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Komatsu WA700-3 (KA SPEC) Wheel Loader Shop Manual SN 51005 and up – PDF DOWNLOAD
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Komatsu WA700-3 (KA SPEC) Wheel Loader Shop Manual
Book Code: SEBM032802
MACHINE MODEL SERIAL NO.
WA700-3 51005 and up
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Description
Komatsu WA700-3 (KA SPEC) Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA700-3 (KA SPEC) Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA700-3 (KA SPEC.)
Serial Number: 51005 and up
Book Code: SEBM032802
Language: English
Pages: 809
File Format: Portable Document Format (PDF)
KOMATSU WA700-3 (KA SPEC) WHEEL LOADER SHOP MANUAL SN 51005 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA700-3 (KA SPEC) Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA700-3 (KA SPEC) Wheel Loader Shop Manual
MAIN MENU................................................................................................................................................................................................. 0
COVER..................................................................................................................................................................................................... 1
CONTENTS.................................................................................................................................................................................................. 2
SAFETY.................................................................................................................................................................................................... 8
SAFETY NOTICE......................................................................................................................................................................................... 8
FOREWORD.................................................................................................................................................................................................. 10
GENERAL............................................................................................................................................................................................... 10
HOW TO READ THE SHOP MANUAL........................................................................................................................................................................... 11
HOISTING INSTRUCTIONS................................................................................................................................................................................. 12
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER............................................................................................................................................ 13
COATING MATERIALS..................................................................................................................................................................................... 15
STANDARD TIGHTENING TORQUE............................................................................................................................................................................ 17
ELECTRIC WIRE CODE.................................................................................................................................................................................... 20
CONVERSION TABLE...................................................................................................................................................................................... 21
UNITS................................................................................................................................................................................................. 27
01 GENERAL................................................................................................................................................................................................ 28
GENERAL ASSEMBLY DRAWING.............................................................................................................................................................................. 29
SPECIFICATIONS........................................................................................................................................................................................ 30
WEIGHT TABLE.......................................................................................................................................................................................... 33
LIST OF LUBRICANT AND WATER........................................................................................................................................................................... 35
10 STRUCTURE AND FUNCTION................................................................................................................................................................................. 38
OUTLINE............................................................................................................................................................................................... 39
POWER TRAIN SYSTEM.................................................................................................................................................................................... 41
DAMPER................................................................................................................................................................................................ 43
RADIATOR AND OIL COOLER............................................................................................................................................................................... 44
TORQUE CONVERTER AND TRANSMISSION PIPING.............................................................................................................................................................. 45
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM................................................................................................................................................................. 47
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................ 49
TORQUE CONVERTER AND PTO.............................................................................................................................................................................. 51
TORQUE CONVERTER REGULATOR VALVE...................................................................................................................................................................... 54
TRANSMISSION.......................................................................................................................................................................................... 56
TRANSMISSION CONTROL VALVE............................................................................................................................................................................ 65
TORQUE CONVERTER OIL COOLER........................................................................................................................................................................... 85
TRANSMISSION OIL FILTER............................................................................................................................................................................... 86
TRANSFER.............................................................................................................................................................................................. 88
AXLE.................................................................................................................................................................................................. 89
DIFFERENTIAL.......................................................................................................................................................................................... 91
FINAL DRIVE........................................................................................................................................................................................... 94
AXLE MOUNT............................................................................................................................................................................................ 97
CENTER HINGE PIN...................................................................................................................................................................................... 99
JOYSTICK STEERING LINKAGE.............................................................................................................................................................................100
STEERING AND SWITCH PUMP..............................................................................................................................................................................101
SWITCH PUMP CUT-OFF SOLENOID..........................................................................................................................................................................103
STEERING DEMAND VALVE.................................................................................................................................................................................104
EPC VALVE.............................................................................................................................................................................................115
ROTARY VALVE..........................................................................................................................................................................................116
TWO WAY RESTRICTOR VALVE..............................................................................................................................................................................119
DIVERTER VALVE........................................................................................................................................................................................120
BRAKE PIPING..........................................................................................................................................................................................124
BRAKE CIRCUIT DIAGRAM.................................................................................................................................................................................125
BRAKE VALVE...........................................................................................................................................................................................127
CHARGE VALVE..........................................................................................................................................................................................133
ACCUMULATOR (FOR BRAKE)...............................................................................................................................................................................137
SLACK ADJUSTER........................................................................................................................................................................................138
BRAKE.................................................................................................................................................................................................141
PARKING BRAKE.........................................................................................................................................................................................143
SPRING CYLINDER.......................................................................................................................................................................................145
PARKING BRAKE SOLENOID VALVE..........................................................................................................................................................................146
HYDRAULIC PIPING......................................................................................................................................................................................147
HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................................................................................149
MAIN PISTON PUMP......................................................................................................................................................................................152
ES • CO VALVE.........................................................................................................................................................................................160
SERVO VALVE...........................................................................................................................................................................................161
PRESSURE DIFFERENTIAL VALVE...........................................................................................................................................................................162
PPC VALVE (PROPORTIONAL PRESSURE VALVE)...............................................................................................................................................................163
PPC RELIEF VALVE......................................................................................................................................................................................167
ACCUMULATOR (FOR PPC VALVE)...........................................................................................................................................................................168
MAIN CONTROL VALVE....................................................................................................................................................................................169
LUBRICATION OF WORK EQUIPMENT.........................................................................................................................................................................183
WORK EQUIPMENT LINKAGE................................................................................................................................................................................185
BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................................187
OPERATION OF PROXIMITY SWITCH.........................................................................................................................................................................189
AIR CONDITIONER.......................................................................................................................................................................................193
ELECTRIC CIRCUIT DIAGRAM..............................................................................................................................................................................196
MACHINE MONITOR SYSTEM................................................................................................................................................................................196
MAIN MONITOR..........................................................................................................................................................................................197
MAINTENANCE MONITOR...................................................................................................................................................................................201
AUTOMATIC TRANSMISSION SYSTEM (ATM)...................................................................................................................................................................203
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)..............................................................................................................................................................214
TRANSMISSION AND JOYSTICK CONTROLLER..................................................................................................................................................................219
ENGINE STARTING CIRCUIT...............................................................................................................................................................................221
ENGINE STOP CIRCUIT...................................................................................................................................................................................222
PREHEATING CIRCUIT....................................................................................................................................................................................223
FUEL SYSTEM...........................................................................................................................................................................................224
KICK-DOWN, HOLD SWITCH................................................................................................................................................................................225
ELECTRIC PARKING BRAKE CONTROL........................................................................................................................................................................226
ELECTRIC CIRCUIT OF ACTIVE POWER MAXIMIZING FUNCITON..................................................................................................................................................235
[RELATED TO VHMS CONTROLLER]..........................................................................................................................................................................241
VHMS CONTROLLER...................................................................................................................................................................................241
BLOW-BY PRESSURE SENSOR...........................................................................................................................................................................241
ENGINE OIL TEMPERATURE SENSOR.....................................................................................................................................................................242
EXHAUST TEMPERATURE SENSOR/AMP....................................................................................................................................................................243
AMBIENT TEMPERATURE SENSOR........................................................................................................................................................................243
TRANSMISSION PUMP OIL PRESSURE SENSOR.............................................................................................................................................................244
BRAKE OIL TEMPERATURE SENSOR AND HYDRAULIC OIL TEMPERATURE SENSOR.................................................................................................................................245
BRAKE OIL PRESSURE SENSOR, STEERING OIL PRESSURE SENSOR AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR...............................................................................................246
COMMUNICATIONS (ORB: ORBCOMM) CONTROLLER/ANTENNA..................................................................................................................................................247
20 TESTING AND ADJUSTING..................................................................................................................................................................................249
STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................................................................250
STANDARD VALUE TABLE FOR CHASSIS......................................................................................................................................................................251
STANDARD VALUE TABLE FOR ELECTRICAL PARTS.............................................................................................................................................................256
TESTING AND ADJUSTING.................................................................................................................................................................................265
TABLE OF TOOLS FOR TESING, ADJUSTING, AND TROUBLESHOOTING.........................................................................................................................................266
ADJUSTING VALVE CLEARANCE.........................................................................................................................................................................268
MEASURING COMPRESSION PRESSURE....................................................................................................................................................................269
MEASURING BLOW-BY PRESSURE........................................................................................................................................................................271
MEASURING EXHAUST GAS COLOR.......................................................................................................................................................................272
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....................................................................................................................................................273
MEASURING EXHAUST TEMPERATURE.....................................................................................................................................................................274
MEASURING ENGINE SPEED............................................................................................................................................................................276
ADJUSTING SET LOAD OF INJECTOR....................................................................................................................................................................278
TROUBLESHOOTING OF INJECTOR.......................................................................................................................................................................280
MEASURING FUEL CIRCUIT PRESSURE...................................................................................................................................................................281
HANDLING EQUIPMENT IN FUEL CIRCUIT................................................................................................................................................................283
BLEEDING AIR FROM FUEL CIRCUIT....................................................................................................................................................................284
ADJUSTING SPEED SENSORS...........................................................................................................................................................................286
TESTING AND ADJUSTING ALTERNATOR BELT TENSION.....................................................................................................................................................287
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.....................................................................................................................................288
MEASURING ACCELERATOR PEDAL.......................................................................................................................................................................289
ADJUSTING ACCELERATOR PEDAL TRAVEL, POTENTIOMETER.................................................................................................................................................290
ADJUSTING ACCELERATOR PEDAL MICRO SWITCH..........................................................................................................................................................292
MEASURING TORQUE CONVERTER, TRANSMISSION HYDRAULIC PRESSURE.......................................................................................................................................293
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL....................................................................................................................................................295
TESTING AND ADJUSTING STEERING OIL PRESSURE.......................................................................................................................................................297
ADJUSTING STEERING STOPPER BOLT...................................................................................................................................................................298
ADJUSTING JOYSTICK STEERING.......................................................................................................................................................................299
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH.................................................................................................................................................300
TESTING BRAKE OIL PRESSURE........................................................................................................................................................................301
MEASURING WEAR OF BRAKE DISC......................................................................................................................................................................302
MEASURING BRAKE PERFORMANCE.......................................................................................................................................................................303
TESTING AND ADJUSTING PARKING BRAKE...............................................................................................................................................................304
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE.................................................................................................................................................306
MEASURING PPC RELIEF VALVE HYDRAULIC PRESSURE.....................................................................................................................................................307
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...........................................................................................................................................309
BLEEDING AIR FROM THE PISTON PUMP.................................................................................................................................................................311
ADJUSTING WORK EQUIPMENT LEVER LINKAGE............................................................................................................................................................312
TESTING AND ADJUSTING BUCKET POSITIONER...........................................................................................................................................................314
TESTING AND ADJUSTING BOOM KICK-OUT...............................................................................................................................................................315
TESTING AND ADJUSTING PROXIMITY SWITCH FOR ACTIVE POWER MAXIMIZING FUNCTION.......................................................................................................................316
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP.....................................................................................................................................................317
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE).......................................................................................................................................................318
BLEEDING AIR......................................................................................................................................................................................319
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................................................................................................................................................320
PM CLINIC INSPECTION TABLE........................................................................................................................................................................321
BASIC PRECAUTIONS.................................................................................................................................................................................323
OUTLINE...........................................................................................................................................................................................326
SETTING UP VHMS CONTROLLER........................................................................................................................................................................332
COLLECTION, TRANSMISSION OF DATA..................................................................................................................................................................334
INSPECTION AND MAINTENANCE........................................................................................................................................................................339
REPLACING PARTS...................................................................................................................................................................................339
TROUBLESHOOTING.......................................................................................................................................................................................340
POINTS TO REMEMBER WHEN TROUBLESHOOTING ..........................................................................................................................................................341
SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................................................................................................342
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................................................................................343
CHECKS BEFORE TROUBLESHOOTING.....................................................................................................................................................................351
CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................................................................................................352
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................................................................................356
T-BRANCH BOX AND T-BRANCH TABLE...................................................................................................................................................................379
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE.................................................................................................................................................381
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION..........................................................................................................................................383
TRANSMISSION CONTROLLER LED DISPLAY...............................................................................................................................................................385
METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................................386
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).........................................................................................................................................................388
METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................................................389
S-1 Starting performance is poor (starting always takes time).................................................................................................................................393
S-2 Engine does not start.....................................................................................................................................................................395
a) Engine does not turn...................................................................................................................................................................395
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)...............................................................................................................397
c) Exhaust smoke comes out but engine does not start (fuel is being injected).............................................................................................................399
S-3 Engine does not pick up smoothly (follow-up is poor)......................................................................................................................................401
S-4 Engine stops during operations............................................................................................................................................................403
S-5 Engine does not rotate smoothly (hunting).................................................................................................................................................405
S-6 Engine lacks output (or lacks power)......................................................................................................................................................407
S-7 Exhaust smoke is black (incomplete combustion)............................................................................................................................................409
S-8 Oil consumption is excessive (or exhaust smoke is blue)...................................................................................................................................411
S-9 Oil becomes contaminated quickly..........................................................................................................................................................412
S-10 Fuel consumption is excessive............................................................................................................................................................413
S-11 Oil is in cooling water, or water spurts back, or water level goes down..................................................................................................................414
S-12 Oil pressure caution lamp lights up (drop in oil pressure)...............................................................................................................................415
S-13 Oil level rises..........................................................................................................................................................................416
S-14 Water temperature becomes too high (overheating).........................................................................................................................................417
S-15 Abnormal noise is made...................................................................................................................................................................418
S-16 Vibration is excessive...................................................................................................................................................................419
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...................................................................................................................................................420
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM..................................................................................................................................................423
M-1 Main monitor does not work................................................................................................................................................................425
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up............................................................................................426
M-3 Speedometer display does not work properly................................................................................................................................................427
M-4 Abnormality in shift indicator............................................................................................................................................................428
a) displays N even when directional lever is at F.........................................................................................................................................428
b) Displays N even when directional lever is at R.........................................................................................................................................428
c) Does not display N even when directional lever is at N, and displays R when directional lever is at F..................................................................................428
d) Does not display N even when directional lever is at N, and displays F when directional lever is at R..................................................................................429
e) Does not display 1st even when speed lever is at 1 (directional lever at F or R).......................................................................................................429
f) Does not display 2nd even when speed lever is at 2 (directional lever at F or R).......................................................................................................429
g) Does not display 3rd even when speed lever is at 3 (directional lever at F or R).......................................................................................................430
h) Does not display 4th even when speed lever is at 4 (directional lever at F or R).......................................................................................................430
M-5 Turn signal display does not light up.....................................................................................................................................................432
a) L.H. turn signal display does not light up.............................................................................................................................................432
b) R.H. turn signal display does not light up.............................................................................................................................................432
M-6 Abnormality in parking display............................................................................................................................................................433
a) Parking lamp display does not light up.................................................................................................................................................433
b) Parking lamp display stays lighted up..................................................................................................................................................433
M-7 Night lighting does not light up..........................................................................................................................................................434
M-8 Abnormality in front working lamp.........................................................................................................................................................435
a) Neither monitor display nor front working lamp light up................................................................................................................................435
b) Working lamp lights up but monitor display does not light up...........................................................................................................................435
c) Monitor display lights up but working lamp does not light up...........................................................................................................................435
M-9 Abnormality in rear working lamp..........................................................................................................................................................437
a) Neither monitor display nor rear working lamp light up.................................................................................................................................437
b) Working lamp lights up but monitor display does not light up...........................................................................................................................437
c) Monitor display lights up but working lamp does not light up...........................................................................................................................437
M-10 Abnormality in transmission cut-off......................................................................................................................................................438
a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not change.............................................................................438
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated....................................................................................................438
c) Transmission cut-off switch turned ON, but cut-off function is not actuated............................................................................................................439
Auto-shift specification..................................................................................................................................................................440
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change.............................................................440
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off funciton is actuated when pedal is depressed............................................440
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated.......................................................................440
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF)..............................................................................440
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated................................................................................441
M-11 Abnormality in parking brake dragging warning............................................................................................................................................442
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N.............................................................442
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at position other than N........................................442
M-12 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated................................................................444
a) Actuated continuously .................................................................................................................................................................444
b) Not actuated...........................................................................................................................................................................444
M-13 Abnormality in buzzer....................................................................................................................................................................445
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)................................................................................................445
b) Buzzer always sounds...................................................................................................................................................................445
M-14 Condition of monitor switched is not stored in memory....................................................................................................................................446
M-15 Abnormality in failure display mode......................................................................................................................................................447
a) Does not enter failure display mode....................................................................................................................................................447
b) Count for time elapsed since failure display mode does not advance.....................................................................................................................447
M-16 Abnormality in emergency steering actuation display......................................................................................................................................448
a) Emergency steering actuation display does not light up.................................................................................................................................448
b) Emergency steering actuation display stays lighted up..................................................................................................................................448
M-17 Abnormality in auto-greasing system......................................................................................................................................................449
a) Forced greasing cannot be carried out..................................................................................................................................................449
b) Monitor display flashes rapidly (2 times/sec.).........................................................................................................................................449
c) When no more grease remains, monitor display flashes rapidly (2 times/sec.)............................................................................................................449
d) Monitor display flashes slowly (1 time/sec.)...........................................................................................................................................450
e) Monitor display goes out...............................................................................................................................................................450
M-18 Abnormality in low idling select system..................................................................................................................................................451
a) Display does not change when switch is pressed.........................................................................................................................................451
b) Monitor display lights up but low idling select function does not work.................................................................................................................451
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)............................................................................................................................................452
ELECTRICAL CIRCUIT DIAGRAM FOR K MODE SYSTEM..................................................................................................................................................453
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does not work......................................................454
a) No lamps on maintenance monitor light up...............................................................................................................................................454
b) Some lamps do not light up.............................................................................................................................................................454
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds).....................................................................455
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out..........................................................456
K-4 When starting switch is turned ON (engine stopped), CHECK items flash.....................................................................................................................457
a) Engine oil level display flashes.......................................................................................................................................................457
b) Engine water level display flashes.....................................................................................................................................................458
K-5 When starting switch is turned ON (engine started), CAUTION items flash...................................................................................................................459
a) Engine oil pressure display flashes (Check that the engine oil pressure is correct.)...................................................................................................459
b) Battery charge level display flashes...................................................................................................................................................460
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct)......................................................................................................461
d) Air cleaner display flashes (Check that there is no clogging of the air cleaner).......................................................................................................462
K-6 CAUTION items are flashing but caution buzzer does not sound..............................................................................................................................463
K-7 There is no abnormality in monitor display but caution buzzer sounds......................................................................................................................464
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash.....................................................................................................465
a) CHECK lamp.............................................................................................................................................................................465
b) CAUTION lamp...........................................................................................................................................................................465
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up..............................................................................466
a) CHECK lamp.............................................................................................................................................................................466
b) CAUTION lamp...........................................................................................................................................................................466
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)..................................................................467
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up...................................................................................................468
K-12 Service meter does not work..............................................................................................................................................................469
K-13 Service meter is running even when engine is stopped.....................................................................................................................................469
K-14 Abnormality is gauge items...............................................................................................................................................................471
a) Abnormality is fuel gauge..............................................................................................................................................................471
b) Abnormality in engine water temperature gauge..........................................................................................................................................472
c) Abnormality in torque converter oil temperature gauge..................................................................................................................................473
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....................................................................................................................................................474
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM..................................................................................................................................................475
ELECTRICAL CIRCUIT DIAGRAM FOR ACTIVE POWER UP SYSTEM.........................................................................................................................................477
E-1 Engine does not start.....................................................................................................................................................................479
E-2 Defective preheating......................................................................................................................................................................484
E-3 Parking brake does not have effect........................................................................................................................................................486
a) Parking brake has no effect when parking brake switch is turned ON.....................................................................................................................486
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure drops.....................................................................................486
E-4 Parking brake is applied when machine is traveling........................................................................................................................................487
E-5 Parking brake is released when starting switch is turned ON...............................................................................................................................489
E-6 Transmission does not change to neutral when parking brake is applied, but parking brake works normally...................................................................................489
E-7 Transmission does not work properly.......................................................................................................................................................492
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit.................................................................................493
b) No continuity in travel FORWARD solenoid circuit.......................................................................................................................................497
c) No continuity in travel REVERSE solenoid circuit.......................................................................................................................................499
d) Short circuit to chassis ground in directional solenoid circuit........................................................................................................................501
e) Abnormality in shift solenoid circuit..................................................................................................................................................507
f) Short circuit to chassis ground in shift solenoid circuit..............................................................................................................................510
E-8 Kick-down switch does not work (shift works correctly during normal gear shift operations F1 - F4)........................................................................................515
E-9 Kick-down works only when kick-down switch is being turned ON (kick-down switch does not carry out self-hold operation)...................................................................518
E-10 Kick-down always works...................................................................................................................................................................519
E-11 Kick-down switch works even when traveling FORWARD in 2nd................................................................................................................................521
E-12 Boom Kick-out does not work..............................................................................................................................................................523
E-13 Defective bucket positioner..............................................................................................................................................................525
E-14 Power window does not work...............................................................................................................................................................527
a) Window does not go up..................................................................................................................................................................527
b) Window does not go down................................................................................................................................................................528
E-15 Defective operation of solenoid for power maximizing function............................................................................................................................531
a) Inspection of timer 1 and no-load relay system.........................................................................................................................................531
b) Inspection of neutral relay 1 and neutral relay 2 (Power supply system)................................................................................................................533
c) Inspection of solenoid (U11) drive system).............................................................................................................................................535
E-16 Abnormality in front working lamp........................................................................................................................................................540
E-17 Abnormality in rear working lamp.........................................................................................................................................................540
E-18 Abnormality in transmission cut-off......................................................................................................................................................540
E-19 Abnormality in parking brake dragging warning............................................................................................................................................540
E-20 Abnormality in buzzer....................................................................................................................................................................540
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).......................................................................................................................................542
METHOD OF USING MATRIX TROUBLESHOOTING TABLES.................................................................................................................................................543
H-1 Machine does not start....................................................................................................................................................................545
H-2 Machine lacks power or speed when traveling (all speed ranges)............................................................................................................................546
H-3 Time lag is excessive when starting or shifting gear......................................................................................................................................547
H-4 Torque converter oil temperature is high..................................................................................................................................................548
H-5 Steering does not turn....................................................................................................................................................................549
H-6 Steering does not turn (machine with joystick)............................................................................................................................................550
H-7 Turning, response of steering is poor.....................................................................................................................................................551
H-8 Turning, response of steering is poor (machine with joystick).............................................................................................................................553
H-9 Steering is heavy.........................................................................................................................................................................555
H-10 Steering wheel shakes or jerks...........................................................................................................................................................556
H-11 Steering shakes or there is excessive shock (machine with joystick)......................................................................................................................557
H-12 Turning radius is different between left and right at maximum steering...................................................................................................................557
H-13 Wheel brakes do not work or braking effect is poor.......................................................................................................................................559
H-14 Wheel brakes are not released or brakes drag.............................................................................................................................................561
H-15 Parking brake does not work or braking effect is poor....................................................................................................................................562
H-16 Parking brake is not released or brake drags.............................................................................................................................................563
H-17 Neither boom nor bucket move.............................................................................................................................................................564
H-18 Both boom and bucket are slow or lack power..............................................................................................................................................565
H-19 Boom does not move.......................................................................................................................................................................566
H-20 Boom is slow or boom lacks power.........................................................................................................................................................567
H-21 Boom cannot be set to FLOAT or cannot be released from FLOAT.............................................................................................................................568
H-22 Boom drops momentarily when control lever is operated from HOLD to RAISE.................................................................................................................568
H-23 Excessive hydraulic drift of boom........................................................................................................................................................569
H-24 Bucket does not move.....................................................................................................................................................................570
H-25 Bucket is slow or lacks power............................................................................................................................................................571
H-26 Excessive hydraulic drift of bucket......................................................................................................................................................572
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)........................................................................................................................................574
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS..............................................................................................................................575
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................................577
ELECTRICAL CIRCUIT DIAGRAM FOR T MODE SYSTEM..................................................................................................................................................583
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed.......................................................................585
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed..............................................................................586
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed..............................................................................587
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed............................................................................588
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed............................................................................589
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed............................................................................590
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed............................................................................591
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed.......................................................................................592
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed................................................................................................593
T-10 Failure code [21] (Short circuit, disconnection in range switch system) is displayed.....................................................................................................597
T-11 Failure code [22] (Disconnection in travelspeed sensor system) is displayed..............................................................................................................600
T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed..............................................................................................601
T-13 Hold switch system.......................................................................................................................................................................602
T-14 Kick-down switch system..................................................................................................................................................................602
T-15 Transmission cut-off signal system.......................................................................................................................................................603
T-16 Neutralizer relay signal system..........................................................................................................................................................604
T-17 Buzzer signal system.....................................................................................................................................................................605
T-18 Network system...........................................................................................................................................................................606
T-19 Transmission controller power source system..............................................................................................................................................607
T-20 Short circuit in travel speed sensor system..............................................................................................................................................608
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM CONTROL SYSTEM) (J MODE)...............................................................................................................610
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM...................................................................................................................611
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY..................................................................................................613
ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL..........................................................................................................617
J-1 Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed..........................................................................619
J-2 Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed...................................................................620
J-3 Error code [58] (Deviation of steering lever angle sensor and frame sensor signals) is displayed..........................................................................................621
J-4 Error code [59] (Disconnection or short circuit with chassis ground in frame angle sensor system) is displayed............................................................................622
J-5 Error code [60] (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed...........................................................623
J-6 Error code [62] (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed..............................................................624
J-7 Error code [63] (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed.................625
J-8 Steering speeds in both directions are different..........................................................................................................................................626
J-9 Abnormality in console switch (adjustment of steering lever angle sensor and frame angle sensor is impossible)............................................................................627
J-10 Abnormality in power source and voltage..................................................................................................................................................628
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (EA MODE)................................................................................................................................................630
METHOD OF ERROR CODE DISPLAY..................................................................................................................................................................632
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..............................................................................................................635
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROL SYSTEM..........................................................................................................................................643
EA-1 Error code [111] (Abnormality in controller memory)......................................................................................................................................645
EA-2 Error code [112] (Abnormality in timing rail actuator)...................................................................................................................................645
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)......................................................................................................646
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system)...........................................................................................................................647
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)........................................................................................................649
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system).........................................................................................................650
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system)..........................................................................................................651
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)...........................................................................................................652
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system)...........................................................................................................................653
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system).............................................................................................................654
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system)..............................................................................................................655
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system)................................................................................................................656
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system).................................................................................................................657
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system)...............................................................................................................658
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)................................................................................................................659
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))..............................................................................................................................660
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)..........................................................................................................661
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system)...........................................................................................................662
EA-19 Error code [151] (Abnormal rise in water temperature)...................................................................................................................................662
EA-20 Error code [153] (Abnormality [high level] in intake air temperature sensor system)....................................................................................................663
EA-21 Error code [154] (Abnormality [low level] in intake air temperature sensor system)......................................................................................................663
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure sensor system).......................................................................................................664
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure sensor system)........................................................................................................665
EA-24 Error code [234] (Overspeed)............................................................................................................................................................667
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)....................................................................................................................668
EA-26 Error code [259] (Abnormality in fuel shut-off valve)..................................................................................................................................669
EA-27 Error code [261] (Abnormal rise in fuel temperature)...................................................................................................................................669
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)...........................................................................................................670
EA-29 Error code [265] (Abnormality [low level] in fuel temperature sensor system)............................................................................................................670
EA-30 Error code [316] (Abnormality in fuel pump actuator system current).....................................................................................................................671
EA-31 Error code [318] (Abnormality in fuel pump actuator)...................................................................................................................................672
EA-32 Error code [343] (Abnormality in controller internal communication)....................................................................................................................672
EA-33 Error code [346] (Abnormality in controller power down)................................................................................................................................673
EA-34 Error code [384] (Abnormality in preheating heater control system)......................................................................................................................674
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))..............................................................................................................................675
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system).........................................................................................................675
EA-37 Error code [431] (Abnormality [1] in idling validation switch system)...................................................................................................................677
EA-38 Error code [432] (Idling validation process error).....................................................................................................................................679
EA-39 Error code [441] (Abnormality [low level] in battery voltage)...........................................................................................................................681
EA-40 Error code [442] (Abnormality [high level] in battery voltage).........................................................................................................................681
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system).........................................................................................................682
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)..........................................................................................................683
EA-43 Error code [455] (Abnormality in fuel rail actuator system current).....................................................................................................................684
EA-44 Error code [467] (Abnormality in timing rail actuator control).........................................................................................................................685
EA-45 Error code [468] (Abnormality in fuel rail actuator control)...........................................................................................................................685
EA-46 Error code [514] (Abnormality in fuel rail actuator)...................................................................................................................................685
EA-47 Error code [527] (Abnormality in dual output solenoid A system).........................................................................................................................686
EA-48 Error code [551] (Abnormality [2] in idling validation switch system)...................................................................................................................686
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor)..................................................................................................................687
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE).............................................................................................................................................689
ELECTRICAL SYSTEM DIAGRAM RELATED TO VHMS CONTROLLER..........................................................................................................................................692
INFORMATION GIVEN IN TROUBLESHOOTING CHART....................................................................................................................................................694
PHENOMENON TYPE CODE LIST.....................................................................................................................................................................695
[DBB0KK] (OR VHMS_LED INDICATES [N901]) ABNORMALITY IN SOURCE VOLTAGE.........................................................................................................................696
[DBB5KP] (OR VHMS_LED INDICATES [N904]) ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM........................................................................................................698
[DBB6KP] (OR VHMS_LED INDICATES [N902]) ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM.......................................................................................................700
[DBBRKR] (OR VHMS_LED DISPLAYS [N801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)............................................702
[DGE1KB] (OR VHMS_LED DISPLAYS [N242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN. (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE)....704
[DGE1KY] (OR VHMS_LED DISPLAYS [N242]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)...............................................................705
[DGE5KX] (OR VHMS_LED DISPLAYS [N401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)..........................................................................706
[DGT4KA] (OR VHMS_LED DISPLAYS [N312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2 , 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)........................................708
[DGT4KB] (OR VHMS_LED DISPLAYS [N311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)...............................................710
[DGT5KA] (OR VHMS_LED DISPLAYS [N322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) .......................................712
[DGT5KB] (OR VHMS_LED DISPLAYS [N321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)..............................................714
[DHE5KB] (OR VHMS_LED DISPLAYS [N332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA).........................................................716
[DHE5KY] (OR VHMS_LED DISPLAYS [N331]) SHORT CIRCUIT WIRTH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY).............................................................718
[DHT3KX] (OR VHMS_LED DISPLAYS [N614]) TROUBLE IN TRANSMISSION OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX).....................................................................720
[DHP2KX] (OR VHMS_LED DISPLAYS [N531]) TROUBLE IN MAIN PUMP OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)........................................................................722
[DHT8KX] (OR VHMS_LED DISPLAYS [N533]) TROUBLE IN STEERING OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIIGNAL RANGE (KX)........................................................................724
[DGH2KX] (OR VHMS_LED DISPLAYS [N537]) TROUBLE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX).....................................................................726
[DHU2KX] (OR VHMS_LED DISPLAYS [N711]) TROUBLE IN FRONT BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)......................................................................728
[DHU3KX] (OR VHMS_LED DISPLAYS [N712]) TROUBLE IN REAR BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX).......................................................................730
[DGR4KX] OR VHMS_LED DISPLAYS [N717]) TROUBLE IN FRONT BRAKE OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....................................................................732
[F@BBZL] (OR VHMS_LED DISPLAYS [N338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL) .................................................................................................................733
[F@BYNR] (OR VHMS_LED DISPLAYS [N362]) NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (2): (NR)...............................................................................................734
[F@BYNS] (OR VHMS_LED DISPLAYS [N361]) NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (1): (NS)...............................................................................................735
[F@BZNR] (OR VHMS_LED DISPLAYS {N372]) NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (2): (NR)..............................................................................................736
[F@BZNS] (OR VHMS_LED DISPLAYS [N371]) NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (1): (NS)..............................................................................................737
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION............................................................................................................................................738
A SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED........................................................................................................................................738
B ABNORMALITY IN DOWNLOADING INTO PC OR SETTING PC........................................................................................................................................742
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED).....................................................................................................................744
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRTUMENT IS NORMAL)..............................................................746
40 MAINTENANCE STANDARD...................................................................................................................................................................................747
ENGINE AND TRANSMISSION MOUNT.........................................................................................................................................................................749
DAMPER................................................................................................................................................................................................750
TORQUE CONVERTER AND PTO..............................................................................................................................................................................752
TORQUE CONVERTER REGULATOR VALVE......................................................................................................................................................................753
TRANSMISSION..........................................................................................................................................................................................754
TRANSMISSION CONTROL VALVE............................................................................................................................................................................758
TRANSFER..............................................................................................................................................................................................764
DRIVE SHAFT...........................................................................................................................................................................................766
CENTER SUPPORT........................................................................................................................................................................................767
DIFFERENTIAL..........................................................................................................................................................................................768
FINAL DRIVE...........................................................................................................................................................................................770
AXLE MOUNT............................................................................................................................................................................................772
CENTER HINGE PIN......................................................................................................................................................................................774
STEERING DEMAND VALVE.................................................................................................................................................................................776
DIVERTER VALVE........................................................................................................................................................................................778
STEERING CYLINDER MOUNT...............................................................................................................................................................................779
EMERGENCY STEERING PUMP...............................................................................................................................................................................780
BRAKE VALVE...........................................................................................................................................................................................781
SLACK ADJUSTER........................................................................................................................................................................................783
BRAKE.................................................................................................................................................................................................784
PARKING BRAKE.........................................................................................................................................................................................786
CONTROL PUMP..........................................................................................................................................................................................787
STEERING AND SWITCH PUMP..............................................................................................................................................................................788
MAIN PISTON PUMP......................................................................................................................................................................................789
MAIN CONTROL VALVE....................................................................................................................................................................................790
PPC VALVE.............................................................................................................................................................................................792
PPC RELIEF VALVE......................................................................................................................................................................................794
HYDRAULIC CYLINDER....................................................................................................................................................................................795
WORK EQUIPMENT LINKAGE................................................................................................................................................................................796
BUCKET................................................................................................................................................................................................798
BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................................799
90 OTHERS.................................................................................................................................................................................................801
ELECTRIC CIRCUIT DIAGRAM (1/7)........................................................................................................................................................................802
ELECTRIC CIRCUIT DIAGRAM (2/7)........................................................................................................................................................................803
ELECTRIC CIRCUIT DIAGRAM (3/7)........................................................................................................................................................................804
ELECTRIC CIRCUIT DIAGRAM (4/7)........................................................................................................................................................................805
ELECTRIC CIRCUIT DIAGRAM (5/7)........................................................................................................................................................................806
ELECTRIC CIRCUIT DIAGRAM (6/7)........................................................................................................................................................................807
ELECTRIC CIRCUIT DIAGRAM (7/7)........................................................................................................................................................................808
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