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Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual – PDF Download
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Description
Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual
FILE DETAILS:
Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual
LANGUAGE:ENGLISH
PAGES:1800+
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU WA800-3E0, WA900-3E0 WHEEL LOADER SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual
- 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine.
- 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
- 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
- 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
- 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
- 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
- 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual
COVER ......................................................................................................................................................................... 1 00 Index and foreword.......................................................................................................................................................... 0 Index...................................................................................................................................................................... 3 Composition of shop manual............................................................................................................................................. 4 Table of contents...................................................................................................................................................... 6 Foreword and general information........................................................................................................................................... 21 Safety notice.......................................................................................................................................................... 22 How to read the shop manual............................................................................................................................................ 27 Explanation of terms for maintenance standard.......................................................................................................................... 29 Handling of electric equipment and hydraulic component................................................................................................................. 31 Handling of connectors newly used for engines.......................................................................................................................... 40 How to read electric wire code......................................................................................................................................... 43 Precautions when carrying out operation................................................................................................................................ 46 Method of disassembling and connecting push-pull type coupler.......................................................................................................... 49 Standard tightening torque table....................................................................................................................................... 52 Conversion table....................................................................................................................................................... 56 01 Specification............................................................................................................................................................... 0 Specification and technical data........................................................................................................................................... 63 General assembly drawing............................................................................................................................................... 64 Specifications......................................................................................................................................................... 66 Weight table........................................................................................................................................................... 69 Table of fuel, coolant and lubricants.................................................................................................................................. 72 10 Structure, function and maintenance standard................................................................................................................................ 0 Engine and cooling system.................................................................................................................................................. 75 Engine mount........................................................................................................................................................... 76 Transmission mount..................................................................................................................................................... 77 Damper................................................................................................................................................................. 78 Radiator, oil cooler, aftercooler...................................................................................................................................... 80 Fuel system............................................................................................................................................................ 83 Power train, Part 1........................................................................................................................................................ 85 Power train............................................................................................................................................................ 86 Power train system..................................................................................................................................................... 87 Torque converter....................................................................................................................................................... 89 Torque converter regulator valve....................................................................................................................................... 95 Transmission........................................................................................................................................................... 97 Transfer............................................................................................................................................................... 108 Transmission control valve............................................................................................................................................. 111 Power train, Part 2........................................................................................................................................................ 129 Torque converter oil cooler............................................................................................................................................ 130 Drive shaft............................................................................................................................................................ 132 Center support......................................................................................................................................................... 134 Axle................................................................................................................................................................... 136 Differential........................................................................................................................................................... 138 Final drive............................................................................................................................................................ 144 Steering system............................................................................................................................................................ 149 Steering piping........................................................................................................................................................ 150 AJSS lever linkage..................................................................................................................................................... 152 EPC valve.............................................................................................................................................................. 153 Steering column........................................................................................................................................................ 154 Rotary valve........................................................................................................................................................... 155 Steering control valve................................................................................................................................................. 158 Steering unit (orbit-roll valve)....................................................................................................................................... 170 Steering pump.......................................................................................................................................................... 173 Steering cylinder...................................................................................................................................................... 175 Slow return valve...................................................................................................................................................... 177 Emergency steering piping.............................................................................................................................................. 178 Diverter valve......................................................................................................................................................... 179 Emergency steering pump................................................................................................................................................ 185 Brake system............................................................................................................................................................... 187 Brake piping........................................................................................................................................................... 188 Brake.................................................................................................................................................................. 189 Brake valve............................................................................................................................................................ 192 Accumulator charge valve............................................................................................................................................... 200 PPC relief valve....................................................................................................................................................... 204 Accumulator (for brake)................................................................................................................................................ 206 Slack adjuster......................................................................................................................................................... 207 Parking brake.......................................................................................................................................................... 209 Parking brake caliper.................................................................................................................................................. 211 Spring cylinder........................................................................................................................................................ 212 Parking brake solenoid................................................................................................................................................. 213 Brake cooling system (if equipped)..................................................................................................................................... 214 Brake cooling system (55°C specification) (If equipped)................................................................................................................ 224 Undercarriage and frame.................................................................................................................................................... 233 Axle mount............................................................................................................................................................. 234 Center hinge pin....................................................................................................................................................... 237 Tire and wheel......................................................................................................................................................... 239 Jack up point.......................................................................................................................................................... 240 Hydraulic system, Part 1................................................................................................................................................... 242 Hydraulic piping....................................................................................................................................................... 243 Work equipment lever linkage........................................................................................................................................... 244 Hydraulic tank......................................................................................................................................................... 245 Torque conbverter charging, PPC and brake pump......................................................................................................................... 248 Hydraulic system, Part 2................................................................................................................................................... 251 Main control valve..................................................................................................................................................... 252 Accumulator (For PPC valve)............................................................................................................................................ 267 Main piston pump....................................................................................................................................................... 268 Main piston pump cut-off solenoid valve................................................................................................................................ 279 PPC valve.............................................................................................................................................................. 280 PPC relief valve....................................................................................................................................................... 285 Switch pump............................................................................................................................................................ 286 Control pump........................................................................................................................................................... 295 Work equipment............................................................................................................................................................. 298 Work equipment linkage................................................................................................................................................. 299 Bucket positioner and lift arm kick-out................................................................................................................................ 303 Remote lift arm positioner............................................................................................................................................. 305 Auto greasing system................................................................................................................................................... 306 Hydraulic cylinder..................................................................................................................................................... 307 Cab and its attachments.................................................................................................................................................... 309 ROPS cab............................................................................................................................................................... 310 Air conditioner........................................................................................................................................................ 311 Electrical system, Part 1.................................................................................................................................................. 315 Machine monitor system................................................................................................................................................. 316 Main monitor........................................................................................................................................................... 318 Maintenance monitor.................................................................................................................................................... 322 Electrical system, Part 2.................................................................................................................................................. 362 Work equipment control system.......................................................................................................................................... 363 Remote position, joystick steering controller.......................................................................................................................... 366 Active power maximizing electrical circuit............................................................................................................................. 367 Automatic transmission system (ATM).................................................................................................................................... 374 Electrical system, Part 3.................................................................................................................................................. 396 Engine starting/stopping circuit....................................................................................................................................... 397 Parking brake circuit.................................................................................................................................................. 399 Preheating circuit..................................................................................................................................................... 405 Emergency engine stop.................................................................................................................................................. 407 Hydraulic oil level sensor............................................................................................................................................. 409 Battery and starting motor disconnector switch and starting aid connector.............................................................................................. 411 Sensor................................................................................................................................................................. 413 20 Standard value table........................................................................................................................................................ 0 Standard service value table............................................................................................................................................... 438 Standard value table for engine........................................................................................................................................ 439 Standard value table for chassis....................................................................................................................................... 440 Standard value table for electrical system............................................................................................................................. 444 30 Testing and adjusting....................................................................................................................................................... 0 Testing and adjusting, Part 1.............................................................................................................................................. 460 Tools for testing, adjusting, and troubleshooting...................................................................................................................... 462 Measuring engine speed................................................................................................................................................. 467 Measuring intake air (boost) pressure.................................................................................................................................. 469 Measuring exhaust gas color............................................................................................................................................ 470 Measuring exhaust temperature.......................................................................................................................................... 471 Adjusting valve clearance.............................................................................................................................................. 473 Measuring compression pressure......................................................................................................................................... 474 Measuring blow-by pressure............................................................................................................................................. 476 Measuring engine oil pressure.......................................................................................................................................... 478 Handling fuel system equipment......................................................................................................................................... 479 Releasing residual pressure in fuel system............................................................................................................................. 479 Testing fuel pressure.................................................................................................................................................. 480 Measuring fuel return rate and leakage................................................................................................................................. 481 Bleeding air from fuel circuit......................................................................................................................................... 484 Testing leakage in fuel system......................................................................................................................................... 486 Handling reduced cylinder mode operation............................................................................................................................... 487 Handling no-injection cranking operation............................................................................................................................... 487 Handling controller voltage circuit.................................................................................................................................... 488 Adjusting speed sensor................................................................................................................................................. 488 Testing and adjusting alternator belt tension.......................................................................................................................... 489 Testing and adjusting belt tension for air conditioner compressor...................................................................................................... 490 Testing and adjusting power train oil pressure......................................................................................................................... 491 Procedure for operating emergency steering spool when transmission valve fails......................................................................................... 496 Testing and adjusting, Part 2.............................................................................................................................................. 500 Measuring operating effort of AJSS lever (AJSS specification).......................................................................................................... 502 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification).............................................................................. 503 Testing and adjusting steering stopper bolt (AJSS specification)....................................................................................................... 505 Testing and adjusting steering stop valve.............................................................................................................................. 507 Measuring steering oil pressure........................................................................................................................................ 508 Testing and adjusting emergency steering oil pressure.................................................................................................................. 509 Bleeding air from steering circuit..................................................................................................................................... 511 Measuring brake pedal.................................................................................................................................................. 512 Measuring brake performance............................................................................................................................................ 513 Testing and adjusting accumulator charge pressure...................................................................................................................... 514 Measuring wheel brake oil pressure reduction........................................................................................................................... 516 Measuring wear of wheel brake disc..................................................................................................................................... 518 Bleeding air from wheel brake circuit.................................................................................................................................. 519 Releasing residual pressure in brake accumulator circuit............................................................................................................... 520 Testing parking brake performance ..................................................................................................................................... 521 Measuring parking brake solenoid oil pressure.......................................................................................................................... 522 Testing and adjusting wear of parking brake pad........................................................................................................................ 523 Testing and adjusting PPC oil pressure................................................................................................................................. 524 Adjusting PPC valve linkage............................................................................................................................................ 526 Testing and adjusting work equipment oil pressure...................................................................................................................... 527 Bleeding air from piston pump.......................................................................................................................................... 529 Bleeding air from work equipment circuit............................................................................................................................... 530 Adjusting work equipment lever linkage................................................................................................................................. 531 Releasing remaining pressure in hydraulic circuit...................................................................................................................... 533 Testing and adjusting bucket proximity switch.......................................................................................................................... 534 Testing and adjusting lift arm proximity switch........................................................................................................................ 535 Testing and adjusting active working proximity switch.................................................................................................................. 536 Checking proximity switch operation pilot lamp......................................................................................................................... 537 Testing and adjusting lift arm position detection lever................................................................................................................ 538 Adjusting speedometer module of main monitor........................................................................................................................... 539 Testing and adjusting, Part 3.............................................................................................................................................. 542 Special function of engine service monitor............................................................................................................................. 543 VHMS controller initial setting procedure.............................................................................................................................. 567 Precautions for replacing VHMS controller.............................................................................................................................. 589 Pm-clinic inspection table............................................................................................................................................. 595 40 Troubleshooting............................................................................................................................................................. 0 Failure code table and fuse locations...................................................................................................................................... 600 Failure code table..................................................................................................................................................... 601 Method of displaying action code and failure code on machine monitor................................................................................................... 608 Transmission & AJSS controller LED display............................................................................................................................. 610 Transmission control system............................................................................................................................................ 611 AJSS (Advanced Joystick Steering System) control system................................................................................................................ 612 Location of fuse....................................................................................................................................................... 613 Location of relay...................................................................................................................................................... 617 General information on troubleshooting..................................................................................................................................... 622 Points to remember when troubleshooting................................................................................................................................ 623 Sequence of events in troubleshooting.................................................................................................................................. 624 Testing before troubleshooting......................................................................................................................................... 625 Classification and procedures of troubleshooting....................................................................................................................... 626 Contents of troubleshooting table...................................................................................................................................... 627 Connection table for connector pin numbers............................................................................................................................. 629 T- branch box and T- branch adapter table.............................................................................................................................. 665 Troubleshooting by failure code (Display of code), Part 1.................................................................................................................. 670 Failure code [15B0NX] (Transmission oil filter: Clogging).............................................................................................................. 673 Failure code [AA1ANX] (Air cleaner L.H: Clogged)....................................................................................................................... 675 Failure code [AA1BNX] (Air cleaner R.H: Clogged)....................................................................................................................... 678 Failure code [AB00L4] (Alternator: Failure on battery charge circuit (Rterminal signal is present and engine is stopped)............................................... 681 Failure code [AB00L6] (Alternator: Failure on battery charge circuit (Rterminal signal is present and engine is stopped)............................................... 683 Failure code [AB00MA] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)................................................ 685 Failure code [AB00MB] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)................................................ 687 Failure code [AB00MC] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)................................................ 689 Failure code [B@BAZK] (Engine oil: Oil level low)...................................................................................................................... 691 Failure code [B@BAZG] (Engine oil: Low oil pressure)................................................................................................................... 693 Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level)............................................................................................... 697 Failure code [B@BDNS] (Engine: Overheating)............................................................................................................................ 699 Failure code [B@C6NS] (Front brake oil temperature: Overheating)....................................................................................................... 701 Failure code [B@CENS] (Torque converter oil temperature overheating)................................................................................................... 703 Failure code [B@JFZG] (Brake oil: Low oil pressure).................................................................................................................... 705 Troubleshooting by failure code (Display of code), Part 2.................................................................................................................. 710 Failure code [CA111] Engine controller (Left bank): Internal abnormality............................................................................................... 713 Failure code [CB111] Engine controller (Right bank): Internal abnormality.............................................................................................. 715 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal............................................................ 717 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal........................................................... 718 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected............................................................ 719 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected.............................................................. 721 Failure code [CA131] Throttle sensor abnormally high level (Only left bank): High voltage detection.................................................................... 722 Failure code [CA132] Throttle sensor too low (At left bank only): Excessively low voltage detected..................................................................... 724 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected............................................................... 725 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected................................................................. 727 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected............................................................................ 729 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected.......................................................... 731 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected......................................................... 733 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected........................................................... 735 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection................................................................... 737 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection.................................................................. 738 Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection...................................................... 739 Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection........................................................ 741 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected....................................................... 742 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected......................................................... 744 Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected................................................................ 745 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection................................................................ 747 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed..................................................................................... 749 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected................................................... 751 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected.................................................. 753 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected................................................................ 755 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected............................................................... 757 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection................................................................... 758 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection.................................................................. 758 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit..................................................................................................... 759 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit.................................................................................................... 760 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection..................................................................................................... 761 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection.................................................................................................... 762 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit..................................................................................................... 763 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit.................................................................................................... 764 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection..................................................................................................... 765 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection.................................................................................................... 766 Troubleshooting by failure code (Display of code), Part 3.................................................................................................................. 768 Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank): Disconnection, short circuit...................................... 771 Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (At left bank): Disconnection, short circuit...................................... 773 Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (At left bank): Disconnection, short circuit...................................... 775 Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (At left bank): Disconnection, short circuit ..................................... 777 Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (At left bank): Disconnection, short circuit...................................... 779 Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (At left bank): Disconnection, short circuit...................................... 781 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch............................................................................................. 783 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch............................................................................................ 784 Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit.................................................................................. 785 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality.............................................................................. 787 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection................................................................... 789 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection.................................................................. 790 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection................................................................. 791 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection................................................................ 793 Failure code [CA431] Trouble in idle validation switch................................................................................................................. 795 Failure code [CA432] Idle validation action error...................................................................................................................... 797 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection...................................................................... 798 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection..................................................................... 798 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection.................................................................... 799 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection................................................................... 799 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence......................................................... 800 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence........................................................ 800 Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected............................................................ 801 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection............................................................ 803 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection.................................................... 805 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection................................................... 805 Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected.............................................................. 806 Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected............................................................. 807 Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error...................................................................... 808 Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error..................................................................... 808 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected......................................................... 809 Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected........................................................ 815 Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal................................................................................... 817 Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal.................................................................................. 819 Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection...................................................... 821 Failure code [CA692] Intake air temperature sensor abnormally low level Failure code [CA692] Intake air temperature sensor abnormally low level........................ 823 Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase............................................................................ 824 Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase........................................................................... 824 Troubleshooting by failure code (Display of code), Part 4.................................................................................................................. 826 Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data............................................................................... 828 Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data.............................................................................. 828 Failure code [CA778] Engine Bkup speed sensor abnormality (At left bank): Bkup signal error............................................................................ 829 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error.............................................................................. 831 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error........................................................................ 833 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error....................................................................... 835 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error.............................................................. 836 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error............................................................. 837 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit................................................ 839 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit................................................ 841 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................... 843 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................... 845 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................... 847 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit................................................ 849 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error.............................................................................................. 851 Failure code [CA2185] Throttle sensor power supply abnormally high level (Only left bank): High voltage detection...................................................... 853 Failure code [CA2186] Throttle sensor power source too low (At left bank only): Excessively low voltage detected....................................................... 855 Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected........................................................ 856 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected....................................................... 856 Failure code [CA2555] Intake heater relay voltage low error (Left bank only)........................................................................................... 857 Failure code [CA2556] Intake heater relay voltage high error (Left bank only).......................................................................................... 859 Failure code [D160KZ] (or TM & AJSS controller LED display [10], abnormality in backup lamp relay system: Disconnection, short circuit or hot short circuit............ 861 Failure code [D180KA] (Preheating relay output system: Disconnection).................................................................................................. 863 Failure code [D180KB] (Preheating relay output system: Grounding fault)................................................................................................ 864 Failure code [D180KY] (Preheating relay output system: Hot short circuit).............................................................................................. 865 Failure code [D19AKB] (or TM & AJSS controller LED display [56], abnormality in joystick caution relay output system: Disconnection or short circuit).................. 867 Failure code [D19BKZ] (or TM & AJSS controller LED display [62], abnormality in joystick neutral interlock relay output system: Disconnection or short circuit)........ 869 Failure code [D1EFKA] (Pre-lubrication start relay output system: Disconnection)....................................................................................... 871 Failure code [D1EFKB] (Pre-lubrication start relay output system: Grounding fault)..................................................................................... 873 Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot short circuit)................................................................................... 875 Failure code [D1EHKA] (Engine start relay output system: Disconnection)................................................................................................ 877 Failure code [D1EHKB] (Engine start relay output system: Grounding fault).............................................................................................. 879 Failure code [D1EHKY] (Engine start relay output system: Hot short circuit)............................................................................................ 881 Failure code [D5ZHL6] (Starting switch terminal C signal: Error)....................................................................................................... 883 Failure code [D5ZSKA] (Machine monitor communication output: Disconnection)............................................................................................ 885 Failure code [D5ZSKB] (Machine monitor communication output: Grounding fault).......................................................................................... 886 Failure code [D5ZSKY] (Machine monitor communication output: Hot short circuit)........................................................................................ 887 Troubleshooting by failure code (Display of code), Part 5.................................................................................................................. 890 Failure code [DB2RKR] (Engine controller CAN-NET communication: Disconnection and grounding fault)..................................................................... 892 Failure code [DBB0KK] (or VHMS LED display: "n9" → "01", VHMS controller: Low supply voltage).......................................................................... 895 Failure code [DBB0KQ] (or VHMS LED display: "nF" → "11", VHMS controller model selection: Disagreement of model selection signals)..................................... 897 Failure code [DBB3KK] (or VHMS LED display: "n9" → "05", VHMS controller: Low direct supply voltage)................................................................... 899 Failure code [DBB5KP] (or VHMS LED display: "n9" → "04", VHMS controller sensor power supply (5 V): Low output voltage)................................................ 901 Failure code [DBB6KP] (or VHMS LED display: "n9" → "02", VHMS controller sensor power supply (24 V): Low output voltage)............................................... 903 Failure code [DBBQKR] (or VHMS LED display: "n8" → "02", VHMS controller CAN communication abnormality)................................................................ 905 Failure code [DBG2KK] (Solenoid power supply: Low voltage)............................................................................................................. 907 Failure code [DBG3KK] (Battery direct power supply: Low voltage)....................................................................................................... 909 Failure code [DBG9KQ] (Model selection signal: Abnormal)............................................................................................................... 911 Failure code [DBGRKR] (Pre-lubrication controller CAN-NET communication: Disconnection or grounding fault)............................................................. 912 Failure code [DBL0KR] (Power ladder controller CAN-NET communication: Disconnection or grounding fault)................................................................ 915 Failure code [DDE2KB] (Engine oil pressure switch error: Grounding fault).............................................................................................. 917 Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection or hot short circuit)........................................................................... 919 Failure code [DDK3KZ] (or TM & AJSS controller LED display [20], abnormality in joystick forward-reverse switch system: Disconnection or hot short circuit)............ 921 Failure code [DDK5KZ] (or TM & AJSS controller LED display: “21”, Abnormality in shifting up/down switch system: Disconnection, short circuit or hot short circuit).... 924 Failure code [DDP5KZ] (Abnormality in steering lock switch system: Disconnection or short circuit)..................................................................... 927 Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input signal range (short)).............................................................................. 929 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range (short))............................................................................ 931 Failure code [DGR4KX] (Front brake oil temperature sensor: Out of input signal range (short)).......................................................................... 933 Troubleshooting by failure code (Display of code), Part 6.................................................................................................................. 936 Failure code [DGT5KA] (or VHMS LED display: "n3" → "12", L.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit)...................... 938 Failure code [dGT5KA] (or VHMS LED display: "n3" → "22", L.H. bank exhaust gas temperature sensor system (Rear): Disconnection or short circuit)....................... 941 Failure code [DGT5KB] (or VHMS LED display: "n3" → "11", L.H. bank exhaust gas temperature sensor system (Front): Hot short circuit)................................... 944 Failure code [dGT5KB] (or VHMS LED display: "n3" → "21", L.H. bank exhaust gas temperature sensor system (Rear): Hot short circuit).................................... 946 Failure code [DGT6KA] (or VHMS LED display: "n3" → "24", R.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit)...................... 948 Failure code [dGT6KA] (or VHMS LED display: "n3" → "26", R.H. exhaust gas temperature sensor system (Rear): Disconnection or short circuit)............................ 951 Failure code [DGT6KB] (or VHMS LED display "n3" → "23", R.H. bank exhaust gas temperature sensor system (front): Hot short circuit).................................... 954 Failure code [dGT6KB] (or VHMS LED display "n3" → "25", R.H. bank exhaust gas temperature sensor system (rear): Hot short circuit)..................................... 956 Failure code [DHE5KB] (or VHMS_LED display: "n3" → "32", Blow-by pressure sensor system: Short circuit)................................................................ 958 Failure code [DHE5KY] (or VHMS LED display: "n3" → "31", Blow-by pressure sensor system: Hot short circuit)............................................................ 960 Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection or short circuit)............................................................................ 962 Failure code [DHT3KX] (or VHMS LED display: "n6" → "14", Transmission oil pressure sensor system: Out of input signal range)........................................... 964 Failure code [DHT8KX] (Steering pump oil pressure sensor error): Disconnection or short circuit)....................................................................... 966 Failure code [DHU2KX] (Front brake oil pressure sensor error: Disconnection or short circuit).......................................................................... 968 Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection or short circuit)........................................................................... 970 Failure code [DK00L8] (or TM & AJSS controller LED display [58], steering and frame angle displacement)................................................................ 972 Failure code [DK30KX] (or TM & AJSS controller LED display [57], abnormality in steering angle potentiometer system): Disconnection or short circuit).................. 973 Failure code [DKD0KX] (or TM & AJSS controller LED display [59], abnormality in frame angle potentiometer system: Disconnection or short circuit)...................... 975 Failure code [DLE4KA] (or TM & AJSS controller LED display [23], abnormality in engine speed sensor system: Disconnection, short circuit or hot short circuit)......... 977 Failure code [DLT4KA] (or TM & AJSS controller LED display [22], abnormality in speed sensor system: Disconnection, short circuit or hot short circuit)................ 979 Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality: Hot short circuit)........................................................................... 981 Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault)............................................................ 982 Failure code [DXF0KZ] (or TM & AJSS controller LED display [63], abnormality in joystick EPC solenoid system: Disconnection, short circuit or hot short circuit)....... 984 Failure code [DXH4KZ] (or TM & AJSS controller LED display [14], abnormality in 1st solenoid system: Disconnection, short circuit or hot short circuit)................ 985 Failure code [DXH5KZ] (or TM & AJSS controller LED display [15], abnormality in 2nd solenoid system: Disconnection, short circuit or hot short circuit)................ 987 Failure code [DXH6KZ] (or TM & AJSS controller LED display [16], abnormality in 3rd solenoid system: Disconnection, short circuit or hot short circuit)................ 989 Failure code [DXH7KZ] (or TM & AJSS controller LED display [13], abnormality in R solenoid system: Disconnection, short circuit or hot short circuit).................. 991 Failure code [DXH8KZ] (or TM & AJSS controller LED display [12], abnormality in F solenoid system: Disconnection, short circuit or hot short circuit).................. 993 Failure code [F@BBZL] (or VHMS LED display: "n3" → "38", Blow-by pressure sensor system: High pressure error).......................................................... 995 Failure code [F@BYNR] (or VHMS LED display: "n3" → "62", L.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)...................... 996 Failure code [f@BYNR] (or VHMS LED display: "n3" → "72", L.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)....................... 996 Failure code [F@BYNS] (or VHMS LED display: "n3" → "61", L.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)...................... 997 Failure code [f@BYNS] (or VHMS LED display: "n3" → "71", L.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)....................... 997 Failure code [F@BZNR] (or VHMS LED display: "n3" → "82", R.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)...................... 998 Failure code [f@BZNR] (or VHMS LED display: "n3" → "92", R.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)....................... 998 Failure code [F@BZNS] (or VHMS LED display: "n3" → "38", R.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)...................... 999 Failure code [f@BZNS] (or VHMS LED display: "n3" → "39", R.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)....................... 999 Troubleshooting of electrical system (E-mode)..............................................................................................................................1001 E-1 Engine does not start..............................................................................................................................................1004 E-2 Abnormality in preheating system...................................................................................................................................1010 E-3 Transmission and AJSS controller does not work.....................................................................................................................1016 E-4 Transmission and AJSS controller model selection error.............................................................................................................1018 E-5 Parking brake does not work (as the emergency brake)...............................................................................................................1020 E-6 Parking brake is applied while machine is traveling................................................................................................................1024 E-7 Parking brake is released as starting switch is turned ON..........................................................................................................1026 E-8 Setting to the neutral position becomes unavailable while the parking brake is in operation (parking brake operates normally)......................................1028 E-9 Parking brake remains in the neutral and not removable to other position (when parking brake is not applied).......................................................1030 E-10 Defective kick-down switch........................................................................................................................................1032 E-11 Defective hold switch.............................................................................................................................................1036 E-12 Lift arm (boom) kick-out is unavailable...........................................................................................................................1040 E-13 Bucket positioner functional error................................................................................................................................1042 E-14 Active working functional error...................................................................................................................................1044 E-15 Turn signal or hazard display do not flash........................................................................................................................1050 E-16 Small lamp does not light up......................................................................................................................................1056 E-17 Head lamp does not light up.......................................................................................................................................1059 E-18 Abnormality in lighting up of front working lamp..................................................................................................................1062 E-19 Abnormality in lighting up of rear working lamp...................................................................................................................1062 E-20 Abnormality in transmission cut-off...............................................................................................................................1062 E-21 Abnormality in low idle selection.................................................................................................................................1062 E-22 Abnormality in parking brake dragging warning.....................................................................................................................1062 E-23 Abnormality in buzzer.............................................................................................................................................1062 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................................................................1065 Method of using troubleshooting chart..................................................................................................................................1067 H-1 Machine does not move..............................................................................................................................................1069 H-2 Machine lacks power or speed (every speed range)...................................................................................................................1070 H-3 Excessive time lag when starting machine or shifting gear..........................................................................................................1071 H-4 Torque converter oil temperature is high...........................................................................................................................1072 H-5 Steering does not turn.............................................................................................................................................1073 H-6 Turning, response of steering is poor..............................................................................................................................1074 H-7 Joystick lever is heavy............................................................................................................................................1075 H-8 Steering wheel shakes or jerks.....................................................................................................................................1076 H-9 Minimum turning radii to right and left are different..............................................................................................................1077 H-10 Wheel brakes do not work or braking effect is poor................................................................................................................1078 H-11 Wheel brakes are not released or brakes drag......................................................................................................................1079 H-12 Lift arm does not rise............................................................................................................................................1080 H-13 Lift arm moves slowly or does not have sufficient lifting power...................................................................................................1081 H-14 When raising lift arm, becomes slow at certain height.............................................................................................................1082 H-15 Lift arm cylinder cannot hold down bucket.........................................................................................................................1082 H-16 Lift arm has large amount of hydraulic drift......................................................................................................................1082 H-17 Lift arm fluctuates while working.................................................................................................................................1083 H-18 Lift arm drops momentarily when lever is operated from HOLD to RAISE..............................................................................................1083 H-19 Bucket does not tilt back.........................................................................................................................................1084 H-20 Bucket moves slowly or has insufficient tilt back power...........................................................................................................1085 H-21 Bucket movement becomes slow during tilt back.....................................................................................................................1086 H-22 Bucket cylinder cannot hold down bucket...........................................................................................................................1086 H-23 Bucket has large amount of hydraulic drift........................................................................................................................1086 H-24 Bucket fluctuates while traveling under load (work equipment valve "HOLD")........................................................................................1087 H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT.................................................................................................1087 H-26 Lift arm and bucket levers do not move smoothly...................................................................................................................1088 Troubleshooting of engine (S-mode).........................................................................................................................................1091 Method of using troubleshooting chart..................................................................................................................................1093 S-1 Starting performance is poor.......................................................................................................................................1096 S-2 Engine does not start..............................................................................................................................................1097 S-3 Engine does not pick up smoothly...................................................................................................................................1100 S-4 Engine stops during operations.....................................................................................................................................1101 S-5 Engine does not rotate smoothly....................................................................................................................................1102 S-6 Engine lacks output (or lacks power)...............................................................................................................................1103 S-7 Exhaust smoke is black (incomplete combustion).....................................................................................................................1105 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................................................................................1106 S-9 Oil becomes contaminated quickly...................................................................................................................................1107 S-10 Fuel consumption is excessive.....................................................................................................................................1108 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................................................................................1109 S-12 Oil pressure drops................................................................................................................................................1110 S-13 Oil level rises (Entry of coolant or fuel)........................................................................................................................1111 S-14 Coolant temperature becomes too high (overheating)................................................................................................................1112 S-15 Abnormal noise is made............................................................................................................................................1113 S-16 Vibration is excessive............................................................................................................................................1114 Troubleshooting of machine monitor system (M-mode).........................................................................................................................1117 Machine monitor system.................................................................................................................................................1119 M-1 Machine monitor does not work......................................................................................................................................1120 M-2 Engine starts immediately after (within 3 sec of) turning starting switch ON, but all the machine monitors remain lit..............................................1122 M-3 Speedometer display does not work..................................................................................................................................1123 M-4 Shift indicator error..............................................................................................................................................1125 M-5 Monitor turn signal (hazard) indicator does not light up...........................................................................................................1135 M-6 Parking indication error...........................................................................................................................................1137 M-7 Abnormality in preheating system...................................................................................................................................1138 M-8 Night lamp does not light up.......................................................................................................................................1142 M-9 Front work lamp error..............................................................................................................................................1144 M-10 Rear work lamp error..............................................................................................................................................1148 M-11 Abnormality in transmission cut-off switch........................................................................................................................1152 M-12 Abnormality in low idle selection.................................................................................................................................1156 M-13 Emergency steering indication error...............................................................................................................................1158 M-14 Parking brake dragging warning error..............................................................................................................................1160 M-15 Buzzer and caution lamp error upon parking brake dragging warning outputting......................................................................................1161 M-16 Buzzer error......................................................................................................................................................1163 M-17 Switching state of machine monitor is not stored..................................................................................................................1169 M-18 Failure indication mode error.....................................................................................................................................1170 M-19 Machine monitor does not indicate failure code....................................................................................................................1172 M-20 Abnormality in auto grease system.................................................................................................................................1174 Troubleshooting of maintenance monitor system (K-mode).....................................................................................................................1179 Maintenance monitor system.............................................................................................................................................1181 K-1 Maintenance monitor does not work..................................................................................................................................1182 K-2 Immediately after turning starting switch ON (within 3 sec.), engine starts but the maintenance monitor remains fully lit up.......................................1184 K-3 Work check item flashes upon turning starting switch ON (engine not running).......................................................................................1186 K-4 Caution item flashes upon turning starting switch ON (engine running)..............................................................................................1190 K-5 The warning buzzer does not sound while caution item indicator flashes.............................................................................................1206 K-6 The warning buzzer sounds while monitor indicates no error.........................................................................................................1208 K-7 The warning lamps (check lamp and caution lamp) do not flash while caution item indicator flashes..................................................................1209 K-8 Warning lamps (check and caution lamps) lights up while the maintenance monitor indicates no error.................................................................1211 K-9 Night lamp does not light up.......................................................................................................................................1214 K-10 Night lamp remains lit up.........................................................................................................................................1216 K-11 Service meter does not work.......................................................................................................................................1218 K-12 Service meter keeps on working (when engine stops)................................................................................................................1220 K-13 Gauge items (fuel, engine coolant temperature and torque converter oil temperature) error.........................................................................1222 Troubleshooting of remote boom positioner controller system (if equipped) (W-mode).........................................................................................1231 W-1 Short circuit, disconnection in dumping solenoid system............................................................................................................1234 W-2 Short circuit in power source at hot end of dumping solenoid.......................................................................................................1235 W-3 Short circuit in power source at return end of dumping solenoid....................................................................................................1236 W-4 Boom kick-out function trouble.....................................................................................................................................1238 W-5 Disconnection in boom RAISE, LOWER detection pressure switch.......................................................................................................1240 W-6 Short circuit, disconnection in boom angle potentiometer system....................................................................................................1242 W-7 Sensor cannot be adjusted..........................................................................................................................................1244 W-8 Abnormality in engine speed signal system..........................................................................................................................1245 W-9 Remote positioner RAISE, LOWER LEDs do not light up................................................................................................................1246 W-10 Remote positioner RAISE set LED does not flash....................................................................................................................1248 W-11 Remote positioner LOWER set LED does not flash....................................................................................................................1250 W-12 Buzzer for switch operation does not sound........................................................................................................................1252 W-13 Shock when stopping boom..........................................................................................................................................1253 W-14 Short circuit in boom RAISE, LOWER pressure detection switch......................................................................................................1254 50 Disassembly and assembly.................................................................................................................................................... 0 General information on disassembly and assembly............................................................................................................................1257 How to read this manual................................................................................................................................................1258 Coating materials list.................................................................................................................................................1260 Special tools list.....................................................................................................................................................1263 Sketches of special tools..............................................................................................................................................1269 Engine and cooling system, Part 1..........................................................................................................................................1279 Removal and installation of engine assembly............................................................................................................................1280 Removal and installation of radiator assembly..........................................................................................................................1285 Removal and installation of damper assembly............................................................................................................................1288 Disassembly and assembly of damper assembly............................................................................................................................1289 Removal and installation of fuel tank assembly.........................................................................................................................1293 Engine and cooling system, Part 2..........................................................................................................................................1297 Removal and installation of right bank fuel supply pump assembly.......................................................................................................1298 Removal and installation of left bank fuel supply pump assembly........................................................................................................1302 Removal and installation of cylinder head assembly.....................................................................................................................1306 Removal and installation of fuel injector assembly.....................................................................................................................1316 Removal and installation of engine front oil seal......................................................................................................................1321 Removal and installation of engine rear oil seal.......................................................................................................................1324 Power train, Part 1........................................................................................................................................................1329 Disassembly and assembly of transfer assembly..........................................................................................................................1330 Disassembly and assembly of PTO assembly...............................................................................................................................1344 Removal and installation of parking brake calipers assembly............................................................................................................1348 Disassembly and assembly of parking brake calipers assembly............................................................................................................1349 Removal and installation of parking brake pad..........................................................................................................................1351 Removal and installation of parking brake spring cylinder..............................................................................................................1352 Removal and installation of torque converter and transmission assembly.................................................................................................1353 Power train, Part 2........................................................................................................................................................1361 Disassembly and assembly of torque converter assembly..................................................................................................................1362 Disassembly and assembly of transmission assembly......................................................................................................................1370 Power train, Part 3........................................................................................................................................................1395 Removal and installation of front axle assembly........................................................................................................................1396 Removal and installation of rear axle assembly.........................................................................................................................1398 Removal and installation of center support assembly....................................................................................................................1404 Disassembly and assembly of center support assembly....................................................................................................................1406 Removal and installation of differential assembly......................................................................................................................1410 Disassembly and assembly of differential assembly......................................................................................................................1412 Disassembly and assembly of final drive assembly.......................................................................................................................1421 Brake system...............................................................................................................................................................1427 Removal and installation of brake assembly.............................................................................................................................1428 Disassembly and assembly of brake assembly.............................................................................................................................1429 Removal and installation of left brake valve assembly..................................................................................................................1434 Removal and installation of right brake valve assembly.................................................................................................................1435 Disassembly and assembly of accumulator charge valve...................................................................................................................1436 Disassembly and assembly of slack adjuster.............................................................................................................................1438 Undercarriage and frame....................................................................................................................................................1441 Removal and installation of center hinge pin...........................................................................................................................1442 Removal and installation of counterweight assembly.....................................................................................................................1450 Hydraulic system...........................................................................................................................................................1453 Removal and installation of hydraulic tank and filter case assembly....................................................................................................1454 Removal and installation of hydraulic pump assembly....................................................................................................................1456 Removal and installation of work equipment control valve assembly......................................................................................................1459 Disassembly and assembly of work equipment control valve assembly......................................................................................................1461 Disassembly and assembly of PPC valve assembly.........................................................................................................................1464 Removal and installation of steering valve assembly....................................................................................................................1465 Removal and installation of diverter valve assembly....................................................................................................................1467 Disassembly and assembly of diverter valve assembly....................................................................................................................1468 Removal and installation of Orbitroll assembly.........................................................................................................................1470 Removal of steering stop valve.........................................................................................................................................1472 Disassembly and assembly of hydraulic cylinder assembly................................................................................................................1473 Work equipment.............................................................................................................................................................1479 Removal and installation of work equipment assembly....................................................................................................................1480 Replacement of boom front bushing......................................................................................................................................1485 Cab and its attachments....................................................................................................................................................1487 Removal and installation of operator cab assembly......................................................................................................................1488 Removal and installation of floor frame assembly.......................................................................................................................1490 Disassembly and assembly of operator’s seat assembly...................................................................................................................1493 Electrical system..........................................................................................................................................................1527 Removal and installation of engine controller assembly.................................................................................................................1528 Removal and installation of transmission and steering controller assembly..............................................................................................1529 Removal and installation of main monitor assembly......................................................................................................................1530 Removal and installation of air conditioner unit assembly..............................................................................................................1532 90 Diagrams and drawings....................................................................................................................................................... 0 Hydraulic diagrams and drawings............................................................................................................................................1535 Power train hydraulic circuit diagram..................................................................................................................................1536 Brake hydraulic circuit diagram........................................................................................................................................1537 Work equipment hydraulic circuit diagram...............................................................................................................................1538 Electrical diagrams and drawings...........................................................................................................................................1540 Electrical circuit diagram (1/8).......................................................................................................................................1542 Electrical circuit diagram (2/8).......................................................................................................................................1543 Electrical circuit diagram (3/8).......................................................................................................................................1544 Electrical circuit diagram (4/8).......................................................................................................................................1545 Electrical circuit diagram (5/8).......................................................................................................................................1546 Electrical circuit diagram (6/8).......................................................................................................................................1547 Electrical circuit diagram (7/8).......................................................................................................................................1548 Electrical circuit diagram (8/8).......................................................................................................................................1549 Electrical circuit diagram of emergency engine stop....................................................................................................................1550 Electrical circuit diagram of hydraulic oil level sensor...............................................................................................................1551 Electrical circuit diagram of battery and starting motor disconnector switch and starting aid connector................................................................1553 Connector arrangement diagram..........................................................................................................................................1555
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