR POWER TRAIN........................................................................................................ 53 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN................................................................................................ 0 ENGINE STOPPED....................................................................................................................... 55 TORQUE CONVERTER......................................................................................................................... 56 REGULATOR VALVE...................................................................................................................... 59 RELIEF VALVE......................................................................................................................... 61 OIL COOLER........................................................................................................................... 62 OIL FILTER........................................................................................................................... 63 TRANSMISSION............................................................................................................................. 65 CONTROL VALVE........................................................................................................................ 73 SOLENOID VALVE....................................................................................................................... 74 UPPER VALVE AND MAIN RELIEF VALVE.................................................................................................... 76 LOWER VALVE.......................................................................................................................... 78 PILOT OIL FILTER......................................................................................................................... 80 PILOT REDUCING VALVE..................................................................................................................... 81 PRIORITY VALVE........................................................................................................................... 82 MODULATING VALVE AND QUICK RETURN VALVE.................................................................................................. 83 REDUCING VALVE........................................................................................................................... 86 ACCUMULATOR VALVE........................................................................................................................ 87 EMERGENCY MANUAL SPOOL................................................................................................................... 90 LUBRICATION BYPASS VALVE................................................................................................................. 91 HYDRAULIC CIRCUIT SCHEMATIC.............................................................................................................. 92 TRANSFER................................................................................................................................. 94 OUTLINE.............................................................................................................................. 94 PATH OF POWER........................................................................................................................ 95 DRIVE SHAFTS............................................................................................................................. 96 CENTER SUPPORT........................................................................................................................... 97 CENTER HINGE PIN......................................................................................................................... 98 AXLE..................................................................................................................................... 99 AXLE MOUNTING........................................................................................................................ 99 FRONT AXLE...........................................................................................................................101 REAR AXLE............................................................................................................................102 DIFFERENTIAL.............................................................................................................................103 FRONT DIFFERENTIAL...................................................................................................................103 REAR DIFFERENTIAL....................................................................................................................104 FINAL DRIVE..............................................................................................................................106 STEERING.................................................................................................................................108 STEERING PIPING......................................................................................................................108 STEERING COLUMN......................................................................................................................109 STEERING CONTROL VALVE...............................................................................................................110 STEERING VALVE.......................................................................................................................113 OVERLOAD RELIEF VALVE................................................................................................................114 MAIN RELIEF VALVE................................................................................................................116 MAIN RELIEF VALVE CIRCUIT OPERATION..............................................................................................117 DEMAND VALVE CIRCUIT OPERATION...................................................................................................118 STEERING VALVE OPERATION.........................................................................................................121 TURNING RIGHT....................................................................................................................122 TURNING LEFT.....................................................................................................................123 TWO-WAY RESTRICTION VALVE............................................................................................................124 STOP VALVE...........................................................................................................................125 GROUND-DRIVEN STEERING...................................................................................................................126 GROUND-DRIVEN STEERING PIPING (IF EQUIPPED)..........................................................................................126 DIVERTER VALVE.......................................................................................................................127 BRAKE SYSTEM.............................................................................................................................130 BRAKE PIPING.........................................................................................................................130 BRAKE CIRCUIT DIAGRAM................................................................................................................131 BRAKE VALVE..........................................................................................................................132 BRAKE VALVE (RIGHT)..............................................................................................................132 BRAKE VALVE (LEFT)...............................................................................................................133 CHARGE VALVE.........................................................................................................................137 ACCUMULATOR (FOR BRAKE)..............................................................................................................141 SLACK ADJUSTER.......................................................................................................................142 BRAKE................................................................................................................................144 PARKING BRAKE............................................................................................................................146 PARKING BRAKE CALIPER................................................................................................................147 SPRING CYLINDER......................................................................................................................148 PARKING BRAKE SOLENOID VALVE.........................................................................................................149 HYDRAULIC PIPING.........................................................................................................................150 WORK EQUIPMENT...........................................................................................................................151 HYDRAULIC CIRCUIT DIAGRAM............................................................................................................151 LEVER LINKAGE........................................................................................................................152 HYDRAULIC TANK...........................................................................................................................153 FILTER BYPASS VALVE..................................................................................................................154 BREATHER.............................................................................................................................155 PPC SYSTEM...............................................................................................................................156 ACCUMULATOR (FOR PPC VALVE)..........................................................................................................156 PPC VALVE............................................................................................................................157 PPC RELIEF VALVE.....................................................................................................................161 CUT-OFF VALVE............................................................................................................................162 MAIN CONTROL VALVE.......................................................................................................................164 2-SPOOL..............................................................................................................................164 3-SPOOL..............................................................................................................................166 MAIN RELIEF VALVE....................................................................................................................168 SAFETY VALVE (WITH SUCTION)..........................................................................................................169 SUCTION VALVE........................................................................................................................170 FLOAT SELECTOR VALVE AND UNLOAD VALVE................................................................................................171 BOOM AND BUCKET SPOOL HOLD POSITION..................................................................................................172 BOOM SPOOL AT RAISE POSITION.........................................................................................................173 BOOM SPOOL AT LOWER POSITION.........................................................................................................174 BOOM SPOOL AT FLOAT POSITION.........................................................................................................175 BUCKET SPOOL AT DUMP POSITION........................................................................................................176 BUCKET SPOOL AT TILT POSITION........................................................................................................177 WORK EQUIPMENT - LUBRICATION.............................................................................................................178 WORK EQUIPMENT - LINKAGE.................................................................................................................180 BUCKET...................................................................................................................................182 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................183 BUCKET POSITIONER....................................................................................................................184 BOOM KICK-OUT........................................................................................................................184 OPERATION............................................................................................................................185 BOOM RAISE.......................................................................................................................185 BUCKET TILT......................................................................................................................188 ROPS CANOPY..............................................................................................................................191 CAB......................................................................................................................................192 AIR CONDITIONER..........................................................................................................................193 AIR CONDITIONER PIPING...............................................................................................................193 AIR CONDITIONER CONDENSER............................................................................................................194 AIR CONDITIONER COMPRESSOR...........................................................................................................195 DRY RESERVOIR........................................................................................................................196 ELECTRICAL...............................................................................................................................197 ELECTRIC CIRCUIT DIAGRAM.............................................................................................................197 MACHINE MONITOR SYSTEM...................................................................................................................202 MAIN MONITOR.........................................................................................................................203 MAIN MONITOR DISPLAY FUNCTION....................................................................................................204 MAIN MONITOR SWITCH FUNCTION.....................................................................................................205 TROUBLE DATA DISPLAY MODE........................................................................................................206 MAINTENANCE MONITOR..................................................................................................................207 MAINTENANCE MONITOR DISPLAY FUNCTION.............................................................................................208 ENGINE STARTING CIRCUIT..................................................................................................................210 SAFETY RELAY.........................................................................................................................211 ENGINE STOP CIRCUIT......................................................................................................................212 ETHER START CIRCUIT......................................................................................................................213 ELECTRIC TRANSMISSION CONTROL............................................................................................................214 COMBINATION SWITCH...................................................................................................................216 KICK-DOWN, HOLD SWITCH...............................................................................................................218 KICK-DOWN SWITCH.................................................................................................................218 HOLD SWITCH......................................................................................................................218 KICK-DOWN ELECTRICAL CIRCUIT.........................................................................................................219 NORMAL OPERATION.................................................................................................................219 WHEN KICK-DOWN SWITCH IS OPERATED................................................................................................220 OPERATION FOR CANCELING KICK-DOWN (directional lever is placed at N or R)........................................................221 OPERATION FOR CANCELING KICK-DOWN (speed lever is at a position other than 2nd)..................................................222 OPERATION FOR CANCELING KICK-DOWN (Parking brake is applied).....................................................................223 OPERATION FOR CANCELING KICK-DOWN (Starting switch is turned OFF)................................................................224 ELECTRIC PARKING BRAKE...................................................................................................................225 ELECTRIC PARKING BRAKE CONTROL.......................................................................................................225 PARKING BRAKE SWITCH.................................................................................................................226 PARKING BRAKE VALVE..................................................................................................................227 PARKING SAFETY RELAY.................................................................................................................227 NEUTRALIZER RELAY....................................................................................................................227 EMERGENCY BRAKE SWITCH...............................................................................................................227 OPERATION............................................................................................................................228 STARTING SWITCH OFF..............................................................................................................228 STARTING SWITCH ON...............................................................................................................229 PARKING BRAKE SWITCH OFF (RELEASED)..............................................................................................231 PARKING BRAKE SWITCH ON (ACTUATED)...............................................................................................232 WHEN MAIN BRAKE OIL PRESSURE DROPS (EMERGENCY BRAKE ACTUATED)....................................................................233 ENGINE DIAGNOSTICS.......................................................................................................................234 EXPLANATION OF THE THREE ENGINE DIAGNOSTIC LIGHTS....................................................................................234 ENGINE FAULT DIAGNOSTICS.............................................................................................................235 FAULT CODES..........................................................................................................................236 20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................................239 STANDARD VALUE TABLE FOR ENGINE IN CHASSIS...............................................................................................241 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................243 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...............................................................................................246 TESTING AND ADJUSTING....................................................................................................................255 SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING...............................................................................257 MEASURING ENGINE SPEEDS..............................................................................................................259 MEASURING ENGINE SPEED (LOW IDLE, HIGH IDLE).....................................................................................259 MEASURING THE TORQUE CONVERTER STALL SPEED.......................................................................................260 MEASURING THE HYDRAULIC STALL SPEED..............................................................................................261 MEASURING THE TORQUE CONVERTER STALL SPEED + THE HYDRAULIC STALL SPEED...........................................................261 MEASURING INTAKE MANIFOLD PRESSURE...................................................................................................262 MEASURING INTAKE AIR RESTRICTION.....................................................................................................263 MEASURING EXHAUST BACK PRESSURE......................................................................................................264 MEASURING BLOW-BY PRESSURE...........................................................................................................265 MEASURING FUEL FILTER INLET RESTRICTION..............................................................................................266 MEASURING ENGINE LUBRICATING OIL PRESSURE............................................................................................267 MEASURING COOLANT TEMPERATURE........................................................................................................268 MEASURING AND ADJUSTING VALVE CLEARANCE..............................................................................................269 ADJUSTING THE ALTERNATOR FAN BELT....................................................................................................270 BELT TENSION CHART...............................................................................................................270 FAN BELT TENSIONER...................................................................................................................271 ENGINE OIL PRESSURE..................................................................................................................272 ENGINE OIL TEMPERATURE...............................................................................................................273 MEASURING EXHAUST GAS COLOR..........................................................................................................274 MEASURING WITH THE HANDY SMOKE CHECKER...........................................................................................274 MEASURING WITH A SMOKE METER.....................................................................................................275 MEASURING THE ACCELERATOR PEDAL OPERATING FORCE......................................................................................276 MEASURING THE TORQUE CONVERTER AND TRANSMISSION OIL PRESSURES........................................................................277 PREPARATORY WORK.................................................................................................................277 LOCATION OF OIL PRESSURE MEASUREMENT PORTS.......................................................................................278 MAIN RELEIF PRESSURE (P6)........................................................................................................278 TORQUE CONVERTER RELIEF (INLET PORT) PRESSURE....................................................................................279 TORQUE CONVERTER OUTLET PORT PRESSURE............................................................................................279 MODULATION PRESSURE (P1).........................................................................................................280 REDUCING VALVE PRESSURE FOR 2ND CLUTCH (P3)......................................................................................280 PILOT PRESSURE (P5)..............................................................................................................281 LUBRICATING PRESSURE (P9)........................................................................................................281 FLUSHING THE TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT.....................................................................282 FLUSH THE HYDRAULIC CIRCUIT IF:..................................................................................................282 FLUSHING PROCEDURE...............................................................................................................282 MOVING AND MACHINE WITH A FAILED TRANSMISSION VALVE..................................................................................284 TESTING AND ADJUSTING THE STEERING WHEEL.............................................................................................287 MEASURING STEERING WHEEL PLAY....................................................................................................287 METHOD OF MEASUREMENT............................................................................................................287 MEASURING THE OPERATING FORCE OF THE STEERING WHEEL..............................................................................287 MEASUREMENT METHOD...............................................................................................................287 MEASURING THE STEERING WHEEL OPERATING TIME......................................................................................288 MEASUREMENT METHOD...............................................................................................................288 MEASURING AND ADJUSTING STEERING OIL PRESSURE........................................................................................289 STEERING RELIEF VALVE PRESSURE...................................................................................................289 STEERING PILOT PRESSURE (ORBITROL VALVE).........................................................................................290 ADJUSTING THE STEERING RELIEF VALVE..............................................................................................291 MEASURING AND ADJUSTING THE STEERING STOP VALVE......................................................................................292 MEASURING THE FRAME STOPPER CLEARANCE............................................................................................292 ADJUSTING THE CLEARANCE..........................................................................................................293 MEASURING THE BRAKE PEDAL............................................................................................................294 PEDAL OPERATING FORCE............................................................................................................294 PEDAL TRAVEL.....................................................................................................................295 PEDAL PLAY.......................................................................................................................295 CHECKING THE BRAKE OIL PRESSURE......................................................................................................296 MEASURING THE BRAKE OIL PRESSURE.................................................................................................296 MEASURING THE DROP IN BRAKE PISTON PRESSURE......................................................................................296 MEASURING BRAKE DISC WEAR............................................................................................................297 MEASUREMENT METHOD...............................................................................................................297 CALCULATING THE PISTON STROKE....................................................................................................298 MEASURING BRAKE PERFORMANCE..........................................................................................................299 CHECKING AND ADJUSTING THE PARKING BRAKE.............................................................................................300 MEASURING THE PARKING BRAKE PAD THICKNESS........................................................................................300 MEASURING THE PAD-TO-DISC CLEARANCE..............................................................................................301 ADJUSTING THE PAD-TO-DISC CLEARANCE..............................................................................................302 TESTING AND ADJUSTING THE ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURES............................................................303 MEASURING........................................................................................................................303 ADJUSTING........................................................................................................................304 MEASURING AND ADJUSTING THE PPC OIL PRESSURE.........................................................................................305 MEASURING THE PPC VALVE SOURCE PRESSURE..........................................................................................305 MEASURING THE PPC VALVE OUTPUT PRESSURE..........................................................................................306 ADJUSTING THE PPC RELIEF VALVE...................................................................................................306 MEASURING THE BUCKET AND BOOM CONTROL LEVERS.........................................................................................308 DUMP AND LIFT CONTROL LEVER OPERATING FORCE......................................................................................308 DUMP AND LIFT CONTROL LEVER TRAVEL...............................................................................................308 MEASURING THE WORK EQUIPMENT OPERATING SPEEDS........................................................................................309 LIFTING TIME OF LIFT ARM.........................................................................................................309 LOWERING THE TIME OF THE LIFT ARM................................................................................................309 DUMPING TIME OF THE BUCKET.......................................................................................................309 TILT-BACK TIME OF BUCKET.........................................................................................................310 MEASURING THE WORK EQUIPMENT HYDRAULIC DRIFT.........................................................................................311 MEASURING AND ADJUSTING THE WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................312 MEASURING THE RELIEF PRESSURE....................................................................................................312 ADJUSTING THE WORK EQUIPMENT RELIEF VALVE........................................................................................313 ADJUSTING THE WORK EQUIPMENT LEVER LINKAGE...........................................................................................314 PPC VALVE LINKAGE................................................................................................................314 WORK EQUIPMENT LINKAGE...........................................................................................................315 SOLENOID INSTALLATION............................................................................................................316 TESTING AND ADJUSTING THE BUCKET POSITIONER..........................................................................................317 TESTING..........................................................................................................................317 ADJUSTING........................................................................................................................317 TESTING AND ADJUSTING THE BOOM KICKOUT...............................................................................................319 TESTING..........................................................................................................................319 ADJUSTING........................................................................................................................319 TESTING THE PROXIMITY SWITCH ACTUATION PILOT LAMP....................................................................................320 ADJUSTING THE MACHINE MONITOR (SPEEDOMETER MODULE)...................................................................................321 PREADJUSTMENT PROCEDURE..........................................................................................................321 SETTING THE MACHINE MODEL........................................................................................................322 ADJUSTING THE ECSS...............................................................................................................322 BLEEDING AIR.........................................................................................................................323 BLEEDING THE BRAKE LINES AND WHEEL CYLINDERS.....................................................................................323 BLEEDING THE HYDRAULIC CYLINDERS.................................................................................................324 RELIEVING REMAINING HYDRAULIC PRESSURE...............................................................................................325 PRESSURE BETWEEN EACH HYDRAULIC CYLINDER AND CONTROL VALVE.......................................................................325 PRESSURE IN THE BRAKE ACCUMULATOR CIRCUIT........................................................................................325 PRESSURE IN THE PPC ACCUMULATOR CIRCUIT..........................................................................................325 WHEELS AND TIRES.....................................................................................................................326 TROUBLESHOOTING: GENERAL INFORMATION....................................................................................................327 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................328 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................329 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................330 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.....................................................................................330 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS........................................................................335 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.............................................................................336 CHECKS BEFORE TROUBLESHOOTING........................................................................................................338 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................339 CONNECTOR ARRANGEMENT DIAGRAM 1......................................................................................................348 CONNECTOR ARRANGEMENT DIAGRAM 2......................................................................................................349 CONNECTOR ARRANGEMENT DIAGRAM 3......................................................................................................350 CONNECTOR ARRANGEMENT DIAGRAM 4......................................................................................................351 CHART OF CONNECTORS AND PIN NUMBERS..................................................................................................352 X-TYPE CONNECTOR.................................................................................................................352 SWP-TYPE CONNECTOR...............................................................................................................353 M-TYPE CONNECTOR.................................................................................................................354 S-TYPE CONNECTOR.................................................................................................................355 AMP040-TYPE CONNECTOR............................................................................................................356 AUTOMOBILE-TYPE CONNECTOR........................................................................................................357 MIC-TYPE CONNECTOR...............................................................................................................358 L-TYPE, PA-TYPE AND BENDIX-TYPE CONNECTORS.......................................................................................359 RELAY CONNECTOR-SOCKET...........................................................................................................360 METRI-PACK CONNECTORS............................................................................................................361 BENDIX CONNECTORS, RELAY CONNECTORS..............................................................................................362 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................363 TROUBLESHOOTING CODE NUMBER CATEGORIES...........................................................................................363 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLSHOOTING MODE...............................................................363 EXAMPLE OF A TYPICAL TROUBLSHOOTING PAGE.........................................................................................364 METHOD OF USING MATRIX TROUBLESHOOTING TABLES........................................................................................365 TROUBLESHOOTING THE TRANSMISSION CONTROLLER SYSTEM (T MODE)..............................................................................367 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM-RELATED PARTS.....................................................................369 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ..........................................................370 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM........................................................................374 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED............376 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................376 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...................377 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................377 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED...................378 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................378 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED.................379 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................379 T-5 FAILURE CODE [154] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED................380 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................380 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED.................381 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................381 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED.................382 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................382 T-8 FAILURE CODE [18] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED............................383 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................383 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED....................................384 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................386 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED............................................388 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................390 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED...........................................................392 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................392 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.....................................393 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................393 T-13 SHIFT-UP SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) AND HOLD SIGNAL SYSTEM (AUTO-SHIFT) (OP))..................................394 T-14 KICK-DOWN SIGNAL SYSTEM AND SHIFT-DOWN SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT)...............................................394 T-13 & T-14 RELATED ELECTRICAL CIRCUIT DIAGRAM..................................................................................394 T-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM..............................................................................................395 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................395 T-16 NEUTRALIZER SIGNAL SYSTEM.......................................................................................................396 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................396 T-17 BUZZER SIGNAL SYSTEM............................................................................................................397 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................397 T-18 NETWORK SYSTEM..................................................................................................................398 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................398 T-19 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM.....................................................................................399 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................399 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM.....................................................................................400 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................400 T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS.................................................................................401 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................401 TROUBLESHOOTING THE MAIN MONITOR SYSTEM (M MODE).........................................................................................403 MAIN MONITOR AND ELECTRICAL CIRCUIT DIAGRAM..........................................................................................406 LAMP AND HORN ELECTRICAL CIRCUIT DIAGRAM.............................................................................................408 M-1 MAIN MONITOR DOES NOT WORK.....................................................................................................409 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................409 M-2 ALL LAMPS STAY ON WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED IMMEDIATELY.......................................410 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................410 M-3 SPEEDOMETER DOESN'T DISPLAY PROPERLY...........................................................................................411 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................411 M-4 ABNORMALITY IN SHIFT INDICATOR.................................................................................................412 A) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F...............................................................................412 B) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R...............................................................................412 C) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N.......................................................................412 D) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROLLER IS AT 1ST....................................................................413 E) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROLLER IS AT 2ND....................................................................413 F) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROLLER IS AT 3RD....................................................................413 G) DOES NOT DISPLAY 4RH EVEN WHEN SPEED CONTROLLER IS AT 4TH.....................................................................413 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................414 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT...............................................................................................415 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................415 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT.............................................................................................416 A) LEFT-HAND TURN SIGNAL DOES NOT LIGHT..........................................................................................416 B) RIGHT-HAND TURN SIGNAL DOES NOT LIGHT.........................................................................................416 C) RELATED ELECTRICAL CIRCUIT DIAGRAM............................................................................................416 M-7 ABNORMALITY IN PARKING LAMP DISPLAY............................................................................................417 A) PARKING LAMP DISPLAY DOES NOT LIGHT..........................................................................................417 B) PARKING LAMP DISPLAY STAYS ON................................................................................................417 C) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................417 M-9 MONITOR NIGHT LIGHTING DOES NOT WORK...........................................................................................419 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................419 M-10 ABNORMALITY IN FRONT WORK LAMP..................................................................................................420 A) NEITHER THE MONITOR DISPLAY NOR THE FRONT WORK LAMP LIGHT....................................................................420 B) WORK LAMP LIGHTS BUT MONITOR DISPLAY DOES NOT LIGHT..........................................................................420 C) MONITOR DISPLAY LIGHTS BUT WORK LAMP DOES NOT LIGHT..........................................................................420 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................421 M-11 ABNORMALITY IN REAR WORK LAMP...................................................................................................422 A) NEITHER THE MONITOR DISPLAY NOR THE REAR WORK LAMP LIGHT.....................................................................422 B) WORK LAMP LIGHTS BUT MONITOR DISPLAY DOES NOT LIGHT..........................................................................422 C) MONITOR DISPLAY LIGHTS BUT WORK LAMP DOES NOT LIGHT...........................................................................422 D) RELATED ELECTRICAL CIRCUIT DIAGRAM............................................................................................423 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.............................................................................................424 A) TRANSMISSION CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE WHEN CUT-OFF SWITCH IS PRESSED.....................424 B) CUT-OFF FUNCTION ALWAYS ACTUATED EVEN WITH CUT-OFF SWITCH TURNED OFF.........................................................424 C) CUT-OFF FUNCTION DOES NOT ACTUATE WHEN CUT-OFF SWITCH IS TURNED ON...........................................................425 D) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................425 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...................................................................................426 A) WHEN PARKING BRAKE IS APPLIED, THE BUZZER SOUNDS INTERMITTENTLY AND THE CAUTION LAMP FLASHES EVEN WITH THE DIRECTIONAL LE....426 B) WHEN PARKING BRAKE IS APPLIED, THE BUZZER DOES NOT SOUND AND THE CAUTION LAMP DOES NOT LIGHT EVEN WITH THE DIRECTIONAL LE....426 C) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................426 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP REMAIN ON CONTINUOUSLY OR DO NOT WORK AT ALL..............427 A) ACTUATED CONTINUOUSLY........................................................................................................427 B) NOT ACTUATED AT ALL..........................................................................................................427 C) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................427 M-15 ABNORMALITY IN BUZZER...........................................................................................................428 A) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH TURNED TO ON......................................428 B) BUZZER ALWAYS SOUNDS.........................................................................................................428 C) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................428 M-16 CONDITION OF MONITOR SWITCHES NOT STORED IN MEMORY..............................................................................429 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................429 M-17 ABNORMALITY IN FAILURE DISPLAY MODE............................................................................................430 A) FAILURE DISPLAY MODE DOES NOT WORK...........................................................................................430 B) COUNT FOR TIME ELAPSED SINCE LAST FAILURE DISPLAY MODE DOES NOT ADVANCE......................................................430 C) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................430 M-18 ABNORMALITY IN GROUND-DRIVEN STEERING DISPLAY..................................................................................431 A) GROUND-DRIVEN STEERING DISPLAY DOES NOT FLASH................................................................................431 B) GROUND-DRIVEN STEERING DISPLAY FLASHES ALL THE TIME..........................................................................431 C) RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................431 TROUBLESHOOTING THE MAINTENANCE MONITOR SYSTEM (K MODE)..................................................................................433 MAINTENANCE MONITOR ELECTRICAL CIRCUIT DIAGRAM.......................................................................................436 K-1 WITH STARTING SWITCH TURNED ON, NO DISPLAYS APPEAR FOR 3 SECONDS; MAINTENANCE MONITOR DOES NOT WORK............................438 A) NO MAINTENANCE MONITOR LAMPS LIGHT UP........................................................................................438 B) SOME LAMPS DO NOT LIGHT......................................................................................................438 K-2 ALL MAINTENANCE MONITOR LAMPS REMAIN LIT EVEN AFTER 3 SECONDS WITH STARTING SWITCH TURNED ON...................................439 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-1 AND K-2...............................................................................439 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS, NO MAINTENANCE MONITOR LAMPS GO........440 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-3.......................................................................................440 K-4 CHECK ITEM DISPLAY FLASHES WITH ENGINE STOPPED AND STARTING SWITCH TURNED TO ON................................................442 A) ENGINE OIL LEVEL DISPLAY FLASHES.............................................................................................442 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-4A).....................................................................................442 B) ENGINE COOLANT LEVEL DISPLAY FLASHES..........................................................................................443 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-4B).....................................................................................443 K-5 CAUTION ITEM DISPLAY FLASHES WITH ENGINE STOPPED AND STARTED SWITCH TURNED TO ON...............................................444 A) ENGINE OIL PRESSURE DISPLAY FLASHES..........................................................................................444 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-5A).....................................................................................444 B) BATTERY CHARGE LEVEL DISPLAY FLASHES.........................................................................................445 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-5B).....................................................................................445 C) BRAKE OIL PRESSURE DISPLAY FLASHES...........................................................................................446 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-5C).....................................................................................446 D) AIR CLEANER CLOGGED DISPLAY FLASHES..........................................................................................447 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-5D).....................................................................................447 K-6 CAUTION ITEM DISPLAY FLASHES, BUT CAUTION BUZZER DOES NOT SOUND................................................................448 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................448 K-7 NO MONITOR DISPLAY LIGHTS, BUT CAUTION BUZZER DOES SOUND.......................................................................449 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................449 K-8 CAUTION ITEM DISPLAY FLASHES, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH....................................450 A) CHECK LAMP...................................................................................................................450 B) CAUTION LAMP.................................................................................................................450 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-8A) AND B)..............................................................................450 K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES LIGHT LIGHT UP...................451 A) CHECK LAMP...................................................................................................................451 B) CAUTION LAMP.................................................................................................................451 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-9A) AND B)..............................................................................451 K-10 ONLY NIGHT LIGHTING OF MONITOR STAYS OFF WHEN LAMP SWITCH IS TURNED ON..........................................................452 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................452 K-11 NIGHT LIGHTING OF MONITOR LIGHTS EVEN WITH LAMP SWITCH OFF......................................................................453 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................453 K-12 SERVICE METER DOES NOT WORK.....................................................................................................454 K-13 SERVICE METER RUNS EVEN WITH ENGINE STOPPED.....................................................................................454 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-12 AND K-13.............................................................................454 K-14 ABNORMALITY IN GUAGES...........................................................................................................456 A) ABNORMALITY IN FUEL GAUGE....................................................................................................456 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-14A)....................................................................................456 B) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE..............................................................................457 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-14B)....................................................................................457 C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE........................................................................458 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR K-14C)....................................................................................458 TROUBLESHOOTING THE ELECTRICAL SYSTEM (E MODE)...........................................................................................459 POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND ETHER INJECTION ELECTRICAL CIRCUIT DIAGRAM........................................461 TRANSMISSION AND PARKING BRAKE ELECTRICAL CIRCUIT DIAGRAM............................................................................462 LAMP AND HORN ELECTRICAL CIRCUIT DIAGRAM.............................................................................................463 BOOM KICK-OUT AND BUCKET POSITIONER ELECTRICAL CIRCUIT DIAGRAM.......................................................................464 E-1 ENGINE DOES NOT START..........................................................................................................466 A) STARTING MOTOR DOES NOT WORK.................................................................................................466 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-1A).....................................................................................470 B) INSPECTION OF BATTERY, BATTERY RELAY AND STARTING SWITCH.....................................................................471 E-2 ENGINE DOES NOT STOP...........................................................................................................472 E-3 ENGINE STOPS WHILE MACHINE IS TRAVELLING.......................................................................................473 E-5 PARKING BRAKE DOES NOT WORK....................................................................................................475 A) PARKING BRAKE DOES NOT WORK WHEN PARKING SWITCH IS TURNED ON.................................................................475 B) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS...........................475 E-6 PARKING BRAKE ACTIVATES WHILE MACHINE IS TRAVELLING............................................................................476 E-7 PARKING BRAKE RELEASES WHEN STARTING SWITCH TURNED TO ON.......................................................................478 E-8 PARKING BRAKE WORKS NORMALLY, BUT TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED........................478 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-5, E-6 AND E-7..........................................................................479 E-9 TRANSMISSION DOES NOT WORK PROPERLY............................................................................................480 A) ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH OR NEUTRALIZER RELAY CIRCUIT...............................482 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-9A).....................................................................................484 B) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT.............................................................................486 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-9)......................................................................................486 C) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT.............................................................................488 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-9C).....................................................................................488 D) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT..............................................................490 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-9D).....................................................................................494 E) ABNORMALITY IN SHIFT SOLENOID CIRCUIT........................................................................................496 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-9E).....................................................................................498 F) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT ...................................................................499 1. SHORT CIRCUIT TO CHASSIS GROUND IN 1ST SOLENOID SWITCH...................................................................499 2. SHORT CIRCUIT TO CHASSIS GROUND IN 2ND SOLENOID CIRCUIT..................................................................500 3. SHORT CIRCUIT TO GROUND CHASSIS IN 3RD SOLENOID CIRCUIT..................................................................501 4. SHORT CIRCUIT TO CHASSIS GROUND IN 4TH SOLENOID CIRCUIT..................................................................502 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-9F).....................................................................................503 E-10 KICK-DOWN SWITCH DOES NOT WORK..................................................................................................504 RELATED CIRCUIT DIAGRAM FOR E-10.................................................................................................506 E-11 KICK-DOWN SWITCH WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON............................................................507 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-11......................................................................................507 E-12 KICK-DOWN SWITCH WORKS IN ALL GEARS.............................................................................................508 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-12......................................................................................509 D-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELLING FORWARD IN 2ND GEAR.................................................................510 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-13......................................................................................511 E-14 BOOM KICK-OUT DOES NOT WORK.....................................................................................................512 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-14......................................................................................514 E-15 DEFECTIVE BUCKET POSITIONER.....................................................................................................516 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-15......................................................................................518 E-16 POWER WINDOW DOES NOT WORK......................................................................................................519 A) POWER WINDOW DOES NOT RISE...................................................................................................519 B) POWER WINDOW DOES NOT LOWER..................................................................................................520 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR E-16......................................................................................521 E-17 ABNORMALITY IN FRONT WORK LAMP..................................................................................................522 E-18 ABNORMALITY IN REAR WORK LAMP...................................................................................................522 E-19 ABNORMALITY IN TRANSMISSION CUT-OFF.............................................................................................522 E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...................................................................................522 ABNORMALITY IN BUZZER................................................................................................................522 TROUBLESHOOTING THE HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)............................................................................523 H-1 MACHINE WON'T START.............................................................................................................525 ASK THE OPERATOR THE FOLLOWING QUESTIONS:........................................................................................525 CHECKS BEFORE TROUBLESHOOTING....................................................................................................525 H-2 TRAVEL SPEED IS SLOW, MACHINE LACKS POWER IN ALL SPEED RANGES...................................................................526 CHECKING FOR ABNORMALITIES.......................................................................................................526 CHECKS BEFORE TROUBLESHOOTING....................................................................................................526 H-3 EXCESSIVE TIME LAG WHEN STARTING ENGINE OR SHIFTING GEARS.......................................................................527 ASK EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...................................................................................527 CHECKS BEFORE TROUBLESHOOTING....................................................................................................527 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH........................................................................................528 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................528 CHECKS BEFORE TROUBLESHOOTING....................................................................................................528 CHECKING FOR ABNORMALITIES.......................................................................................................528 H-5 STEERING WHEEL DOES NOT TURN....................................................................................................529 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................529 CHECKS BEFORE TROUBLESHOOTING....................................................................................................529 H-6 POOR TURNING AND STEERING RESPONSE..............................................................................................530 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................530 CHECKS BEFORE TROUBLESHOOTING....................................................................................................530 H-7 STEERING IS HEAVY...............................................................................................................531 CHECKING FOR ABNORMALITIES.......................................................................................................531 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................531 CHECKS BEFORE TROUBLESHOOTING....................................................................................................531 H-8 STEERING WHEEL SHAKES OR JERKS..................................................................................................532 CHECKING FOR ABNORMALITIES.......................................................................................................532 CHECKS BEFORE TROUBLESHOOTING....................................................................................................532 H-9 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING..........................................................532 H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.............................................................................533 CHECKING FOR ABNORMALITIES.......................................................................................................533 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................533 CHECKS BEFORE TROUBLESHOOTING....................................................................................................533 H-11 WHEEL BRAKES DO NOT RELEASE OR BRAKES DRAG.....................................................................................535 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................535 CHECKS BEFORE TROUBLESHOOTING....................................................................................................535 H-12 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR..........................................................................536 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................536 H-13 PARKING BRAKE DOES NOT RELEASE OR DRAGS........................................................................................537 CHECK BEFORE TROUBLESHOOTING.....................................................................................................537 H-14 NEITHER THE BOOM NOR BUCKET MOVE...............................................................................................538 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................538 CHECKS BEFORE TROUBLESHOOTING....................................................................................................538 H-15 BOTH THE BOOM AND BUCKET ARE SLOW OR LACK POWER................................................................................539 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................539 H-16 BOOM DOES NOT MOVE.............................................................................................................540 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................540 H-17 BOOM IS SLOW OR LACKS POWER....................................................................................................541 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................541 H-18 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT...................................................................542 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................542 CHECKS BEFORE TROUBLESHOOTING....................................................................................................542 H-19 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS MOVED FROM HOLD TO RAISE..........................................................542 CHECKING FOR ABNORMALITIES.......................................................................................................542 CAUSES AND REMEDY................................................................................................................542 H-20 EXCESSIVE HYDRAULIC DRIFT OF BOOM..............................................................................................543 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................543 H-21 BUCKET DOES NOT MOVE...........................................................................................................544 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................544 H-22 BUCKET IS SLOW OR LACKS POWER..................................................................................................545 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................545 H-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET............................................................................................546 ASK THE EQUIPMENT OPERATOR THE FOLLOWING QUESTIONS...............................................................................546 TROUBLESHOOTING THE JOYSTICK STEERING CONTROLLER SYSTEM (J MODE).........................................................................547 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM-RELATED PARTS.........................................................................548 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY AND PROBLEMS OCCUR ON MACHINE............................................................550 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM..............................................................................554 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED...........................................556 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................556 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID - DETECTED WHEN SIGNAL IS OUTPUT) IS DISPLAYED......................557 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................557 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID - DETECTED WHEN SIGNAL IS OUTPUT) IS DISPLAYED.......................558 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................558 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID - POWER SUPPLY SIDE) IS DISPLAYED...................................559 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................559 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID - POWER SUPPLY SIDE) IS DISPLAYED....................................560 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................560 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY) IS DISPLAYED....................................561 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................561 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED..............................562 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................562 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED..........................563 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................563 J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE...............................................................................564 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................564 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT.................................................................................565 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................565 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID........................................................................................566 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................566 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.........................................................................................567 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................567 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................569 HOW TO USE THIS MANUAL...................................................................................................................574 REMOVAL AND INSTALLATION PROCEDURES..................................................................................................574 GENERAL PRECAUTIONS..................................................................................................................574 SPECIAL TOOLS........................................................................................................................574 PRECAUTIONS WHEN CARRYING OUT THESE OPERATIONS...........................................................................................575 PRECAUTIONS FOR REMOVAL PROCEDURES...................................................................................................575 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK......................................................................................576 PRECAUTIONS WHEN COMPLETING THE OPERATIONS...........................................................................................577 SPECIAL TOOL LIST........................................................................................................................578 ILLUSTRATIONS OF SPECIAL TOOLS...........................................................................................................586 STARTING MOTOR...........................................................................................................................594 ALTERNATOR...............................................................................................................................595 ENGINE OIL COOLER........................................................................................................................596 FUEL INJECTION PUMP......................................................................................................................597 WATER PUMP...............................................................................................................................598 NOZZLE HOLDER............................................................................................................................599 TURBOCHARGER.............................................................................................................................600 RADIATOR.................................................................................................................................601 REMOVAL..............................................................................................................................601 INSTALLATION.........................................................................................................................603 ENGINE AND TORQUE CONVERTER ASSEMBLY.....................................................................................................604 TORQUE CONVERTER.........................................................................................................................606 REMOVAL..............................................................................................................................606 INSTALLATION.........................................................................................................................607 DISASSEMBLY..........................................................................................................................608 ASSEMBLY.............................................................................................................................613 TRANSMISSION.............................................................................................................................620 REMOVAL..............................................................................................................................620 INSTALLATION.........................................................................................................................622 DISASSEMBLY..........................................................................................................................624 ASSEMBLY.............................................................................................................................639 TRANSMISSION VALVE.......................................................................................................................656 REMOVAL..............................................................................................................................656 INSTALLATION.........................................................................................................................657 TRANSFER.................................................................................................................................658 DISASSEMBLY..........................................................................................................................658 ASSEMBLY.............................................................................................................................666 CENTER SUPPORT...........................................................................................................................678 REMOVAL..............................................................................................................................678 INSTALLATION.........................................................................................................................679 DISASSEMBLY..........................................................................................................................679 ASSEMBLY.............................................................................................................................681 DRIVE SHAFT..............................................................................................................................684 DISASSEMBLY..........................................................................................................................684 REASSEMBLY...........................................................................................................................686 FRONT AXLE...............................................................................................................................690 REMOVAL..............................................................................................................................690 INSTALLATION.........................................................................................................................691 FRONT DIFFERENTIAL.......................................................................................................................692 REMOVAL..............................................................................................................................692 INSTALLATION.........................................................................................................................693 REAR AXLE................................................................................................................................694 REMOVAL..............................................................................................................................694 INSTALLATION.........................................................................................................................697 REAR DIFFERENTIAL........................................................................................................................698 REMOVAL..............................................................................................................................698 INSTALLATION.........................................................................................................................699 DIFFERENTIAL GEAR ASSEMBLY...............................................................................................................700 DISASSEMBLY..........................................................................................................................700 ASSEMBLY.............................................................................................................................704 FINAL DRIVE..............................................................................................................................712 REMOVAL..............................................................................................................................712 INSTALLATION.........................................................................................................................714 STEERING CONTROL VALVE...................................................................................................................718 REMOVAL..............................................................................................................................718 INSTALLATION.........................................................................................................................719 STEERING CYLINDER........................................................................................................................720 REMOVAL..............................................................................................................................720 INSTALLATION.........................................................................................................................721 DISASSEMBLY..........................................................................................................................722 ASSEMBLY.............................................................................................................................723 STEERING VALVE...........................................................................................................................726 REMOVAL..............................................................................................................................726 INSTALLATION.........................................................................................................................727 CUT-OFF VALVE............................................................................................................................728 REMOVAL..............................................................................................................................728 INSTALLATION.........................................................................................................................728 BRAKE VALVE..............................................................................................................................730 REMOVAL..............................................................................................................................730 INSTALLATION.........................................................................................................................731 BRAKE VALVE (RIGHT SIDE).................................................................................................................732 DISASSEMBLY..........................................................................................................................732 ASSEMBLY.............................................................................................................................734 BRAKE VALVE (LEFT SIDE)..................................................................................................................736 DISASSEMBLY..........................................................................................................................736 ASSEMBLY.............................................................................................................................738 SLACK ADJUSTER...........................................................................................................................740 REMOVAL..............................................................................................................................740 INSTALLATION.........................................................................................................................740 DISASSEMBLY..........................................................................................................................741 ASSEMBLY.............................................................................................................................742 BRAKE....................................................................................................................................744 REMOVAL..............................................................................................................................744 INSTALLATION.........................................................................................................................745 DISASSEMBLY (FRONT OR REAR).........................................................................................................746 ASSEMBLY (FRONT OR REAR).............................................................................................................748 HYDRAULIC PUMP...........................................................................................................................752 REMOVAL..............................................................................................................................752 INSTALLATION.........................................................................................................................753 HYDRAULIC TANK...........................................................................................................................754 REMOVAL..............................................................................................................................754 INSTALLATION.........................................................................................................................755 HYDRAULIC FILTER.........................................................................................................................756 REMOVAL..............................................................................................................................756 INSTALLATION.........................................................................................................................757 PPC VALVE................................................................................................................................758 REMOVAL..............................................................................................................................758 INSTALLATION.........................................................................................................................759 DISASSEMBLY..........................................................................................................................760 ASSEMBLY.............................................................................................................................760 WORK EQUIPMENT VALVE.....................................................................................................................762 REMOVAL..............................................................................................................................762 INSTALLATION.........................................................................................................................763 MAIN CONTROL VALVE.......................................................................................................................764 DISASSEMBLY..........................................................................................................................765 ASSEMBLY.............................................................................................................................768 DUMP CYLINDER............................................................................................................................770 REMOVAL..............................................................................................................................770 INSTALLATION.........................................................................................................................771 LIFT CYLINDER............................................................................................................................772 REMOVAL..............................................................................................................................772 INSTALLATION.........................................................................................................................773 LIFT CYLINDER AND DUMP CYLINDER..........................................................................................................774 DISASSEMBLY..........................................................................................................................774 ASSEMBLY.............................................................................................................................776 CENTER HINGE PIN.........................................................................................................................780 REMOVAL..............................................................................................................................780 INSTALLATION.........................................................................................................................785 WORK EQUIPMENT...........................................................................................................................788 REMOVAL..............................................................................................................................788 INSTALLATION.........................................................................................................................792 BULKHEAD.................................................................................................................................794 REMOVAL..............................................................................................................................794 INSTALLATION.........................................................................................................................795 FLOOR FRAME..............................................................................................................................796 REMOVAL..............................................................................................................................796 INSTALLATION.........................................................................................................................798 COUNTERWEIGHT............................................................................................................................800 REMOVAL..............................................................................................................................800 INSTALLATION.........................................................................................................................800 FUEL TANK................................................................................................................................802 REMOVAL..............................................................................................................................802 INSTALLATION.........................................................................................................................803 CAB......................................................................................................................................804 REMOVAL..............................................................................................................................804 INSTALLATION.........................................................................................................................806 STOP VALVE...............................................................................................................................807 REMOVAL..............................................................................................................................807 INSTALLATION.........................................................................................................................807 ACCUMULATOR..............................................................................................................................808 REMOVAL..............................................................................................................................808 INSTALLATION.........................................................................................................................809 ACCUMULATOR CHARGE VALVE.................................................................................................................810 REMOVAL..............................................................................................................................810 INSTALLATION.........................................................................................................................810 PARKING BRAKE SOLENOID VALVE.............................................................................................................811 REMOVAL..............................................................................................................................811 INSTALLATION.........................................................................................................................811 DIVERTER VALVE...........................................................................................................................812 REMOVAL..............................................................................................................................812 INSTALLATION.........................................................................................................................813 GROUND-DRIVEN STEERING PUMP..............................................................................................................814 REMOVAL..............................................................................................................................814 INSTALLATION.........................................................................................................................815 PARKING BRAKE............................................................................................................................816 REMOVAL..............................................................................................................................816 INSTALLATION.........................................................................................................................817 PARKING BRAKE CALIPERS...................................................................................................................818 DISASSEMBLY..........................................................................................................................818 ASSEMBLY.............................................................................................................................819 PARKING BRAKE PAD........................................................................................................................820 REMOVAL..............................................................................................................................820 INSTALLATION.........................................................................................................................821 REAR TIRES...............................................................................................................................822 REMOVAL..............................................................................................................................822 INSTALLATION.........................................................................................................................822 AIR CONDITIONER COMPRESSOR...............................................................................................................823 REMOVAL..............................................................................................................................823 INSTALLATION.........................................................................................................................823 AIR CONDITIONER CONDENSER................................................................................................................824 REMOVAL..............................................................................................................................824 INSTALLATION.........................................................................................................................825 RECEIVER TANK............................................................................................................................826 REMOVAL..............................................................................................................................826 INSTALLATION.........................................................................................................................826 AIR CONDITIONER UNIT.....................................................................................................................828 REMOVAL..............................................................................................................................828 INSTALLATION.........................................................................................................................829 MONITOR..................................................................................................................................830 REMOVAL..............................................................................................................................830 INSTALLATION.........................................................................................................................831 40 MAINTENANCE STANDARD......................................................................................................................833 ENGINE MOUNT.............................................................................................................................835 TRANSMISSION MOUNT.......................................................................................................................836 TORQUE CONVERTER.........................................................................................................................837 TORQUE CONVERTER REGULATOR VALVE.....................................................................................................839 TRANSMISSION.............................................................................................................................840 CLUTCHES.............................................................................................................................840 GEAR BACKLASH........................................................................................................................842 TRANSMISSION CONTROL VALVE...........................................................................................................843 UPPER VALVE......................................................................................................................843 RELIEF VALVE.....................................................................................................................843 LOWER VALVE......................................................................................................................845 SOLENOID VALVE...................................................................................................................847 TRANSFER.................................................................................................................................848 DRIVE SHAFT..............................................................................................................................850 CENTER SUPPORT...........................................................................................................................852 CENTER HINGE PIN.........................................................................................................................853 AXLE MOUNT...............................................................................................................................856 DIFFERENTIAL.............................................................................................................................858 GEAR AND PINION......................................................................................................................858 BOLT TORQUE..........................................................................................................................860 FINAL DRIVE..............................................................................................................................862 STEERING.................................................................................................................................864 STEERING COLUMN......................................................................................................................864 STEERING VALVE.......................................................................................................................866 GROUND-DRIVEN STEERING PUMP..........................................................................................................867 DIVERTER VALVE.......................................................................................................................868 STEERING CYLINDER MOUNT..............................................................................................................869 BRAKES...................................................................................................................................870 BRAKE VALVE - LEFT...................................................................................................................870 BRAKE VALVE - RIGHT..................................................................................................................872 SLACK ADJUSTER.......................................................................................................................874 BRAKE................................................................................................................................875 PARKING BRAKE........................................................................................................................877 HYDRAULICS...............................................................................................................................878 TORQUE CONVERTER CHARGING PUMP AND PPC PUMP .........................................................................................878 WORK EQUIPMENT PUMPS 1 AND 2.........................................................................................................879 STEERING PUMP AND SWITCH PUMP........................................................................................................880 PPC VALVE FOR BOOM AND BUCKET........................................................................................................881 PPC VALVE FOR ATTACHMENT.............................................................................................................882 CUT-OFF VALVE........................................................................................................................883 MAIN CONTROL VALVE...................................................................................................................884 STEERING CYLINDER....................................................................................................................886 BUCKET CYLINDER......................................................................................................................887 BOOM CYLINDER........................................................................................................................888 WORK EQUIPMENT...........................................................................................................................889 WORK EQUIPMENT LINKAGE...............................................................................................................889 BUCKET...............................................................................................................................891 BUCKET POSITIONER AND BOOM KICK-OUT..................................................................................................892 ROPS CANOPY..............................................................................................................................893
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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