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Komatsu WA800-3 Avance Loader Wheel Loader Shop Manual 50001 and up – PDF DOWNLOAD
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Komatsu WA800-3 Avance Loader Wheel Loader Shop Manual
Book Code: SEBM013413
MACHINE MODEL SERIAL NO.
WA800-3 50001 and up
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Description
Komatsu WA800-3 Avance Loader Wheel Loader Shop Manual 50001 and up
FILE DETAILS:
Komatsu WA800-3 Avance Loader Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA800-3 Avance Loader
Serial Number: 50001 and up
Book Code: SEBM013413
Language: English
Pages: 1334
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA800-3 Avance Loader 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 WA800-3 Avance Loader Wheel Loader Shop Manual
COVER........................................................................................................................................................................................ 0
CONTENTS..................................................................................................................................................................................... 2
01 GENERAL................................................................................................................................................................................... 31
GENERAL ASSEMBLY DRAWING................................................................................................................................................................. 32
SPECIFICATIONS........................................................................................................................................................................... 33
WEIGHT TABLE ............................................................................................................................................................................ 36
LIST OF LUBRICANT AND WATER.............................................................................................................................................................. 38
10 STRUCTURE AND FUNCTION.................................................................................................................................................................... 41
POWER TRAIN.............................................................................................................................................................................. 42
POWER TRAIN SYSTEM....................................................................................................................................................................... 43
ENGINE CONTROL........................................................................................................................................................................... 44
SERVO CYLINDER .......................................................................................................................................................................... 45
RADIATOR AND COOLER...................................................................................................................................................................... 49
DAMPER................................................................................................................................................................................... 50
TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................................................................. 51
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.................................................................................................................................................... 52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................... 53
TORQUE CONVERTER ....................................................................................................................................................................... 54
TRANSMISSION ........................................................................................................................................................................... 59
TRANSFER................................................................................................................................................................................. 69
TRANSMISSION CONTROL VALVE............................................................................................................................................................... 70
TORQUE CONVERTER OIL COOLER.............................................................................................................................................................. 88
DRIVE SHAFT.............................................................................................................................................................................. 89
CENTER SUPPORT........................................................................................................................................................................... 90
AXLE..................................................................................................................................................................................... 91
FINAL DRIVE.............................................................................................................................................................................. 96
AXLE MOUNT............................................................................................................................................................................... 98
CENTER HINGE PIN......................................................................................................................................................................... 100
TIRE AND WHEEL .......................................................................................................................................................................... 101
STEERING PIPING DIAGRAM.................................................................................................................................................................. 102
STEERING COLUMN.......................................................................................................................................................................... 105
JOYSTICK LINKAGE......................................................................................................................................................................... 106
STEERING PUMP............................................................................................................................................................................ 108
SWITCH PUMP.............................................................................................................................................................................. 112
STEERING DEMAND VALVE.................................................................................................................................................................... 124
STEERING UNIT (ORBIT-ROLL VALVE)......................................................................................................................................................... 135
PROPORTIONAL SOLENOID VALVE.............................................................................................................................................................. 138
EPC VALVE................................................................................................................................................................................ 139
ROTARY VALVE............................................................................................................................................................................. 140
TOW-WAY RESTRICTOR VALVE................................................................................................................................................................. 144
DIVERTER VALVE........................................................................................................................................................................... 145
BRAKE PIPING............................................................................................................................................................................. 150
BRAKE CIRCUIT DIAGRAM.................................................................................................................................................................... 152
BRAKE VALVE.............................................................................................................................................................................. 156
CHARGE VALVE............................................................................................................................................................................. 167
ACCUMULATOR (FOR BRAKE).................................................................................................................................................................. 171
SLACK ADJUSTER........................................................................................................................................................................... 172
BRAKE.................................................................................................................................................................................... 175
PARKING BRAKE............................................................................................................................................................................ 176
SPRING CYLINDER.......................................................................................................................................................................... 180
PARKING BRAKE SOLENOID VALVE............................................................................................................................................................. 181
HYDRAULIC PIPING ........................................................................................................................................................................ 182
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................. 188
WORK EQUIPMENT LEVER LINKAGE............................................................................................................................................................. 203
HYDRAULIC TANK........................................................................................................................................................................... 206
MAIN PISTON PUMP......................................................................................................................................................................... 209
ES VALVE................................................................................................................................................................................. 221
SERVO VALVE.............................................................................................................................................................................. 223
PPC VALVE................................................................................................................................................................................ 226
PPC RELIEF VALVE......................................................................................................................................................................... 230
ACCUMULATOR (FOR PPC VALVE).............................................................................................................................................................. 231
WORK EQUIPMENT CONTROL LEVER............................................................................................................................................................. 232
WORK EQUIPMENT EPC VALVE................................................................................................................................................................. 235
WORK EQUIPMENT NEUTRAL LOCK SOLENOID VALVE............................................................................................................................................... 238
MAIN CONTROL VALVE....................................................................................................................................................................... 240
LUBRICATION OF WORK EQUIPMENT............................................................................................................................................................ 266
WORK EQUIPMENT LINKAGE................................................................................................................................................................... 268
BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................... 270
OPERATION OF PROXIMITY SWITCH............................................................................................................................................................ 272
CAB...................................................................................................................................................................................... 276
ROPS CANOPY.............................................................................................................................................................................. 277
AIR CONDITIONER.......................................................................................................................................................................... 278
ELECTRIC CIRCUIT DIAGRAM................................................................................................................................................................. 281
MACHINE MONITOR SYSTEM................................................................................................................................................................... 282
MAIN MONITOR............................................................................................................................................................................. 284
MAINTENANCE MONITOR...................................................................................................................................................................... 290
MULTI MONITOR SYSTEM (IF EQUIPPED)....................................................................................................................................................... 296
WORK EQUIPMENT CONTROL SYSTEM............................................................................................................................................................ 318
WORK EQUIPMENT CONTROLLER ............................................................................................................................................................... 324
ENGINE STARTING CIRCUIT.................................................................................................................................................................. 326
ENGINE STOP CIRCUIT...................................................................................................................................................................... 329
PREHEATING CIRCUIT....................................................................................................................................................................... 330
ELECTRICAL TRANSMISSION CONTROL.......................................................................................................................................................... 331
KICK-DOWN, HOLD SWITCH................................................................................................................................................................... 334
JOYSTICK STEERING SYSTEM................................................................................................................................................................. 335
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)................................................................................................................................................. 340
ELECTRIC PARKING BRAKE CONTROL........................................................................................................................................................... 347
ENGINE CONTROL SYSTEM (FOR OPTIONAL ELECTRONIC GOVERNOR SPECIFICATION)................................................................................................................... 356
20 TESTING AND ADJUSTING..................................................................................................................................................................... 363
STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................................................... 364
STANDARD VALUE TABLE FOR CHASSIS......................................................................................................................................................... 365
STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................................................................ 373
TESTING AND ADJUSTING.................................................................................................................................................................... 393
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................................... 394
MEASURING ENGINE SPEED............................................................................................................................................................... 395
MEASURING EXHAUST GAS COLOR.......................................................................................................................................................... 397
ADJUSTING VALVE CLEARANCE............................................................................................................................................................ 398
MEASURING COMPRESSION PRESSURE....................................................................................................................................................... 399
MEASURING BLOW-BY PRESSURE........................................................................................................................................................... 400
TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................................................................... 401
MEASURING ENGINE OIL PRESSURE........................................................................................................................................................ 407
MEASURING EXHAUST TEMPERATURE........................................................................................................................................................ 408
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....................................................................................................................................... 409
TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................................................................ 410
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................................................................... 411
MEASURING ACCELERATOR PEDAL OPERATING EFFORT......................................................................................................................................... 412
MEASURING ACCELERATOR PEDAL OPERATING ANGLE.......................................................................................................................................... 413
ADJUSTING ACCELERATORPEDAL POTENTIOMETER (For optional electronic governor specification)............................................................................................ 414
ADJUSTING ACCELERATORPEDAL MICROSWITCH (For optional electronic governor specification).............................................................................................. 416
ADJUSTING FUEL CONTROL CABLE,LINKAGE,AND SERVO CYLINDER.............................................................................................................................. 418
ADJUSTING ENGINE STOPPING MOTOR CABLE................................................................................................................................................ 420
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE................................................................................................................. 422
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS....................................................................................................... 425
TESTING AND ADJUSTING STEERING OIL PRESSRUE.......................................................................................................................................... 427
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE................................................................................................................................ 428
BLEEDING AIR FROM STEERING CIRCUIT .................................................................................................................................................. 430
TESTING AND ADJUSTING STEERING STOP VALVE............................................................................................................................................ 431
TESTING AND ADJUSTING STEERING STOPPER BOLT.......................................................................................................................................... 432
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR............................................................................................................. 433
TESTING WHEEL BRAKE PERFORMANCE ..................................................................................................................................................... 434
TESTING WHEEL BRAKE OIL PRESSURE DROP................................................................................................................................................ 435
MEASURING WEAR OF WHEEL BRAKE DISC................................................................................................................................................... 437
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE................................................................................................................. 438
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT ............................................................................................................................................... 440
TESTING PARKING BRAKE PERFORMANCE.................................................................................................................................................... 441
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE..................................................................................................................................... 442
CHECKING AND ADJUSTING PARKING BRAKE PAD............................................................................................................................................. 443
TESTING AND ADJUSTING PPC PRESSURE .................................................................................................................................................. 445
ADJUSTING PPC VALVE LINKAGE.......................................................................................................................................................... 447
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................................................. 448
BLEEDING AIR FROM PISTON PUMP ....................................................................................................................................................... 450
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT............................................................................................................................................. 451
ADJUSTING WORK EQUIPMENT LEVER LINKAGE .............................................................................................................................................. 452
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ................................................................................................................................... 454
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH........................................................................................................................................ 455
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH.......................................................................................................................................... 456
TESTING PROXIMITY ACTUATION PILOT LAMP............................................................................................................................................... 457
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR ........................................................................................................................................ 458
ADJUSTING JOYSTICK LEVER POTENTIOMETER............................................................................................................................................... 459
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH.................................................................................................................................... 460
ADJUSTING WORK EQUIPMENT CONTROL LEVER............................................................................................................................................... 461
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER................................................................................................................. 465
ADJUSTING WORK EQUIPMENT BOOM ANGLE.................................................................................................................................................. 471
TROUBLESHOOTING.......................................................................................................................................................................... 473
POINTS TO REMEMBER WHEN TROUBLESHOOTING ............................................................................................................................................. 474
SEQUENCE OF EVENTS IN TROUBLESHOOTING ............................................................................................................................................... 475
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .................................................................................................................................... 476
CHECKS BEFORE TROUBLESHOOTING ....................................................................................................................................................... 484
TYPES AND LOCATIONS OF CONNECTORS ................................................................................................................................................... 487
CONNECTOR ARRANGEMENT DIAGRAM ....................................................................................................................................................... 494
WIRING TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................................... 505
T-ADAPTER BOX AND T-ADAPTER TABLE.................................................................................................................................................... 538
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM............................................................................................................................... 541
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE.................................................................................................................................... 548
CHART OF ACTION CODES AND FAILURE CODES,AND RE-ENACTION ............................................................................................................................. 550
TRANSMISSION CONTROLLER LED DISPLAY.................................................................................................................................................. 557
METHOD OF USING JUDGEMENT TABLE...................................................................................................................................................... 559
METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................... 560
METHOD OF USING MATRIX TROUBLESHOOTING TABLES........................................................................................................................................ 562
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................................................................ 565
METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................................... 566
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................................................................................... 570
S-2 ENGINE DOES NOT START........................................................................................................................................................ 571
(1) ENGINE DOES NOT TURN..................................................................................................................................................... 571
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)................................................................................................... 572
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................................................................................................. 573
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................................................................... 574
S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................................................... 575
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................................................... 576
S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................................................................................... 577
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)................................................................................................................................. 578
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)........................................................................................................................ 579
S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................................................. 580
S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................................................... 581
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN....................................................................................................... 582
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................... 583
S-13 OIL LEVEL RISES ............................................................................................................................................................ 584
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................ 585
S-15 ABNORMAL NOISE IS MADE...................................................................................................................................................... 586
S-16 VIBRATION IS EXCESSIVE...................................................................................................................................................... 587
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE).............................................................................................................................. 589
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS ................................................................................................................... 590
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...................................................................................................... 592
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM....................................................................................................................... 600
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED............................................................ 604
T-2 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED ........................................................... 605
T-3 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED................................................................... 606
T-4 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED................................................................... 607
T-5 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 1st SOLENOID) IS DISPLAYED................................................................. 608
T-6 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 2nd SOLENOID) IS DISPLAYED................................................................. 609
T-7 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 3rd SOLENOID) IS DISPLAYED................................................................. 610
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED........................................................................... 611
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.................................................................................... 612
T-10 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVER SWITCH SYSTEM) IS DISPLAYED............................................................................. 615
T-11 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED......................................................................................... 616
T-12 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED............................................................... 619
T-13 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED....................................................................................................... 620
T-14 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................. 621
T-15 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM................................................................................................................. 622
T-16 SHIFT-DOWN SWITCH SIGNAL SYSTEM AND SHIFT-UP SWITCH SIGNAL SYSTEM........................................................................................................... 623
T-17 TRANSMISSION CUT-OFF SIGNAL SYSTEM.......................................................................................................................................... 624
T-18 NEUTRALIZER SIGNAL SYSTEM................................................................................................................................................... 625
T-19 BUZZER SIGNAL SYSTEM........................................................................................................................................................ 626
T-20 NETWORK SYSTEM.............................................................................................................................................................. 627
T-21 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM................................................................................................................................. 628
T-22 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM................................................................................................................................. 629
T-23 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS............................................................................................................................. 630
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...................................................................................................................................... 631
TROUBLE DATA DISPLAY............................................................................................................................................................. 633
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM............................................................................................................................... 636
M-1 MAIN MONITOR DOES NOT WORK................................................................................................................................................... 638
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP............................................................. 639
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY................................................................................................................................... 640
M-4 ABNORMALITY IN SHIFT INDICATOR .............................................................................................................................................. 641
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F............................................................................................................................ 641
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R............................................................................................................................ 641
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N (DISPLAYS 1st-3rd)................................................................................................. 642
d) DOES NOT DISPLAY 1ST EVEN WHEN GEAR SHIFT LEVER IS AT 1st POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)............................................................... 642
e) DOES NOT DISPLAY 2nd EVEN WHEN GEAR SHIFT LEVER IS AT 2nd POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)............................................................... 642
f) DOES NOT DISPLAY 3rd EVEN WHEN GEAR SHIFT LEVER IS AT 3rd POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)............................................................... 643
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP.......................................................................................................................................... 644
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP........................................................................................................................................ 645
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................................ 645
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................................ 645
M-7 ABNORMALITY IN PARKING DISPLAY............................................................................................................................................... 646
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP.................................................................................................................................... 646
b) PARKING LAMP DISPLAY STAYS LIGHTED UP..................................................................................................................................... 646
M-8 ABNORMALITY IN PREHEATING SYSTEM............................................................................................................................................. 647
a) DOES NOT CARRY OUT PREHEATING............................................................................................................................................. 647
b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS.............................................................................................................................. 648
c) PREHEATING STAYS ON....................................................................................................................................................... 648
d) PREHEATING TIME BECOMES SHORTER,OR THERE IS VARIATION..................................................................................................................... 649
M-9 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................................................................................. 651
M-10 ABNORMALITY IN FRONT WORKING LAMP........................................................................................................................................... 652
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP................................................................................................................... 652
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.............................................................................................................. 652
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP........................................................................................................ 652
M-11 ABNORMALITY IN REAR WORKING LAMP............................................................................................................................................ 654
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.................................................................................................................... 654
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP......................................................................................................... 654
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP......................................................................................................... 654
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF......................................................................................................................................... 656
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH ) IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE................................................ 656
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH )IS OFF,MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED................................ 656
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF),CUT-OFF FUNCTION IS ALWAYS ACTUATED........................................................... 656
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)................................................................. 656
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON),BUT CUT-OFF FUNCTION IS NOT ACTUATED.................................................................... 657
M-13 ABNORMALITY IN LOW IDLING SELECTION......................................................................................................................................... 658
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON,THE LOW IDLING SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE................................................ 658
b) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH ) IS TURNED ON,THE MONITOR LIGHTS UP BUT THE LOW IDLING SPEED ODES NOT RISE............................................. 658
c) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH ) IS TURNED OFF,THE MONITOR GOES OFF BUT THE LOW IDLING SPEED DOES NOT LOWER............................................ 659
M-14 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY............................................................................................................................ 660
EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP.......................................................................................................................... 660
M-15 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY......................................................................................................................... 661
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP.................................................................................................................... 661
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP..................................................................................................................... 661
M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................................................................................... 662
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N................................................. 662
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............................ 662
M-17 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP))............................................................................................ 664
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N................................................. 664
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............................ 664
M-18 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED..................................................... 666
a) ACTUATED CONTINUOUSLY..................................................................................................................................................... 666
b) NOT ACTUATED.............................................................................................................................................................. 666
M-19 ABNORMALITY IN BUZZER....................................................................................................................................................... 667
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)................................................................................... 667
b) BUZZER ALWAYS SOUNDS...................................................................................................................................................... 667
M-20 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY....................................................................................................................... 668
M-21 ABNORMALITY IN FAILURE DISPLAY MODE......................................................................................................................................... 669
a) DOES NOT ENTER FAILURE DISPLAY MODE....................................................................................................................................... 669
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE............................................................................................. 669
M-22 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER.................................................................................................. 670
M-23 ABNORMALITY IN AUTO-GREASING SYSTEM (OP).................................................................................................................................... 671
a) FORCED GREASING CANNOT BE CARRIED OUT..................................................................................................................................... 671
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)............................................................................................................................. 671
c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)................................................................................................. 671
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)............................................................................................................................... 672
e) MONITOR DISPLAY GOES OUT.................................................................................................................................................. 672
M-24 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP)...................................................................................................... 673
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)............................................................................................................................... 675
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM........................................................................................................................ 676
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK................................................... 678
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP.................................................................................................................................. 678
b) SOME LAMPS DO NOT LIGHT UP................................................................................................................................................ 678
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)................................................................. 679
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS),NO LAMPS ON MAINTENANCE MONITOR GO OUT.............................................. 680
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH......................................................................................................... 681
a) ENGINE OIL LEVEL DISPLAY FLASHES.......................................................................................................................................... 681
b) ENGINE WATER LEVEL DISPLAY FLASHES........................................................................................................................................ 682
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH....................................................................................................... 683
a) ENGINE OIL PRESSURE DISPLAY FLASHES....................................................................................................................................... 683
b) BATTERY CHARGE LEVEL DISPLAY FLASHES...................................................................................................................................... 684
c) BRAKE OIL PRESSURE DISPLAY FLASHES........................................................................................................................................ 685
d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES............................................................................................................................... 687
e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES............................................................................................................................... 688
f) TRANSMISSION OIL FILTER DISPLAY FLASHES................................................................................................................................... 689
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND......................................................................................................................... 690
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS......................................................................................................... 691
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES................................................................................................... 692
a) CHECK LAMP................................................................................................................................................................ 692
b) CAUTION LAMP.............................................................................................................................................................. 692
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP.............................................................................. 693
a) CHECK LAMP................................................................................................................................................................ 693
b) CAUTION LAMP.............................................................................................................................................................. 693
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON.............................................................................. 694
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF............................................................................................................ 695
K-12 SERVICE METER DOES NOT WORK................................................................................................................................................. 696
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED........................................................................................................................ 696
K-14 ABNORMALITY IN GAUGE DISPLAY................................................................................................................................................ 697
a) ABNORMALITY FUEL GAUGE.................................................................................................................................................... 697
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE............................................................................................................................. 698
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..................................................................................................................... 699
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................................................................ 701
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTING,ENGINE STOPPING AND PREHEATING....................................................................................... 702
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE..................................................................................................................................... 704
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER............................................................................................................... 705
E-1 ENGINE DOES NOT START........................................................................................................................................................ 706
a) STARTING MOTOR DOES NOT TURN.............................................................................................................................................. 706
b) STARTING MOTOR TURNS (STD SPEC.).......................................................................................................................................... 710
E-2 ENGINE DOES NOT STOP (STD SPEC.)............................................................................................................................................. 712
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (STD SPEC.)........................................................................................................................... 713
E-4 ABNORMALITY IN PREHEATING SYSTEM............................................................................................................................................. 715
a) DOES NOT CARRY OUT PREHEATING ............................................................................................................................................ 715
b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS.............................................................................................................................. 716
c) PREHEATING STAYS ON....................................................................................................................................................... 716
d) PREHEATING TIME BECOMES SHORTER,OR THERE IS FLUCTUATION................................................................................................................... 717
E-5 PARKING BRAKE DOES NOT HAVE EFFECT........................................................................................................................................... 719
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON........................................................................................................ 719
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)........................................................... 719
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING........................................................................................................................... 720
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.................................................................................................................. 722
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)..................................................................... 722
E-9 KICK-DOWN SWITCH DOES NOT WORK .............................................................................................................................................. 724
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY...................................................................................................... 724
b) KICK-DOWN CANNOT BE CANCELED.............................................................................................................................................. 725
E-10 BOOM KICK-OUT DOES NOT WORK................................................................................................................................................. 726
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION .................................................................................................................................. 730
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP............................................................................................................................ 733
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP............................................................................................................................. 733
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF......................................................................................................................................... 733
E-15 ABNORMALITY IN LOW IDLING SELECTION......................................................................................................................................... 733
E-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................................................................................... 733
E-17 ABNORMALITY IN BUZZER....................................................................................................................................................... 733
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).......................................................................................................................... 735
H-1 MACHINE DOES NOT MOVE........................................................................................................................................................ 736
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)............................................................................................................................. 737
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.................................................................................................................... 738
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................................................................... 739
H-5 STEERING DOES NOT TURN (STEERING WHEEL SPECIFICATION)........................................................................................................................ 740
H-6 STEERING DOES NOT TURN (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................................. 741
H-7 STEERING DOES NOT TURN (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).............................................................................................. 742
H-8 TURNING,RESPONSE OF STEERING IS POOR (STEERING WHEEL SPECIFICATION).......................................................................................................... 743
H-9 TURNING,RESPONSE OF STEERING IS POOR (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION).................................................................................... 744
H-10 TURNING,RESPONSE OF STEERING IS POOR (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)............................................................................... 745
H-11 STEERING IS HEAVY (STEERING WHEEL SPECIFICATION)............................................................................................................................ 746
H-12 JOYSTICK LEVER IS HEAVY (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)................................................................................................ 746
H-13 JOYSTICK LEVER IS HEAVY (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)............................................................................................ 747
H-14 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL SPECIFICATION)............................................................................................................... 748
H-15 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)......................................................................................... 749
H-16 STEERING WHEEL SHAKES OR JERKS (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)..................................................................................... 750
H-17 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)..................................... 751
H-18 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION).............................................................. 751
H-19 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.......................................................................................................................... 752
H-20 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG................................................................................................................................ 753
H-21 BOOM DOES NOT RISE.......................................................................................................................................................... 754
H-22 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER................................................................................................................. 755
H-23 WHEN RAISING BOOM,BECOMES SLOW AT CERTAIN HEIGHT ........................................................................................................................... 756
H-24 BOOM CYLINDER CANNOT HOLD DOWN BUCKET....................................................................................................................................... 756
H-25 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT.................................................................................................................................... 756
H-26 BOOM FLUCTUATES WHILE WORKING............................................................................................................................................... 757
H-27 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE............................................................................................................ 757
H-28 BUCKET DOES NOT TILT BACK................................................................................................................................................... 758
H-29 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER..................................................................................................................... 759
H-30 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK............................................................................................................................... 760
H-31 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET..................................................................................................................................... 760
H-32 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT.................................................................................................................................. 760
H-33 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE "HOLD").................................................................................................. 761
H-34 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT........................................................................................................... 761
H-35 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY................................................................................................................................. 762
TROUBLESHOOTING OF JOYSTICK STEERING CONTROL SYSTEM (J MODE)......................................................................................................................... 763
JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL SYSTEM RELATED PARTS............................................................................................................... 764
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................... 766
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING CONTROL SYSTEM.................................................................................................................. 770
J-1 FAILURE CODE [56] (SHORT CIRCUIT,DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED......................................................................................... 772
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED................................................................... 773
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED.................................................................... 774
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................................................................ 775
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................................................................. 776
J-6 FAILURE CODE [61] (SHORT CIRCUIT,DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED........................................................................... 777
J-7 FAILURE CODE [62] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED............................................................................ 778
J-8 FAILURE CODE [63] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED........................................................................ 779
J-9 ABNORMALITY IN POWER SUPPLY,POWER SUPPLY VOLTAGE............................................................................................................................. 780
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT............................................................................................................................. 781
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID.................................................................................................................................... 782
J-12 DISCONNECTION IN STEERING LEFT SOLENOID..................................................................................................................................... 783
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE).................................................................................................. 785
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM...................................................................................................... 786
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY..................................................................................... 788
ELECTRIC CIRCUIT DIAGRAM FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL.................................................................................................... 792
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED........................................................... 794
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED.................................................... 795
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED..................................................................... 796
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED............................................................. 797
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED............................................ 798
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED............................................... 799
A-7 FAILURE CODE [63] (DISCONNECTION,SHORT CIRCUIT WITH CHASSIS GROUND,OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED.... 800
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT............................................................................................................................. 801
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)............................................................... 802
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE..................................................................................................................................... 803
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE).......................................................................................................................... 805
CONTENTS OF ABNORMALITY IN WORK EQUIPMENT CONTROL SYSTEM AND ACTIONS OF CONTROLLER AGAINST THEM.................................................................................. 808
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROL SYSTEM..................................................................................................................... 814
[WRK-1] LOWERING OF WORK EQUIPMENT CONTROLLER SOURCE VOLTAGE..................................................................................................................... 817
[WRK-2] ABNORMALITY IN SENSOR POWER SOURCE SYSTEM................................................................................................................................ 818
[WRK-3] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM.............................................................................................................................. 820
[WRK-4] GROUNDING FAULT IN REMOTE POSITIONER RAISE POSITION SET SWITCH SYSTEM.................................................................................................... 821
[WRK-5] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE POSITION SET SWITCH........................................................................ 822
[WRK-6] GROUNDING FAULT IN REMOTE POSITIONER LOWER POSITION SET SWITCH SYSTEM.................................................................................................... 823
[WRK-7] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER POSITION SET SWITCH SYSTEM................................................................. 824
[WRK-8] GROUNDING FAULT IN REMOTE POSITIONER RAISE/LOWER SELECTOR SWITCH SYSTEM.................................................................................................. 825
[WRK-9] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE/LOWER SELECTOR SWITCH SYSTEM............................................................... 826
[WRK-10] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM ANGLE POTENTIOMETER SIGNAL SYSTEM............................................................ 827
[WRK-11] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN MAIN CIRCUIT)................................................................... 828
[WRK-12] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM [SHORT CIRCUIT IN MAIN CIRCUIT (WITH SOURCE POWER)].................................................................. 829
[WRK-13] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN SUB CIRCUIT).................................................................... 830
[WRK-14] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM [SHORT CIRCUIT IN SUB CIRCUIT (WITH SOURCE POWER)]................................................................... 831
[WRK-15] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (SHIFTING OF MAIN CIRCUIT AND SUB CIRCUIT FORM EACH OTHER)........................................................... 832
[WRK-16] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN MAIN CIRCUIT)................................................................. 833
[WRK-17] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM {SHORT CIRCUIT IN MAIN CIRCUIT (WITH SOURCE POWER)]................................................................ 834
[WRK-18] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN SUB CIRCUIT).................................................................. 835
[WRK-19] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT CIRCUIT IN SUB CIRCUIT)..................................................................................... 836
[WRK-20] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHIFTING OF MAIN CIRCUIT AND SUB CIRCUIT FORM EACH OTHER)......................................................... 837
[WRK-21] DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM............................................................................................................................. 838
[WRK-22] GROUNDING FAULT IN ENGINE SPEED SENSOR SYSTEM........................................................................................................................... 839
[WRK-23] GROUNDING FAULT IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM.................................................................................................. 840
[WRK-24] DISCONNECTION IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM.................................................................................................... 841
[WRK-25] SHORT CIRCUIT (WITH POWER SOURCE)IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM................................................................................. 842
[WRK-26] GROUNDING FAULT IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM.................................................................................................. 843
[WRK-27] DISCONNECTION IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM.................................................................................................... 844
[WRK-28] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM................................................................................ 845
[WRK-29] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM........................................................................................ 846
[WRK-30] DISCONNECTION IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM............................................................................................................ 848
[WRK-31] GROUNDING FAULT IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM.......................................................................................................... 850
[WRK-32] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM........................................................................................ 852
[WRK-33] DISCONNECTION IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM............................................................................................................ 854
[WRK-34] GROUNDING FAULT IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM.......................................................................................................... 856
[WRK-35] DISCONNECTION IN BOOM RAISE MAGNET DETENT SYSTEM........................................................................................................................ 858
[WRK-36] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE MAGNET DETENT SYSTEM.................................................................................................... 859
[WRK-37] GROUNDING FAULT IN BOOM RAISE MAGNET DETENT SYSTEM...................................................................................................................... 860
[WRK-38] DISCONNECTION IN BOOM FLOAT MAGNET DETENT SYSTEM........................................................................................................................ 861
[WRK-39] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM FLOAT MAGNET DETENT SYSTEM.................................................................................................... 862
[WRK-40] GROUNDING FAULT IN BOOM FLOAT MAGNET DETENT SYSTEM...................................................................................................................... 863
[WRK-41] DISCONNECTION IN BUCKET TILT MAGNET DETENT SYSTEM....................................................................................................................... 864
[WRK-42] SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT MAGNET DETENT SYSTEM................................................................................................... 865
[WRK-43] GROUNDING FAULT IN BUCKET TILT MAGNET DETENT SYSTEM..................................................................................................................... 866
[WRK-44] DISCONNECTION OR GROUNDING FAULT IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID A SYSTEM....................................................................................... 867
[WRK-45] SHORT CIRCUIT (WITH POWER SOURCE) IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID A SYSTEM...................................................................................... 868
[WRK-46] DISCONNECTION OR GROUNDING FAULT IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID B SYSTEM....................................................................................... 869
[WRK-47] SHORT CIRCUIT (WITH POWER SOURCE) IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID B SYSTEM...................................................................................... 870
[WRK-48] DISCONNECTION IN ALARM BUZZER SYSTEM.................................................................................................................................... 871
[WRK-49] GROUNDING FAULT IN ALARM BUZZER SYSTEM.................................................................................................................................. 872
[WRK-50] SHORT CIRCUIT (WITH POWER SOURCE) IN ALARM BUZZER SYSTEM................................................................................................................ 873
[WRK-51] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE EPC SOLENOID A SYSTEM.................................................................................. 874
[WRK-52] GROUNDING FAULT IN BOOM RAISE EPC SOLENOID A SYSTEM..................................................................................................................... 875
[WRK-53] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE EPC SOLENOID B SYSTEM.................................................................................. 876
[WRK-54] GROUNDING FAULT IN BOOM RAISE EPC SOLENOID B SYSTEM..................................................................................................................... 877
[WRK-55] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOWER EPC SOLENOID A SYSTEM.................................................................................. 878
[WRK-56] GROUNDING FAULT IN BOOM LOWER EPC SOLENOID A SYSTEM..................................................................................................................... 879
[WRK-57] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOWER EPC SOLENOID B SYSTEM.................................................................................. 880
[WRK-58] GROUNDING FAULT IN BOOM LOWER EPC SOLENOID B SYSTEM..................................................................................................................... 881
[WRK-59] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT EPC SOLENOID A SYSTEM................................................................................. 882
[WRK-60] GROUNDING FAULT IN BUCKET TILT EPC SOLENOID A SYSTME.................................................................................................................... 883
[WRK-61] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT EPC SOLENOID B SYSTEM................................................................................. 884
[WRK-62] GROUNDING FAULT IN BUCKET TILT EPC SOLENOID B SYSTEM.................................................................................................................... 885
[WRK-63] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET DUMP EPC SOLENOID A SYSTEM................................................................................. 886
[WRK-64] GROUNDING FAULT IN BUCKET DUMP EPC SOLENOID A SYSTEM.................................................................................................................... 887
[WRK-65] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET DUMP EPC SOLENOID B SYSTEM................................................................................. 888
[WRK-66] GROUNDING FAULT IN BUCKET DUMP EPC SOLENOID B SYSTEM.................................................................................................................... 889
[WRK-67] ABNORMALITY IN WORK EQUIPMENT LEVER NEUTRAL CAUTION SYSTEM.............................................................................................................. 890
[WRK-68] DISCONNECTION OR GROUNDING FAULT IN BOOM LOCK SWITCH SYSTEM............................................................................................................. 891
[WRK-69] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOCK SWITCH SYSTEM............................................................................................................ 892
[WRK-70] ABNORMALITY IN BUCKET CYLINDER PROXIMITY SWITCH SYSTEM.................................................................................................................. 893
[WRK-71] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN EPC LEVER ADJUSTMENT MODE INPUT SYSTEM............................................................ 894
[WRK-72] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM ANGLE ADJUSTMENT MODE INPUT SYSTEM........................................................... 895
TROUBLESHOOTING OF ELECTRONIC GOVERNOR SYSTEM (G MODE)............................................................................................................................... 897
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS................................................................................................................... 898
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...................................................................................................... 900
ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS.................................................................................................. 908
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM................................................................................................. 909
JUDGEMENT TABLE FOR ENGINE CONTROLLER............................................................................................................................................ 911
G-1 [90] [10] Abnormality in power source system................................................................................................................................. 912
G-2 [90] [11] Abnormality in controller system................................................................................................................................... 912
G-3 [90] [21] Mistaken connection of connector................................................................................................................................... 913
G-4 [90] [56] Abnormality in right bank solenoid power source system............................................................................................................. 913
G-5 [90] [57] Abnormality in left bank solenoid power source system.............................................................................................................. 913
G-6 [90] [58] Abnormality in back-up power source system......................................................................................................................... 914
G-7 [90] [59] Abnormality in switch power source system.......................................................................................................................... 915
G-8 [91] [14] Abnormality in right bank governor solenoid system................................................................................................................. 916
G-9 [91] [15] Abnormality in left bank governor solenoid system.................................................................................................................. 917
G-10 [91] [16] Abnormality in right bank governor cut relay system............................................................................................................... 918
G-11 [91] [17] Abnormality in left bank governor cut relay system................................................................................................................ 919
G-12 [91] [19] Abnormality in right bank governor servo system................................................................................................................... 920
G-13 [91] [1A] Abnormality in left bank governor servo system.................................................................................................................... 921
G-14 [91] [1d] Abnormality in right bank pre-stroke solenoid system.............................................................................................................. 922
G-15 [91] [1E] Abnormality in left bank pre-stroke solenoid system............................................................................................................... 923
G-16 [92] [12] Abnormality in right bank rack sensor system...................................................................................................................... 924
G-17 [92] [13] Abnormality in left bank rack sensor system....................................................................................................................... 925
G-18 [92] [18] Abnormality in rack sensor power source system.................................................................................................................... 926
G-19 [93] [1b] Abnormality in engine speed sensor A system....................................................................................................................... 927
G-20 [94] [1c] Abnormality in engine speed sensor B system....................................................................................................................... 928
G-21 [93, 94] [1b, 1c] Abnormality in engine speed sensor A, B system............................................................................................................ 929
G-22 [95] [40] Abnormality in engine water temperature sensor system............................................................................................................. 929
G-23 [97] [31] Abnormality in accelerator sensor system.......................................................................................................................... 930
G-24 [98] [18] Abnormality in model selection.................................................................................................................................... 932
G-25 [99] [22] Engine overrun.................................................................................................................................................... 933
G-26 Engine does not start....................................................................................................................................................... 933
G-27 Engine does not stop........................................................................................................................................................ 937
30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................. 939
HOW TO READ THIS MANUAL.................................................................................................................................................................. 941
STANDARD TIGHTENING TORQUE TABLE......................................................................................................................................................... 943
PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................................. 947
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER............................................................................................................................ 950
COATING MATERIALS LIST................................................................................................................................................................... 953
SPECIAL TOOL LIST........................................................................................................................................................................ 956
SKETCHES OF SPECIAL TOOLS................................................................................................................................................................ 965
STARTING MOTOR........................................................................................................................................................................... 973
REMOVAL AND INSTALLATION............................................................................................................................................................. 973
ALTERNATOR............................................................................................................................................................................... 974
REMOVAL AND INSTALLATION............................................................................................................................................................. 974
ENGINE OIL COOLER........................................................................................................................................................................ 975
REMOVAL AND INSTALLATION............................................................................................................................................................. 975
FUEL INJECTION PUMP FOR LEFT BANK (WITH GOVERNOR)........................................................................................................................................ 976
REMOVAL AND INSTALLATION............................................................................................................................................................. 976
FUEL INJECTION PUMP FOR RIGHT BANK (WITH GOVERNOR)....................................................................................................................................... 977
REMOVAL AND INSTALLATION............................................................................................................................................................. 977
WATER PUMP............................................................................................................................................................................... 978
REMOVAL AND INSTALLATION............................................................................................................................................................. 978
NOZZLE HOLEDR............................................................................................................................................................................ 979
REMOVAL AND INSTALLATION............................................................................................................................................................. 979
TURBOCHARGER............................................................................................................................................................................. 980
REMOVAL AND INSTALLATION............................................................................................................................................................. 980
ENGINE FRONT SEAL ....................................................................................................................................................................... 981
REMOVAL AND INSTALLATION............................................................................................................................................................. 981
ENGINE REAR SEAL......................................................................................................................................................................... 983
REMOVAL AND INSTALLATION............................................................................................................................................................. 983
CYLINDER HEAD............................................................................................................................................................................ 985
REMOVAL.............................................................................................................................................................................. 985
INSTALLATION......................................................................................................................................................................... 989
RADIATOR................................................................................................................................................................................. 992
REMOVAL.............................................................................................................................................................................. 992
INSTALLATION......................................................................................................................................................................... 995
ENGINE................................................................................................................................................................................... 996
REMOVAL.............................................................................................................................................................................. 996
INSTALLATION.........................................................................................................................................................................1002
DAMPER...................................................................................................................................................................................1003
REMOVAL AND INSTALLATION.............................................................................................................................................................1003
DISASSEMBLY..........................................................................................................................................................................1004
ASSEMBLY.............................................................................................................................................................................1006
TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...............................................................................................................................................1010
REMOVAL..............................................................................................................................................................................1010
INSTALLATION.........................................................................................................................................................................1017
TORQUE CONVERTER.........................................................................................................................................................................1019
DISASSEMBLY..........................................................................................................................................................................1019
ASSEMBLY.............................................................................................................................................................................1023
TORQUE CONVERTER VALVE...................................................................................................................................................................1028
DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1028
TRANSMISSION.............................................................................................................................................................................1029
DISASSEMBLY..........................................................................................................................................................................1029
ASSEMBLY.............................................................................................................................................................................1046
TRANSMISSION VALVE.......................................................................................................................................................................1064
REMOVAL AND INSTALLATION.............................................................................................................................................................1064
DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1065
TRANSFER.................................................................................................................................................................................1069
DISASSEMBLY..........................................................................................................................................................................1069
ASSEMBLY.............................................................................................................................................................................1077
PTO......................................................................................................................................................................................1087
DISASSEMBLY..........................................................................................................................................................................1087
ASSEMBLY.............................................................................................................................................................................1089
CENTER SUPPORT...........................................................................................................................................................................1092
REMOVAL..............................................................................................................................................................................1092
INSTALLATION.........................................................................................................................................................................1093
DISASSEMBLY..........................................................................................................................................................................1094
ASSEMBLY.............................................................................................................................................................................1096
DRIVE SHAFT..............................................................................................................................................................................1099
DISASSEMBLY..........................................................................................................................................................................1099
ASSEMBLY.............................................................................................................................................................................1101
FRONT AXLE...............................................................................................................................................................................1103
REMOVAL..............................................................................................................................................................................1103
INSTALLATION.........................................................................................................................................................................1105
REAR AXLE................................................................................................................................................................................1106
REMOVAL..............................................................................................................................................................................1106
INSTALLATION.........................................................................................................................................................................1112
DIFFERENTIAL.............................................................................................................................................................................1113
REMOVAL..............................................................................................................................................................................1113
INSTALLATION.........................................................................................................................................................................1115
DISASSEMBLY..........................................................................................................................................................................1116
ASSEMBLY.............................................................................................................................................................................1120
FINAL DRIVE..............................................................................................................................................................................1126
DISASSEMBLY..........................................................................................................................................................................1126
ASSEMBLY.............................................................................................................................................................................1129
ORBIT-ROLL...............................................................................................................................................................................1132
REMOVAL..............................................................................................................................................................................1132
INSTALLATION.........................................................................................................................................................................1133
EMERGENCY STEERING PUMP..................................................................................................................................................................1134
REMOVAL AND INSTALLATION.............................................................................................................................................................1134
DIVERTER VALVE...........................................................................................................................................................................1135
REMOVAL AND INSTALLATION.............................................................................................................................................................1135
DISASSEMBLY..........................................................................................................................................................................1136
ASSEMBLY.............................................................................................................................................................................1137
ACCUMULATOR CHARGE VALVE.................................................................................................................................................................1139
REMOVAL AND INSTALLATION.............................................................................................................................................................1139
DISASSEMBLY..........................................................................................................................................................................1140
ASSEMBLY.............................................................................................................................................................................1141
STEERING STOP VALVE......................................................................................................................................................................1143
REMOVAL AND INSTALLATION.............................................................................................................................................................1143
STEERING CYLINDER........................................................................................................................................................................1144
REMOVAL..............................................................................................................................................................................1144
INSTALLATION.........................................................................................................................................................................1145
STEERING VALVE...........................................................................................................................................................................1150
REMOVAL..............................................................................................................................................................................1150
INSTALLATION.........................................................................................................................................................................1151
BRAKE VALVE..............................................................................................................................................................................1152
REMOVAL AND INSTALLATION.............................................................................................................................................................1152
SLACK ADJUSTER...........................................................................................................................................................................1153
REMOVAL AND INSTALLATION.............................................................................................................................................................1153
DISASSEMBLY..........................................................................................................................................................................1154
ASSEMBLY.............................................................................................................................................................................1155
BRAKE....................................................................................................................................................................................1156
REMOVAL AND INSTALLATION.............................................................................................................................................................1156
DISASSEMBLY..........................................................................................................................................................................1157
ASSEMBLY.............................................................................................................................................................................1160
PARKING BRAKE CALIPERS...................................................................................................................................................................1164
REMOVAL AND INSTALLATION.............................................................................................................................................................1164
DISASSEMBLY..........................................................................................................................................................................1165
ASSEMBLY.............................................................................................................................................................................1167
PARKING BRAKE PAD........................................................................................................................................................................1169
REMOVAL AND INSTALLATION.............................................................................................................................................................1169
PARKING BRAKE SPRING CYLINDER............................................................................................................................................................1170
REMOVAL AND INSTALLATION.............................................................................................................................................................1170
BRAKE OIL TANK...........................................................................................................................................................................1171
REMOVAL AND INSTALLATION.............................................................................................................................................................1171
HYDRAULIC PUMP ..........................................................................................................................................................................1172
REMOVAL..............................................................................................................................................................................1172
INSTALLATION.........................................................................................................................................................................1173
PISTON PUMP..............................................................................................................................................................................1174
DISASSEMBLY..........................................................................................................................................................................1174
ASSEMBLY.............................................................................................................................................................................1180
SERVO CYLINDER...........................................................................................................................................................................1196
REMOVAL AND INSTALLATION.............................................................................................................................................................1196
HYDRAULIC TANK AND FILTER CASE ASSEMBLY .................................................................................................................................................1197
REMOVAL..............................................................................................................................................................................1197
INSTALLATION.........................................................................................................................................................................1198
PPC VALVE................................................................................................................................................................................1199
REMOVAL..............................................................................................................................................................................1199
INSTALLATION.........................................................................................................................................................................1200
DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1201
WORK EQUIPMENT CONTROL VALVE.............................................................................................................................................................1202
REMOVAL..............................................................................................................................................................................1202
INSTALLATION.........................................................................................................................................................................1203
DISASSEMBLY..........................................................................................................................................................................1204
ASSEMBLY.............................................................................................................................................................................1206
CAB......................................................................................................................................................................................1208
REMOVAL..............................................................................................................................................................................1208
INSTALLATION.........................................................................................................................................................................1210
FLOOR FRAME..............................................................................................................................................................................1211
REMOVAL..............................................................................................................................................................................1211
INSTALLATION.........................................................................................................................................................................1213
CENTER HINGE PIN ........................................................................................................................................................................1214
REMOVAL..............................................................................................................................................................................1214
INSTALLATION.........................................................................................................................................................................1220
WORK EQUIPMENT .........................................................................................................................................................................1226
REMOVAL..............................................................................................................................................................................1226
INSTALLATION.........................................................................................................................................................................1231
BOOM FRONT END BUSH......................................................................................................................................................................1232
REPLACEMENT..........................................................................................................................................................................1232
BUCKET CYLIMDER..........................................................................................................................................................................1233
REMOVAL AND INSTALLATION.............................................................................................................................................................1233
LIFT CYLINDER............................................................................................................................................................................1234
REMOVAL..............................................................................................................................................................................1234
INSTALLATION.........................................................................................................................................................................1235
HYDRAULIC CYLINDER.......................................................................................................................................................................1236
DISASSEMBLY..........................................................................................................................................................................1236
ASSEMBLY.............................................................................................................................................................................1238
AIR CONDITIONER UNIT.....................................................................................................................................................................1240
REMOVAL..............................................................................................................................................................................1240
INSTALLATION.........................................................................................................................................................................1241
AIR CONDITIONER COMPRESSOR...............................................................................................................................................................1242
REMOVAL AND INSTALLATION.............................................................................................................................................................1242
RECEIVER TANK............................................................................................................................................................................1243
REMOVAL AND INSTALLATION.............................................................................................................................................................1243
AIR CONDITIONER CONDENSER................................................................................................................................................................1244
REMOVAL AND INSTALLATION.............................................................................................................................................................1244
TRANSMISSION AND STEERING CONTROLLER.....................................................................................................................................................1245
REMOVAL AND INSTALLATION.............................................................................................................................................................1245
MAIN MONITOR.............................................................................................................................................................................1246
REMOVAL..............................................................................................................................................................................1246
INSTALLATION.........................................................................................................................................................................1247
FUEL TANK................................................................................................................................................................................1248
REMOVAL..............................................................................................................................................................................1248
INSTALLATION.........................................................................................................................................................................1249
COUNTERWEIGHT............................................................................................................................................................................1250
REMOVAL AND INSTALLATION.............................................................................................................................................................1250
40 MAINTENANCE STANDARD......................................................................................................................................................................1251
ENGINE MOUNT.............................................................................................................................................................................1252
TRANSMISSION MOUNT.......................................................................................................................................................................1253
DAMPER...................................................................................................................................................................................1254
TORQUE CONVERTER CHARGING,PPC AND BRAKE PUMP.............................................................................................................................................1256
TORQUE CONVERTER .......................................................................................................................................................................1258
TORQUE CONVERTER REGULATOR VALVE.........................................................................................................................................................1259
TRANSMISSION.............................................................................................................................................................................1260
TRANSFER.................................................................................................................................................................................1263
TRANSMISSION CONTROL VALVE...............................................................................................................................................................1266
DRIVE SHAFT..............................................................................................................................................................................1271
CENTER SUPPORT...........................................................................................................................................................................1272
DIFFERENTIAL.............................................................................................................................................................................1273
FINAL DRIVE..............................................................................................................................................................................1276
AXLE MOUNT...............................................................................................................................................................................1278
CENTER HINGE PIN.........................................................................................................................................................................1280
STEERING COLUMN..........................................................................................................................................................................1282
STEERING DEMAND VALVE....................................................................................................................................................................1284
DIVERTER VALVE...........................................................................................................................................................................1286
STEERING CYLINDER MOUNT..................................................................................................................................................................1287
EMERGENCY STEERING PUMP..................................................................................................................................................................1288
BRAKE VALVE..............................................................................................................................................................................1290
SLACK ADJUSTER...........................................................................................................................................................................1294
BRAKE....................................................................................................................................................................................1296
PARKING BRAKE............................................................................................................................................................................1298
PPC VALVE................................................................................................................................................................................1300
PPC RELIEF VALVE.........................................................................................................................................................................1302
CONTROL PUMP.............................................................................................................................................................................1303
STEERING PUMP............................................................................................................................................................................1304
SWITCH PUMP..............................................................................................................................................................................1305
MAIN PISTON PUMP.........................................................................................................................................................................1306
MAIN CONTROL VALVE.......................................................................................................................................................................1308
HYDRAULIC CYLINDER.......................................................................................................................................................................1312
BUCKET LINKAGE...........................................................................................................................................................................1314
BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................................................................1316
90 OTHERS....................................................................................................................................................................................1317
ELECTRIC CIRCUIT DIAGRAM (1/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (2/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (3/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (4/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (5/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (6/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (7/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (8/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (9/16).......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (10/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (11/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (12/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (13/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (14/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (15/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (16/16)......................................................................................................................................................... 0
ELECTRIC CIRCUIT DIAGRAM (REMOTE BOOM POSITIONER)........................................................................................................................................ 0
KOMATSU WA800-3 AVANCE LOADER WHEEL LOADER SHOP MANUAL 50001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
2 reviews for Komatsu WA800-3 Avance Loader Wheel Loader Shop Manual 50001 and up – PDF DOWNLOAD
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Mordechai Kenneth –
Kylen Wade –
The information gave me the direction I needed to move forward with my repair Thx