Komatsu WA700-3 Shop Manual SEBM032804 – PDF DOWNLOAD

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Komatsu WA700-3 Shop Manual SEBM032804 – PDF DOWNLOAD

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Komatsu WA700-3 Shop Manual SEBM032804 – PDF DOWNLOAD

Language : English
Pages :822
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA700-3 Shop Manual SEBM032804 – PDF DOWNLOAD

MACHINE MODEL SERIAL NO.
WA700-3 51005 and up

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu WA700-3 Shop Manual SEBM032804 – PDF DOWNLOAD

MACHINE MODEL SERIAL NO.
WA700-3 51005 and up

COVER 1
CONTENTS 2
SAFETY 9
SAFETY NOTICE 9
FOREWORD 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 21
CONVERSION TABLE 22
UNITS 28
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 34
LIST OF LUBRICANT AND WATER 36
10 STRUCTURE AND FUNCTION 39
OUTLINE 40
POWER TRAIN SYSTEM 42
DAMPER 44
RADIATOR AND OIL COOLER 45
TORQUE CONVERTER AND TRANSMISSION PIPING 46
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 48
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 50
TORQUE CONVERTER AND PTO 52
TORQUE CONVERTER REGULATOR VALVE 55
TRANSMISSION 57
TRANSMISSION CONTROL VALVE 68
TORQUE CONVERTER OIL COOLER 88
TRANSMISSION OIL FILTER 89
TRANSFER 91
AXLE 92
DIFFERENTIAL 94
FINAL DRIVE 97
AXLE MOUNT100
CENTER HINGE PIN102
JOYSTICK STEERING LINKAGE103
STEERING AND SWITCH PUMP104
SWITCH PUMP CUT-OFF SOLENOID106
STEERING DEMAND VALVE107
EPC VALVE118
ROTARY VALVE119
TWO WAY RESTRICTOR VALVE122
DIVERTER VALVE123
BRAKE PIPING127
BRAKE CIRCUIT DIAGRAM128
BRAKE VALVE130
CHARGE VALVE136
ACCUMULATOR (FOR BRAKE)140
SLACK ADJUSTER141
BRAKE144
PARKING BRAKE146
SPRING CYLINDER148
PARKING BRAKE SOLENOID VALVE149
HYDRAULIC PIPING150
HYDRAULIC CIRCUIT DIAGRAM152
MAIN PISTON PUMP155
ES • CO VALVE163
SERVO VALVE164
PRESSURE DIFFERENTIAL VALVE165
PPC VALVE (PROPORTIONAL PRESSURE VALVE)166
PPC RELIEF VALVE170
ACCUMULATOR (FOR PPC VALVE)171
MAIN CONTROL VALVE172
LUBRICATION OF WORK EQUIPMENT186
WORK EQUIPMENT LINKAGE188
BUCKET POSITIONER AND BOOM KICK-OUT190
OPERATION OF PROXIMITY SWITCH192
AIR CONDITIONER196
ELECTRIC CIRCUIT DIAGRAM199
MACHINE MONITOR SYSTEM199
MAIN MONITOR200
MAINTENANCE MONITOR204
AUTOMATIC TRANSMISSION SYSTEM (ATM)206
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)217
TRANSMISSION AND JOYSTICK CONTROLLER222
ENGINE STARTING CIRCUIT224
ENGINE STOP CIRCUIT225
PREHEATING CIRCUIT226
FUEL SYSTEM227
KICK-DOWN, HOLD SWITCH228
ELECTRIC PARKING BRAKE CONTROL229
ELECTRIC CIRCUIT OF ACTIVE POWER MAXIMIZING FUNCITON238
[RELATED TO VHMS CONTROLLER]244
VHMS CONTROLLER244
BLOW-BY PRESSURE SENSOR244
ENGINE OIL TEMPERATURE SENSOR245
EXHAUST TEMPERATURE SENSOR/AMP246
AMBIENT TEMPERATURE SENSOR246
TRANSMISSION PUMP OIL PRESSURE SENSOR247
BRAKE OIL TEMPERATURE SENSOR AND HYDRAULIC OIL TEMPERATURE SENSOR248
BRAKE OIL PRESSURE SENSOR, STEERING OIL PRESSURE SENSOR AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR249
COMMUNICATIONS (ORB: ORBCOMM) CONTROLLER/ANTENNA250
20 TESTING AND ADJUSTING251
STANDARD VALUE TABLE FOR ENGINE252
STANDARD VALUE TABLE FOR CHASSIS253
STANDARD VALUE TABLE FOR ELECTRICAL PARTS258
TESTING AND ADJUSTING267
TABLE OF TOOLS FOR TESING, ADJUSTING, AND TROUBLESHOOTING268
ADJUSTING VALVE CLEARANCE270
MEASURING COMPRESSION PRESSURE271
MEASURING BLOW-BY PRESSURE273
MEASURING EXHAUST GAS COLOR274
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)275
MEASURING EXHAUST TEMPERATURE276
MEASURING ENGINE SPEED278
ADJUSTING SET LOAD OF INJECTOR280
TROUBLESHOOTING OF INJECTOR282
MEASURING FUEL CIRCUIT PRESSURE283
HANDLING EQUIPMENT IN FUEL CIRCUIT285
BLEEDING AIR FROM FUEL CIRCUIT286
ADJUSTING SPEED SENSORS288
TESTING AND ADJUSTING ALTERNATOR BELT TENSION289
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION290
MEASURING ACCELERATOR PEDAL291
ADJUSTING ACCELERATOR PEDAL TRAVEL, POTENTIOMETER292
ADJUSTING ACCELERATOR PEDAL MICRO SWITCH294
TESTING OF UPPER DRIVE SHAFT SLIDING PART295
MEASURING TORQUE CONVERTER, TRANSMISSION HYDRAULIC PRESSURE297
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL299
TESTING AND ADJUSTING STEERING OIL PRESSURE301
ADJUSTING STEERING STOPPER BOLT302
ADJUSTING JOYSTICK STEERING303
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH304
TESTING BRAKE OIL PRESSURE305
MEASURING WEAR OF BRAKE DISC306
MEASURING BRAKE PERFORMANCE307
TESTING AND ADJUSTING PARKING BRAKE308
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE310
MEASURING PPC RELIEF VALVE HYDRAULIC PRESSURE311
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE313
BLEEDING AIR FROM THE PISTON PUMP315
ADJUSTING WORK EQUIPMENT LEVER LINKAGE316
TESTING AND ADJUSTING BUCKET POSITIONER318
TESTING AND ADJUSTING BOOM KICK-OUT319
TESTING AND ADJUSTING PROXIMITY SWITCH FOR ACTIVE POWER MAXIMIZING FUNCTION320
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP321
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)322
BLEEDING AIR323
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT324
PM CLINIC INSPECTION TABLE325
BASIC PRECAUTIONS327
OUTLINE330
SETTING UP VHMS CONTROLLER336
COLLECTION, TRANSMISSION OF DATA338
INSPECTION AND MAINTENANCE343
REPLACING PARTS343
TROUBLESHOOTING345
POINTS TO REMEMBER WHEN TROUBLESHOOTING 346
SEQUENCE OF EVENTS IN TROUBLESHOOTING347
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE348
CHECKS BEFORE TROUBLESHOOTING356
CONNECTOR TYPES AND MOUNTING LOCATIONS357
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS361
T-BRANCH BOX AND T-BRANCH TABLE384
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE386
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION388
TRANSMISSION CONTROLLER LED DISPLAY390
METHOD OF USING TROUBLESHOOTING CHARTS391
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)393
METHOD OF USING TROUBLESHOOTING CHARTS394
S-1 Starting performance is poor (starting always takes time)398
S-2 Engine does not start400
a) Engine does not turn400
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)402
c) Exhaust smoke comes out but engine does not start (fuel is being injected)404
S-3 Engine does not pick up smoothly (follow-up is poor)406
S-4 Engine stops during operations408
S-5 Engine does not rotate smoothly (hunting)410
S-6 Engine lacks output (or lacks power)412
S-7 Exhaust smoke is black (incomplete combustion)414
S-8 Oil consumption is excessive (or exhaust smoke is blue)416
S-9 Oil becomes contaminated quickly417
S-10 Fuel consumption is excessive418
S-11 Oil is in cooling water, or water spurts back, or water level goes down419
S-12 Oil pressure caution lamp lights up (drop in oil pressure)420
S-13 Oil level rises421
S-14 Water temperature becomes too high (overheating)422
S-15 Abnormal noise is made423
S-16 Vibration is excessive424
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)425
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM428
M-1 Main monitor does not work430
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up431
M-3 Speedometer display does not work properly432
M-4 Abnormality in shift indicator433
a) displays N even when directional lever is at F433
b) Displays N even when directional lever is at R433
c) Does not display N even when directional lever is at N, and displays R when directional lever is at F433
d) Does not display N even when directional lever is at N, and displays F when directional lever is at R434
e) Does not display 1st even when speed lever is at 1 (directional lever at F or R)434
f) Does not display 2nd even when speed lever is at 2 (directional lever at F or R)434
g) Does not display 3rd even when speed lever is at 3 (directional lever at F or R)435
h) Does not display 4th even when speed lever is at 4 (directional lever at F or R)435
M-5 Turn signal display does not light up437
a) LH turn signal display does not light up437
b) RH turn signal display does not light up437
M-6 Abnormality in parking display438
a) Parking lamp display does not light up438
b) Parking lamp display stays lighted up438
M-7 Night lighting does not light up439
M-8 Abnormality in front working lamp440
a) Neither monitor display nor front working lamp light up440
b) Working lamp lights up but monitor display does not light up440
c) Monitor display lights up but working lamp does not light up440
M-9 Abnormality in rear working lamp442
a) Neither monitor display nor rear working lamp light up442
b) Working lamp lights up but monitor display does not light up442
c) Monitor display lights up but working lamp does not light up442
M-10 Abnormality in transmission cut-off443
a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not change443
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated443
c) Transmission cut-off switch turned ON, but cut-off function is not actuated444
Auto-shift specification445
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change445
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off funciton is actuated when pedal is depressed445
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated445
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF)445
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated446
M-11 Abnormality in parking brake dragging warning447
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N447
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 N447
M-12 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated449
a) Actuated continuously 449
b) Not actuated449
M-13 Abnormality in buzzer450
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)450
b) Buzzer always sounds450
M-14 Condition of monitor switched is not stored in memory451
M-15 Abnormality in failure display mode452
a) Does not enter failure display mode452
b) Count for time elapsed since failure display mode does not advance452
M-16 Abnormality in emergency steering actuation display453
a) Emergency steering actuation display does not light up453
b) Emergency steering actuation display stays lighted up453
M-17 Abnormality in auto-greasing system454
a) Forced greasing cannot be carried out454
b) Monitor display flashes rapidly (2 times/sec)454
c) When no more grease remains, monitor display flashes rapidly (2 times/sec)454
d) Monitor display flashes slowly (1 time/sec)455
e) Monitor display goes out455
M-18 Abnormality in low idling select system456
a) Display does not change when switch is pressed456
b) Monitor display lights up but low idling select function does not work456
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)457
ELECTRICAL CIRCUIT DIAGRAM FOR K MODE SYSTEM458
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does not work459
a) No lamps on maintenance monitor light up459
b) Some lamps do not light up459
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds)460
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out461
K-4 When starting switch is turned ON (engine stopped), CHECK items flash462
a) Engine oil level display flashes462
b) Engine water level display flashes463
K-5 When starting switch is turned ON (engine started), CAUTION items flash464
a) Engine oil pressure display flashes (Check that the engine oil pressure is correct)464
b) Battery charge level display flashes465
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct)466
d) Air cleaner display flashes (Check that there is no clogging of the air cleaner)467
K-6 CAUTION items are flashing but caution buzzer does not sound468
K-7 There is no abnormality in monitor display but caution buzzer sounds469
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash470
a) CHECK lamp470
b) CAUTION lamp470
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up471
a) CHECK lamp471
b) CAUTION lamp471
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)472
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up473
K-12 Service meter does not work474
K-13 Service meter is running even when engine is stopped474
K-14 Abnormality is gauge items476
a) Abnormality is fuel gauge476
b) Abnormality in engine water temperature gauge477
c) Abnormality in torque converter oil temperature gauge478
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)479
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM480
ELECTRICAL CIRCUIT DIAGRAM FOR ACTIVE POWER UP SYSTEM482
E-1 Engine does not start484
E-2 Defective preheating489
E-3 Parking brake does not have effect491
a) Parking brake has no effect when parking brake switch is turned ON491
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure drops491
E-4 Parking brake is applied when machine is traveling492
E-5 Parking brake is released when starting switch is turned ON494
E-6 Transmission does not change to neutral when parking brake is applied, but parking brake works normally494
E-7 Transmission does not work properly497
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit498
b) No continuity in travel FORWARD solenoid circuit502
c) No continuity in travel REVERSE solenoid circuit504
d) Short circuit to chassis ground in directional solenoid circuit506
e) Abnormality in shift solenoid circuit512
f) Short circuit to chassis ground in shift solenoid circuit515
E-8 Kick-down switch does not work (shift works correctly during normal gear shift operations F1 – F4)520
E-9 Kick-down works only when kick-down switch is being turned ON (kick-down switch does not carry out self-hold operation)523
E-10 Kick-down always works524
E-11 Kick-down switch works even when traveling FORWARD in 2nd526
E-12 Boom Kick-out does not work528
E-13 Defective bucket positioner530
E-14 Power window does not work532
a) Window does not go up532
b) Window does not go down533
E-15 Defective operation of solenoid for power maximizing function536
a) Inspection of timer 1 and no-load relay system536
b) Inspection of neutral relay 1 and neutral relay 2 (Power supply system)538
c) Inspection of solenoid (U11) drive system)540
E-16 Abnormality in front working lamp545
E-17 Abnormality in rear working lamp545
E-18 Abnormality in transmission cut-off545
E-19 Abnormality in parking brake dragging warning545
E-20 Abnormality in buzzer545
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)547
METHOD OF USING MATRIX TROUBLESHOOTING TABLES548
H-1 Machine does not start550
H-2 Machine lacks power or speed when traveling (all speed ranges)551
H-3 Time lag is excessive when starting or shifting gear552
H-4 Torque converter oil temperature is high553
H-5 Steering does not turn554
H-6 Steering does not turn (machine with joystick)555
H-7 Turning, response of steering is poor556
H-8 Turning, response of steering is poor (machine with joystick)558
H-9 Steering is heavy560
H-10 Steering wheel shakes or jerks561
H-11 Steering shakes or there is excessive shock (machine with joystick)562
H-12 Turning radius is different between left and right at maximum steering562
H-13 Wheel brakes do not work or braking effect is poor564
H-14 Wheel brakes are not released or brakes drag566
H-15 Parking brake does not work or braking effect is poor567
H-16 Parking brake is not released or brake drags568
H-17 Neither boom nor bucket move569
H-18 Both boom and bucket are slow or lack power570
H-19 Boom does not move571
H-20 Boom is slow or boom lacks power572
H-21 Boom cannot be set to FLOAT or cannot be released from FLOAT573
H-22 Boom drops momentarily when control lever is operated from HOLD to RAISE573
H-23 Excessive hydraulic drift of boom574
H-24 Bucket does not move575
H-25 Bucket is slow or lacks power576
H-26 Excessive hydraulic drift of bucket577
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)579
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS580
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE582
ELECTRICAL CIRCUIT DIAGRAM FOR T MODE SYSTEM588
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed590
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed591
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed592
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed593
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed594
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed595
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed596
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed597
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed598
T-10 Failure code [21] (Short circuit, disconnection in range switch system) is displayed602
T-11 Failure code [22] (Disconnection in travelspeed sensor system) is displayed605
T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed606
T-13 Hold switch system607
T-14 Kick-down switch system607
T-15 Transmission cut-off signal system608
T-16 Neutralizer relay signal system609
T-17 Buzzer signal system610
T-18 Network system611
T-19 Transmission controller power source system612
T-20 Short circuit in travel speed sensor system613
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM CONTROL SYSTEM) (J MODE)615
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM616
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY618
ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL622
J-1 Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed624
J-2 Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed625
J-3 Error code [58] (Deviation of steering lever angle sensor and frame sensor signals) is displayed626
J-4 Error code [59] (Disconnection or short circuit with chassis ground in frame angle sensor system) is displayed627
J-5 Error code [60] (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed628
J-6 Error code [62] (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed629
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 displayed630
J-8 Steering speeds in both directions are different631
J-9 Abnormality in console switch (adjustment of steering lever angle sensor and frame angle sensor is impossible)632
J-10 Abnormality in power source and voltage633
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (EA MODE)635
METHOD OF ERROR CODE DISPLAY637
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED640
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROL SYSTEM648
EA-1 Error code [111] (Abnormality in controller memory)650
EA-2 Error code [112] (Abnormality in timing rail actuator)650
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)651
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system)652
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)654
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system)655
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system)656
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)657
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system)658
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system)659
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system)660
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system)661
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system)662
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system)663
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)664
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))665
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)666
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system)667
EA-19 Error code [151] (Abnormal rise in water temperature)667
EA-20 Error code [153] (Abnormality [high level] in intake air temperature sensor system)668
EA-21 Error code [154] (Abnormality [low level] in intake air temperature sensor system)668
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure sensor system)669
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure sensor system)670
EA-24 Error code [234] (Overspeed)672
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)673
EA-26 Error code [259] (Abnormality in fuel shut-off valve)674
EA-27 Error code [261] (Abnormal rise in fuel temperature)674
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)675
EA-29 Error code [265] (Abnormality [low level] in fuel temperature sensor system)675
EA-30 Error code [316] (Abnormality in fuel pump actuator system current)676
EA-31 Error code [318] (Abnormality in fuel pump actuator)677
EA-32 Error code [343] (Abnormality in controller internal communication)677
EA-33 Error code [346] (Abnormality in controller power down)678
EA-34 Error code [384] (Abnormality in preheating heater control system)679
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))680
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system)680
EA-37 Error code [431] (Abnormality [1] in idling validation switch system)682
EA-38 Error code [432] (Idling validation process error)684
EA-39 Error code [441] (Abnormality [low level] in battery voltage)686
EA-40 Error code [442] (Abnormality [high level] in battery voltage)686
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system)687
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)688
EA-43 Error code [455] (Abnormality in fuel rail actuator system current)689
EA-44 Error code [467] (Abnormality in timing rail actuator control)690
EA-45 Error code [468] (Abnormality in fuel rail actuator control)690
EA-46 Error code [514] (Abnormality in fuel rail actuator)690
EA-47 Error code [527] (Abnormality in dual output solenoid A system)691
EA-48 Error code [551] (Abnormality [2] in idling validation switch system)691
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor)692
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)695
ELECTRICAL SYSTEM DIAGRAM RELATED TO VHMS CONTROLLER698
INFORMATION GIVEN IN TROUBLESHOOTING CHART700
PHENOMENON TYPE CODE LIST701
[DBB0KK] (OR VHMS_LED INDICATES [N901]) ABNORMALITY IN SOURCE VOLTAGE702
[DBB5KP] (OR VHMS_LED INDICATES [N904]) ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM704
[DBB6KP] (OR VHMS_LED INDICATES [N902]) ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM706
[DBBRKR] (OR VHMS_LED DISPLAYS [N801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)708
[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)710
[DGE1KY] (OR VHMS_LED DISPLAYS [N242]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)711
[DGE5KX] (OR VHMS_LED DISPLAYS [N401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)712
[DGT4KA] (OR VHMS_LED DISPLAYS [N312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO 1, 2 , 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)714
[DGT4KB] (OR VHMS_LED DISPLAYS [N311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO 1, 2, 3 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)716
[DGT5KA] (OR VHMS_LED DISPLAYS [N322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) 718
[DGT5KB] (OR VHMS_LED DISPLAYS [N321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)720
[DHE5KB] (OR VHMS_LED DISPLAYS [N332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)722
[DHE5KY] (OR VHMS_LED DISPLAYS [N331]) SHORT CIRCUIT WIRTH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)724
[DHT3KX] (OR VHMS_LED DISPLAYS [N614]) TROUBLE IN TRANSMISSION OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)726
[DHP2KX] (OR VHMS_LED DISPLAYS [N531]) TROUBLE IN MAIN PUMP OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)728
[DHT8KX] (OR VHMS_LED DISPLAYS [N533]) TROUBLE IN STEERING OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIIGNAL RANGE (KX)730
[DGH2KX] (OR VHMS_LED DISPLAYS [N537]) TROUBLE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)732
[DHU2KX] (OR VHMS_LED DISPLAYS [N711]) TROUBLE IN FRONT BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)734
[DHU3KX] (OR VHMS_LED DISPLAYS [N712]) TROUBLE IN REAR BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)736
[DGR4KX] OR VHMS_LED DISPLAYS [N717]) TROUBLE IN FRONT BRAKE OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)738
[F@BBZL] (OR VHMS_LED DISPLAYS [N338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL) 739
[F@BYNR] (OR VHMS_LED DISPLAYS [N362]) NO 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (2): (NR)740
[F@BYNS] (OR VHMS_LED DISPLAYS [N361]) NO 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (1): (NS)741
[F@BZNR] (OR VHMS_LED DISPLAYS {N372]) NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (2): (NR)742
[F@BZNS] (OR VHMS_LED DISPLAYS [N371]) NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (1): (NS)743
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION744
A SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED744
B ABNORMALITY IN DOWNLOADING INTO PC OR SETTING PC748
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)750
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRTUMENT IS NORMAL)752
40 MAINTENANCE STANDARD753
ENGINE AND TRANSMISSION MOUNT755
DAMPER756
TORQUE CONVERTER AND PTO758
TORQUE CONVERTER REGULATOR VALVE759
TRANSMISSION760
TRANSMISSION CONTROL VALVE764
TRANSFER770
DRIVE SHAFT772
CENTER SUPPORT773
DIFFERENTIAL774
FINAL DRIVE776
AXLE MOUNT778
CENTER HINGE PIN780
STEERING DEMAND VALVE782
DIVERTER VALVE784
STEERING CYLINDER MOUNT785
EMERGENCY STEERING PUMP786
BRAKE VALVE787
SLACK ADJUSTER789
BRAKE790
PARKING BRAKE792
CONTROL PUMP793
STEERING AND SWITCH PUMP794
MAIN PISTON PUMP795
MAIN CONTROL VALVE796
PPC VALVE798
PPC RELIEF VALVE800
HYDRAULIC CYLINDER801
WORK EQUIPMENT LINKAGE802
BUCKET804
BUCKET POSITIONER AND BOOM KICK-OUT805
90 OTHERS807
ELECTRIC CIRCUIT DIAGRAM (1/7)809
ELECTRIC CIRCUIT DIAGRAM (2/7)811
ELECTRIC CIRCUIT DIAGRAM (3/7)813
ELECTRIC CIRCUIT DIAGRAM (4/7)815
ELECTRIC CIRCUIT DIAGRAM (5/7)817
ELECTRIC CIRCUIT DIAGRAM (6/7)819
ELECTRIC CIRCUIT DIAGRAM (7/7)821

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24