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Komatsu WA900-3 Avance Loader Wheel Loader Shop Manual 50001 and up – PDF DOWNLOAD
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Komatsu WA900-3 Avance Loader Wheel Loader Shop Manual
Book Code: SEBM013516
MACHINE MODEL SERIAL NO.
WA900-3 50001 and up
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Description
Komatsu WA900-3 Avance Loader Wheel Loader Shop Manual
.
FILE DETAILS:
Komatsu WA900-3 Avance Loader Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA900-3 Avance Loader
Serial Number: 50001 and up
Book Code: SEBM013516
Language: English
Pages: 1159
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA900-3 Avance Loader Wheel Loader Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA900-3 Avance Loader Wheel Loader Shop Manual
COVER........................................................................................................................................................................................ 0 CONTENTS..................................................................................................................................................................................... 2 01 GENERAL................................................................................................................................................................................... 31 GENERAL ASSEMBLY DRAWING................................................................................................................................................................. 32 SPECIFICATIONS........................................................................................................................................................................... 33 WEIGHT TABLE............................................................................................................................................................................. 36 LIST OF LUBRICANT AND WATER.............................................................................................................................................................. 38 10 STRUCTURE AND FUNCTION.................................................................................................................................................................... 40 POWER TRAIN.............................................................................................................................................................................. 41 POWER TRAIN SYSTEM....................................................................................................................................................................... 42 ENGINE CONTROL........................................................................................................................................................................... 44 SERVO CYLINDER........................................................................................................................................................................... 45 RADIATOR AND COOLER...................................................................................................................................................................... 49 DAMPER................................................................................................................................................................................... 52 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................................................................. 53 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.................................................................................................................................................... 54 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................... 55 TORQUE CONVERTER......................................................................................................................................................................... 56 TRANSMISSION............................................................................................................................................................................. 61 TRANSFER................................................................................................................................................................................. 71 TRANSMISSION CONTROL VALVE............................................................................................................................................................... 72 TORQUE CONVERTOR OIL COOLER.............................................................................................................................................................. 89 DRIVE SHAFT.............................................................................................................................................................................. 90 CENTER SUPPORT........................................................................................................................................................................... 91 AXLE..................................................................................................................................................................................... 92 FINAL DRIVE.............................................................................................................................................................................. 97 AXLE MOUNT............................................................................................................................................................................... 98 CENTER HINGE PIN......................................................................................................................................................................... 100 TIRE AND WHEEL........................................................................................................................................................................... 101 STEERING PIPING DIAGRAM.................................................................................................................................................................. 102 STEERING COLUMN.......................................................................................................................................................................... 105 JOYSTICK LINKAGE......................................................................................................................................................................... 106 STEERING PUMP............................................................................................................................................................................ 107 SWITCH PUMP.............................................................................................................................................................................. 113 STEERING DEMAND VALVE.................................................................................................................................................................... 124 STEERING UNIT (ORBIT-ROLL VALVE)......................................................................................................................................................... 135 PROPORTIONAL SOLENOID VALVE.............................................................................................................................................................. 138 EPC VALVE................................................................................................................................................................................ 139 ROTARY VALVE............................................................................................................................................................................. 140 TOW-WAY RESTRICTOR VALVE................................................................................................................................................................. 143 DIVERTER VALVE........................................................................................................................................................................... 144 BRAKE PIPING............................................................................................................................................................................. 148 BRAKE CIRCUIT DIAGRAM.................................................................................................................................................................... 150 BRAKE VALVE.............................................................................................................................................................................. 154 CHARGE VALVE............................................................................................................................................................................. 164 ACCUMULATOR (FOR BRAKE).................................................................................................................................................................. 168 SLACK ADJUSTER........................................................................................................................................................................... 169 BRAKE.................................................................................................................................................................................... 172 PARKING BRAKE............................................................................................................................................................................ 173 SPRING CYLINDER.......................................................................................................................................................................... 176 PARKING BRAKE SOLENOID VALVE............................................................................................................................................................. 177 HYDRAULIC PIPING......................................................................................................................................................................... 178 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................. 181 WORK EQUIPMENT LEVER LINKAGE............................................................................................................................................................. 193 HYDRAULIC TANK........................................................................................................................................................................... 194 MAIN PISTON PUMP......................................................................................................................................................................... 197 ES VALVE (ENGINE SENSING VALVE).......................................................................................................................................................... 208 SERVO VALVE.............................................................................................................................................................................. 210 PPC VALVE (PROPORTIONAL PRESSURE VALVE).................................................................................................................................................. 213 PPC RELIEF VALVE......................................................................................................................................................................... 217 ACCUMULATOR (FOR PPC VALVE).............................................................................................................................................................. 218 MAIN CONTROL VALVE....................................................................................................................................................................... 219 COOLING FAN HYDRAULIC PIPING............................................................................................................................................................. 243 COOLING FAN HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................................... 244 PRIORITY VALVE........................................................................................................................................................................... 245 COOLING FAN MOTOR........................................................................................................................................................................ 246 LUBRICATION OF WORK EQUIPMENT............................................................................................................................................................ 250 WORK EQUIPMENT LINKAGE................................................................................................................................................................... 252 BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................... 254 OPERATION OF PROXIMITY SWITCH............................................................................................................................................................ 256 CAB...................................................................................................................................................................................... 260 ROPS CANOPY.............................................................................................................................................................................. 261 AIR CONDITIONER.......................................................................................................................................................................... 262 ELECTRIC CIRCUIT DIAGRAM................................................................................................................................................................. 265 MACHINE MONITOR SYSTEM................................................................................................................................................................... 267 MAIN MONITOR............................................................................................................................................................................. 269 MAINTENANCE MONITOR...................................................................................................................................................................... 275 MULTI MONITOR SYSTEM (IF EQUIPPED)....................................................................................................................................................... 277 ENGINE STARTING CIRCUIT.................................................................................................................................................................. 299 ENGINE STOP CIRCUIT...................................................................................................................................................................... 302 PREHEATING CIRCUIT....................................................................................................................................................................... 303 ELECTRICAL TRANSMISSION CONTROL.......................................................................................................................................................... 304 KICK-DOWN, HOLD SWITCH................................................................................................................................................................... 307 JOYSTICK STEERING SYSTEM................................................................................................................................................................. 308 TRANSMISSION AND JOYSTICK STEERING CONTROLLER............................................................................................................................................ 310 AJSS (ADVANCED JOYSTICK STEERING SYSTEM)................................................................................................................................................. 312 TRANSMISSION AND JOYSTICK STEERING CONTROLLER............................................................................................................................................ 316 ELECTRIC PARKING BRAKE CONTROL........................................................................................................................................................... 318 BRAKE COOLING SYSTEM (IF EQUIPPED)....................................................................................................................................................... 327 55℃ SPECIFICATION........................................................................................................................................................................ 336 EMERGENCY ENGINE STOP (FOR RIO TINTO).................................................................................................................................................... 340 HYDRAULIC OIL LEVEL SENSOR (FOR RIO TINTO)............................................................................................................................................... 343 BATTERY AND STARTER ISOLATOR, BATTERY JUMP START (FOR RIO TINTO)......................................................................................................................... 346 20 TESTING AND ADJUSTING..................................................................................................................................................................... 349 STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................................................... 350 STANDARD VALUE TABLE FOR CHASSIS......................................................................................................................................................... 351 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................................................................ 357 TESTING AND ADJUSTING.................................................................................................................................................................... 375 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................................... 376 MEASURING ENGINE SPEED............................................................................................................................................................... 377 MEASURING EXHAUST GAS COLOR.......................................................................................................................................................... 379 ADJUSTING VALVE CLEARANCE............................................................................................................................................................ 380 MEASURING COMPRESSION PRESSURE....................................................................................................................................................... 381 MEASURING BLOW-BY PRESSURE........................................................................................................................................................... 382 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................................................................... 383 MEASURING ENGINE OIL PRESSURE........................................................................................................................................................ 385 MEASURING EXHAUST TEMPERATURE........................................................................................................................................................ 386 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....................................................................................................................................... 387 TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................................................................ 388 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................................................................... 389 MEASURING ACCELERATOR PEDAL OPERATING EFFORT......................................................................................................................................... 390 MEASURING ACCELERATOR PEDAL OPERATING ANGLE.......................................................................................................................................... 391 ADJUSTING FUEL CONTROL CABLE, LINKAGE, AND SERVO CYLINDER............................................................................................................................ 392 ADJUSTING ENGINE STOPPING MOTOR CABLE................................................................................................................................................ 394 TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE................................................................................................................. 396 PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS....................................................................................................... 399 TESTING AND ADJUSTING STEERING OIL PRESSURE.......................................................................................................................................... 401 TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE................................................................................................................................ 402 BLEEDING AIR FROM STEERING CIRCUIT................................................................................................................................................... 404 TESTING AND ADJUSTING STEERING STOP VALVE............................................................................................................................................ 405 TESTING AND ADJUSTING STEERING STOPPER BOLT.......................................................................................................................................... 406 TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR............................................................................................................. 407 TESTING WHEEL BRAKE PERFORMANCE...................................................................................................................................................... 408 TESTING WHEEL BRAKE OIL PRESSURE DROP................................................................................................................................................ 409 MEASURING WEAR OF WHEEL BRAKE DISC................................................................................................................................................... 411 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE................................................................................................................. 412 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT................................................................................................................................................ 414 TESTING PARKING BRAKE PERFORMANCE.................................................................................................................................................... 415 MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE..................................................................................................................................... 416 CHECKING AND ADJUSTING PARKING BRAKE PAD ............................................................................................................................................ 417 TESTING AND ADJUSTING PPC PRESSURE................................................................................................................................................... 419 ADJUSTING PPC VALVE LINKAGE.......................................................................................................................................................... 421 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................................................. 422 BLEEDING AIR FROM PISTON PUMP........................................................................................................................................................ 424 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT............................................................................................................................................. 425 ADJUSTING WORK EQUIPMENT LEVER LINKAGE............................................................................................................................................... 426 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................................................................................................................................... 428 TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH........................................................................................................................................ 429 TESTING AND ADJUSTING BOOM PROXIMITY SWITCH.......................................................................................................................................... 430 TESTING PROXIMITY ACTUATION PILOT LAMP............................................................................................................................................... 431 ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR......................................................................................................................................... 432 ADJUSTING JOYSTICK LEVER POTENTIOMETER............................................................................................................................................... 433 ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH.................................................................................................................................... 434 TROUBLESHOOTING.......................................................................................................................................................................... 435 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................................................. 436 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................................................................ 437 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................................................................... 438 CHECKS BEFORE TROUBLESHOOTING........................................................................................................................................................ 446 TYPES AND LOCATIONS OF CONNECTORS.................................................................................................................................................... 447 CONNECTOR ARRANGEMENT DIAGRAM........................................................................................................................................................ 454 WIRING TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................................... 460 T-ADAPTER BOX AND T-ADAPTER TABLE.................................................................................................................................................... 493 EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM............................................................................................................................... 496 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE.................................................................................................................................... 501 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION............................................................................................................................. 503 TRANSMISSION CONTROLLER LED DISPLAY.................................................................................................................................................. 508 METHOD OF USING JUDGEMENT TABLE...................................................................................................................................................... 509 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................... 510 METHOD OF USING MATRIX TROUBLESHOOTING TABLES........................................................................................................................................ 512 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................................................................ 514 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................................... 515 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................................................................................... 519 S-2 ENGINE DOES NOT START........................................................................................................................................................ 520 ① ENGINE DOES NOT TURN....................................................................................................................................................... 520 ② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)..................................................................................................... 521 ③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................................................................................................... 522 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................................................................... 523 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................................................... 524 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................................................... 525 S-6 ENGINE LACKS UOTPUT (NO POWER)............................................................................................................................................... 526 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)................................................................................................................................. 527 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)........................................................................................................................ 528 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................................................. 529 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................................................... 530 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..................................................................................................... 531 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................... 532 S-13 OIL LEVEL RISES............................................................................................................................................................. 533 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................ 534 S-15 ABNORMAL NOISE IS MADE...................................................................................................................................................... 535 S-16 VIBRATION IS EXCESSIVE...................................................................................................................................................... 536 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE).............................................................................................................................. 537 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS.................................................................................................................... 538 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................... 540 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM....................................................................................................................... 548 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED.......................................................... 552 STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION............................................................................................. 552 T-2 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED.......................................................... 553 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 553 T-3 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED................................................................. 554 T-4 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED................................................................. 555 T-5 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED............................................................... 556 T-6 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED............................................................... 557 T-7 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYEED.............................................................. 558 T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.......................................................................... 559 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED................................................................................... 560 STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION............................................................................................. 560 T-10 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED....................................................................... 563 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 563 T-11 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED........................................................................................ 564 STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION............................................................................................. 564 T-12 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED............................................................... 567 T-13 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED....................................................................................................... 568 T-14 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED................................................................................. 569 T-15 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM................................................................................................................. 570 T-16 SHIFT-DOWN SWITCH SIGNAL SYSTEM AND SHIFT-UP SWITCH SIGNAL SYSTEM........................................................................................................... 571 T-17 TRANSMISSION CUT-OFF SIGNAL SYSTEM.......................................................................................................................................... 572 T-18 NEUTRALIZER SIGNAL SYSTEM................................................................................................................................................... 573 T-19 BUZZER SIGNAL SYSTEM........................................................................................................................................................ 574 T-20 NETWORK SYSTEM.............................................................................................................................................................. 575 T-21 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM................................................................................................................................. 576 T-22 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM................................................................................................................................. 577 T-23 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS............................................................................................................................. 578 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...................................................................................................................................... 579 TROUBLE DATA DISPLAY............................................................................................................................................................. 581 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM............................................................................................................................... 583 M-1 MAIN MONITOR DOES NOT WORK................................................................................................................................................... 585 M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP............................................................ 586 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY................................................................................................................................... 587 M-4 ABNORMALITY IN SHIFT INDICATOR............................................................................................................................................... 588 a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F............................................................................................................................ 588 b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R............................................................................................................................ 588 c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N (DISPLAY 1ST-3RD).................................................................................................. 589 d) DOES NOT DISPLAY 1ST EVEN WHEN GEAR SHIFT LEVER IS AT 1ST POSITION (DIRECTIONAL LEVER IS AT F OR R POSITION).............................................................. 589 e) DOES NOT DISPLAY 2ND EVEN WHEN GEAR SHIFT IS AT 2ND POSITION (DIRECTION LEVER IS AT F OR R POSITION)...................................................................... 589 f) DOES NOT DISPLAY 3RD EVEN WHEN THE GEAR SHIFT IS AT 3RD POSITION (DIRECTION LEVER IS AT F OR R POSITION).................................................................. 590 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP.......................................................................................................................................... 591 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP........................................................................................................................................ 592 a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................................ 592 b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................................ 592 M-7 ABNORMALITY IN PARKING DISPLAY............................................................................................................................................... 593 a) PARKING LAMP DISPLAY DOES NOT LIGHT UP.................................................................................................................................... 593 b) PARKING LAMP DISPLAY STAYS LIGHTED UP..................................................................................................................................... 593 M-8 ABNORMALITY IN PREHEATING SYSTEM............................................................................................................................................. 594 a) DOES NOT CARRY OUT PREHEATING............................................................................................................................................. 594 b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS ............................................................................................................................. 595 c) PREHEATING STAYS ON....................................................................................................................................................... 595 d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION.................................................................................................................... 596 M-9 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................................................................................. 598 M-10 ABNORMALITY IN FRONT WORKING LAMP........................................................................................................................................... 599 a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP................................................................................................................... 599 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.............................................................................................................. 599 c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP........................................................................................................ 599 M-11 ABNORMALITY IN REAR WORKING LAMP............................................................................................................................................ 601 a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP ................................................................................................................... 601 b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP ........................................................................................................ 601 c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP......................................................................................................... 601 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF......................................................................................................................................... 603 a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE................................................ 603 b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED............................... 603 c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED.......................................................... 603 d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)................................................................. 603 e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED................................................................... 604 M-13 ABNORMALITY IN LOW IDLING SELECTION......................................................................................................................................... 605 a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLING SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE .............................................. 605 b) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLING SPEED DOES NOT RISE............................................. 605 c) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLING SPEED DOES NOT LOWER............................................ 606 M-14 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY............................................................................................................................ 607 EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP.......................................................................................................................... 607 M-15 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY......................................................................................................................... 608 a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP.................................................................................................................... 608 b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP..................................................................................................................... 608 M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................................................................................... 609 a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N................................................ 609 b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N........................... 609 M-17 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP))............................................................................................ 611 a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N................................................ 611 b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N........................... 611 M-18 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED................................................... 613 a) ACTUATED CONTINUOUSLY..................................................................................................................................................... 613 b) NOT ACTUATED.............................................................................................................................................................. 613 M-19 ABNORMALITY IN BUZZER....................................................................................................................................................... 614 a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)................................................................................... 614 b) BUZZER ALWAYS SOUNDS...................................................................................................................................................... 614 M-20 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY....................................................................................................................... 615 M-21 ABNORMALITY IN FAILURE DISPLAY MODE......................................................................................................................................... 616 a) DOES NOT ENTER FAILURE DISPLAY MODE....................................................................................................................................... 616 b) COUNT FOR TIME ELAPSED SINCE FAILURE DISPLAY MODE DOES NOT ADVANCE........................................................................................................ 616 M-22 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER.................................................................................................. 617 M-23 ABNORMALITY IN AUTO-GREASING SYSTEM (OP).................................................................................................................................... 618 a) FORCED GREASING CANNOT BE CARRIED OUT..................................................................................................................................... 618 b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)............................................................................................................................. 618 c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)................................................................................................ 618 d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY.............................................................................................. 619 e) MONITOR DISPLAY GOES OUT.................................................................................................................................................. 619 M-24 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP)...................................................................................................... 620 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)............................................................................................................................... 621 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM........................................................................................................................ 622 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK......................................... 624 a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP.................................................................................................................................. 624 b) SOME LAMPS DO NOT LIGHT UP................................................................................................................................................ 624 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)........................................................ 625 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT............................................. 626 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH........................................................................................................ 627 a) ENGINE OIL LEVEL DISPLAY FLASHES.......................................................................................................................................... 627 b) ENGINE WATER LEVEL DISPLAY FLASHES........................................................................................................................................ 628 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH...................................................................................................... 629 a) ENGINE OIL PRESSURE DISPLAY FLASHES....................................................................................................................................... 629 b) BATTERY CHARGE LEVEL DISPLAY FLASHES...................................................................................................................................... 630 c) BRAKE OIL PRESSURE DISPLAY FLASHES........................................................................................................................................ 631 d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES............................................................................................................................... 633 e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES............................................................................................................................... 634 f) TRANSMISSION OIL FILTER DISPLAY FLASHES................................................................................................................................... 635 K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND......................................................................................................................... 636 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS......................................................................................................... 637 K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES................................................................................................... 638 a) CHECK LAMP................................................................................................................................................................ 638 b) CAUTION LAMP.............................................................................................................................................................. 638 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP ............................................................................. 639 a) CHECK LAMP................................................................................................................................................................ 639 b) CAUTION LAMP.............................................................................................................................................................. 639 K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON.............................................................................. 640 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF............................................................................................................ 641 K-12 SERVICE METER DOES NOT WORK................................................................................................................................................. 642 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED........................................................................................................................ 642 K-14 ABNORMALITY IN GAUGE DISPLAY................................................................................................................................................ 643 a) ABNORMALITY IN FUEL GAUGE................................................................................................................................................. 643 b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE............................................................................................................................. 644 c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..................................................................................................................... 645 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................................................................ 646 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING..................................................................................... 647 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE..................................................................................................................................... 649 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER............................................................................................................... 650 E-1 ENGINE DOES NOT START........................................................................................................................................................ 651 a) STARTING MOTOR DOES NOT TURN.............................................................................................................................................. 651 b) STARTING MOTOR TURNS (STD SPEC.).......................................................................................................................................... 655 E-2 ENGINE DOES NOT STOP (STD SPEC.)............................................................................................................................................. 657 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (STD SPEC.)........................................................................................................................... 658 E-4 ABNORMALITY IN PREHEATING SYSTEM............................................................................................................................................. 660 a) DOES NOT CARRY OUT PREHEATING............................................................................................................................................. 660 b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS.............................................................................................................................. 661 c) PREHEATING STAYS ON....................................................................................................................................................... 661 d) PREHEATING TIME BECOMES SHORTER, OR THERE IS FLUCTUATION.................................................................................................................. 662 E-5 PARKING BRAKE DOES NOT HAVE EFFECT........................................................................................................................................... 664 a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON........................................................................................................ 664 b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)........................................................... 664 E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING........................................................................................................................... 665 E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNDED ON................................................................................................................. 667 E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)..................................................................... 667 E-9 KICK-DOWN SWITCH DOES NOT WORK............................................................................................................................................... 669 a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY...................................................................................................... 669 b) KICK-DOWN CANNOT BE CANCELED.............................................................................................................................................. 670 E-10 BOOM KICK-OUT DOES NOT WORK................................................................................................................................................. 671 E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION................................................................................................................................... 674 E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP............................................................................................................................ 677 E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP............................................................................................................................. 677 E-14 ABNORMALITY IN TRANSMISSION CUT-OFF......................................................................................................................................... 677 E-15 ABNORMALITY IN LOW IDLING SELECTION......................................................................................................................................... 677 E-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING .............................................................................................................................. 677 E-17 ABNORMALITY IN BUZZER ...................................................................................................................................................... 677 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).......................................................................................................................... 678 H-1 MACHINE DOES NOT MOVE........................................................................................................................................................ 679 H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)............................................................................................................................. 680 H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.................................................................................................................... 681 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................................................................... 682 H-5 STEERING DOES NOT TURN....................................................................................................................................................... 683 STEERING WHEEL SPECIFICATION................................................................................................................................................. 683 H-6 STEERING DOES NOT TURN....................................................................................................................................................... 684 STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION........................................................................................................................... 684 H-7 STEERING DOES NOT TURN....................................................................................................................................................... 685 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 685 H-8 TURNING, RESPONSE OF STEERING IS POOR........................................................................................................................................ 686 STEERING WHEEL SPECIFICATION................................................................................................................................................. 686 H-9 TURNING, RESPONSE OF STEERING IS POOR........................................................................................................................................ 687 STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION........................................................................................................................... 687 H-10 TURNING, RESPONSE OF STEERING IS POOR....................................................................................................................................... 688 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 688 H-11 STEERING IS HEAVY........................................................................................................................................................... 689 STEERING WHEEL SPECIFICATION................................................................................................................................................. 689 H-12 JOYSTICK LEVER IS HEAVY..................................................................................................................................................... 689 STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION........................................................................................................................... 689 H-13 JOYSTICK LEVER IS HEAVY..................................................................................................................................................... 690 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 690 H-14 STEERING WHEEL SHAKES OR JERKS.............................................................................................................................................. 691 STEERING WHEEL SPECIFICATION................................................................................................................................................. 691 H-15 STEERING WHEEL SHAKES OR JERKS.............................................................................................................................................. 692 STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION........................................................................................................................... 692 H-16 STEERING WHEEL SHAKES OR JERKS.............................................................................................................................................. 693 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 693 H-17 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT....................................................................................................................... 694 STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION............................................................................................. 694 H-18 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT....................................................................................................................... 694 AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....................................................................................................................... 694 H-19 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.......................................................................................................................... 695 H-20 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG................................................................................................................................ 696 H-21 BOOM DOES NOT RISE.......................................................................................................................................................... 697 H-22 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER................................................................................................................. 698 H-23 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT........................................................................................................................... 699 H-24 BOOM CYLINDER CANNOT HOLD DOWN BUCKET....................................................................................................................................... 699 H-25 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT.................................................................................................................................... 699 H-26 BOOM FLUCTUATES WHILE WORKING............................................................................................................................................... 700 H-27 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE............................................................................................................ 700 H-28 BUCKET DOES NOT TILT BACK................................................................................................................................................... 701 H-29 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER..................................................................................................................... 702 H-30 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK............................................................................................................................... 703 H-31 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET..................................................................................................................................... 703 H-32 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT.................................................................................................................................. 703 H-33 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE “HOLD”).................................................................................................. 704 H-34 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT........................................................................................................... 704 H-35 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY................................................................................................................................. 705 TROUBLESHOOTING OF JOYSTICK STEERING CONTROL SYSTEM (J MODE)......................................................................................................................... 706 JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL SYSTEM RELATED PARTS............................................................................................................... 707 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................... 708 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING CONTROL SYSTEM.................................................................................................................. 712 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED........................................................................................ 714 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED................................................................... 715 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED.................................................................... 716 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................................................................ 717 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................................................................. 718 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED.......................................................................... 719 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED........................................................................... 720 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED....................................................................... 721 J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE............................................................................................................................ 722 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT............................................................................................................................. 723 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID.................................................................................................................................... 724 J-12 DISCONNECTION IN STEERING LEFT SOLENOID..................................................................................................................................... 725 TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE).................................................................................................. 726 JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM...................................................................................................... 727 OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY..................................................................................... 728 ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL............................................................................................. 732 A-1 ERROR CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED............................................................. 734 A-2 ERROR CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED...................................................... 735 A-3 ERROR CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED....................................................................... 736 A-4 ERROR CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED............................................................... 737 A-5 ERROR CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED.............................................. 738 A-6 ERROR CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED................................................. 739 A-7 ERROR CODE [63] (DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND, OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED.... 740 A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT............................................................................................................................. 741 A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)............................................................... 742 A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE..................................................................................................................................... 743 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................. 744 HOW TO READ THIS MANUAL.................................................................................................................................................................. 746 STANDARD TIGHTENING TORQUE TABLE......................................................................................................................................................... 748 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................................. 752 METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER............................................................................................................................ 755 COATING MATERIALS LIST................................................................................................................................................................... 758 SPECIAL TOOL LIST........................................................................................................................................................................ 761 SKETCHES OF SPECIAL TOOLS................................................................................................................................................................ 768 STARTING MOTOR........................................................................................................................................................................... 776 REMOVAL AND INSTALLATION............................................................................................................................................................. 776 ALTERNATOR............................................................................................................................................................................... 777 REMOVAL AND INSTALLATION............................................................................................................................................................. 777 ENGINE OIL COOLER........................................................................................................................................................................ 778 REMOVAL AND INSTALLATION............................................................................................................................................................. 778 FUEL INJECTION PUMP FOR LEFT BANK........................................................................................................................................................ 779 REMOVAL AND INSTALLATION (WITH GOVERNOR)............................................................................................................................................. 779 FUEL INJECTION PUMP FOR RIGHT BANK....................................................................................................................................................... 780 REMOVAL AND INSTALLATION (WHTHOUT GOVERNOR).......................................................................................................................................... 780 WATER PUMP............................................................................................................................................................................... 781 REMOVAL AND INSTALLATION............................................................................................................................................................. 781 NOZZLE HOLDER............................................................................................................................................................................ 782 REMOVAL AND INSTALLATION............................................................................................................................................................. 782 TURBOCHARGER............................................................................................................................................................................. 783 REMOVAL AND INSTALLATION............................................................................................................................................................. 783 ENGINE FRONT SEAL........................................................................................................................................................................ 784 REMOVAL AND INSTALLATION............................................................................................................................................................. 784 ENGINE REAR SEAL......................................................................................................................................................................... 786 REMOVAL AND INSTALLATION............................................................................................................................................................. 786 CYLINDER HEAD............................................................................................................................................................................ 788 REMOVAL.............................................................................................................................................................................. 788 INSTALLATION......................................................................................................................................................................... 792 RADIATOR................................................................................................................................................................................. 795 REMOVAL.............................................................................................................................................................................. 795 INSTALLATION......................................................................................................................................................................... 798 ENGINE................................................................................................................................................................................... 799 REMOVAL.............................................................................................................................................................................. 799 INSTALLATION......................................................................................................................................................................... 805 DAMPER................................................................................................................................................................................... 806 REMOVAL AND INSTALLATION............................................................................................................................................................. 806 DISASSEMBLY.......................................................................................................................................................................... 807 ASSEMBLY............................................................................................................................................................................. 809 TORQUE CONVERTER AND TRANSMISSION ASSEMBLY............................................................................................................................................... 813 REMOVAL.............................................................................................................................................................................. 813 INSTALLATION......................................................................................................................................................................... 820 TORQUE CONVERTER......................................................................................................................................................................... 822 DISASSEMBLY.......................................................................................................................................................................... 822 ASSEMBLY............................................................................................................................................................................. 826 TORQUE CONVERTER VALVE................................................................................................................................................................... 831 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................. 831 TRANSMISSION ............................................................................................................................................................................ 832 DISASSEMBLY.......................................................................................................................................................................... 832 ASSEMBLY............................................................................................................................................................................. 848 TRANSMISSION VALVE....................................................................................................................................................................... 865 REMOVAL AND INSTALLATION............................................................................................................................................................. 865 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................. 866 TRANSFER................................................................................................................................................................................. 870 DISASSEMBLY.......................................................................................................................................................................... 870 ASSEMBLY............................................................................................................................................................................. 878 PTO...................................................................................................................................................................................... 888 DISASSEMBLY.......................................................................................................................................................................... 888 ASSEMBLY............................................................................................................................................................................. 890 CENTER SUPPORT........................................................................................................................................................................... 893 REMOVAL.............................................................................................................................................................................. 893 INSTALLATION......................................................................................................................................................................... 894 DISASSEMBLY.......................................................................................................................................................................... 895 ASSEMBLY............................................................................................................................................................................. 897 DRIVE SHAFT.............................................................................................................................................................................. 900 DISASSEMBLY.......................................................................................................................................................................... 900 ASSEMBLY............................................................................................................................................................................. 902 FRONT AXLE............................................................................................................................................................................... 904 REMOVAL.............................................................................................................................................................................. 904 INSTALLATION......................................................................................................................................................................... 906 REAR AXLE................................................................................................................................................................................ 907 REMOVAL.............................................................................................................................................................................. 907 INSTALLATION......................................................................................................................................................................... 913 DIFFERENTIAL............................................................................................................................................................................. 914 REMOVAL.............................................................................................................................................................................. 914 INSTALLATION......................................................................................................................................................................... 916 DISASSEMBLY.......................................................................................................................................................................... 917 ASSEMBLY............................................................................................................................................................................. 921 FINAL DRIVE.............................................................................................................................................................................. 927 DISASSEMBLY.......................................................................................................................................................................... 927 ASSEMBLY............................................................................................................................................................................. 930 ORBIT-ROLL............................................................................................................................................................................... 933 REMOVAL.............................................................................................................................................................................. 933 INSTALLATION......................................................................................................................................................................... 934 EMERGENCY STEERING PUMP.................................................................................................................................................................. 935 REMOVAL AND INSTALLATION............................................................................................................................................................. 935 DIVERTER VALVE........................................................................................................................................................................... 936 REMOVAL AND INSTALLATION............................................................................................................................................................. 936 DISASSEMBLY.......................................................................................................................................................................... 937 ASSEMBLY............................................................................................................................................................................. 938 ACCUMULATOR CHARGE VALVE................................................................................................................................................................. 940 REMOVAL AND INSTALLATION............................................................................................................................................................. 940 DISASSEMBLY.......................................................................................................................................................................... 941 ASSEMBLY............................................................................................................................................................................. 942 STEERING STOP VALVE...................................................................................................................................................................... 944 REMOVAL AND INSTALLATION............................................................................................................................................................. 944 STEERING CYLINDER........................................................................................................................................................................ 945 REMOVAL.............................................................................................................................................................................. 945 INSTALLATION......................................................................................................................................................................... 946 STEERING VALVE........................................................................................................................................................................... 951 REMOVAL.............................................................................................................................................................................. 951 INSTALLATION......................................................................................................................................................................... 952 BRAKE VALVE.............................................................................................................................................................................. 953 REMOVAL AND INSTALLATION............................................................................................................................................................. 953 SLACK ADJUSTER........................................................................................................................................................................... 954 REMOVAL AND INSTALLATION............................................................................................................................................................. 954 DISASSEMBLY.......................................................................................................................................................................... 955 ASSEMBLY............................................................................................................................................................................. 956 BRAKE.................................................................................................................................................................................... 957 REMOVAL AND INSTALLATION............................................................................................................................................................. 957 DISASSEMBLY.......................................................................................................................................................................... 958 ASSEMBLY............................................................................................................................................................................. 961 PARKING BRAKE CALIPERS................................................................................................................................................................... 965 REMOVAL AND INSTALLATION............................................................................................................................................................. 965 DISASSEMBLY.......................................................................................................................................................................... 966 ASSEMBLY............................................................................................................................................................................. 968 PARKING BRAKE PAD........................................................................................................................................................................ 970 REMOVAL AND INSTALLATION............................................................................................................................................................. 970 PARKING BRAKE SPRING CYLINDER............................................................................................................................................................ 971 REMOVAL AND INSTALLATION............................................................................................................................................................. 971 BRAKE OIL TANK........................................................................................................................................................................... 972 REMOVAL AND INSTALLATION............................................................................................................................................................. 972 HYDRAULIC PUMP........................................................................................................................................................................... 973 REMOVAL.............................................................................................................................................................................. 973 INSTALLATION......................................................................................................................................................................... 975 SERVO CYLINDER........................................................................................................................................................................... 976 REMOVAL AND INSTALLATION............................................................................................................................................................. 976 HYDRAULIC TANK AND FILTER CASE ASSEMBLY.................................................................................................................................................. 977 REMOVAL.............................................................................................................................................................................. 977 INSTALLATION......................................................................................................................................................................... 978 PPC VALVE................................................................................................................................................................................ 979 REMOVAL.............................................................................................................................................................................. 979 INSTALLATION......................................................................................................................................................................... 980 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................. 981 WORK EQUIPMENT CONTROL VALVE............................................................................................................................................................. 982 REMOVAL.............................................................................................................................................................................. 982 INSTALLATION......................................................................................................................................................................... 983 DISASSEMBLY.......................................................................................................................................................................... 984 ASSEMBLY............................................................................................................................................................................. 986 CAB...................................................................................................................................................................................... 988 REMOVAL.............................................................................................................................................................................. 988 INSTALLATION......................................................................................................................................................................... 990 FLOOR FRAME.............................................................................................................................................................................. 991 REMOVAL.............................................................................................................................................................................. 991 INSTALLATION......................................................................................................................................................................... 993 CENTER HINGE PIN......................................................................................................................................................................... 994 REMOVAL.............................................................................................................................................................................. 994 INSTALLATION.........................................................................................................................................................................1000 WORK EQUIPMENT...........................................................................................................................................................................1006 REMOVAL..............................................................................................................................................................................1006 INSTALLATION.........................................................................................................................................................................1011 BOOM FRONT END BUSH......................................................................................................................................................................1012 REPLACEMENT..........................................................................................................................................................................1012 BUCKET CYLINDER..........................................................................................................................................................................1013 REMOVAL AND INSTALLATION.............................................................................................................................................................1013 LIFT CYLINDER............................................................................................................................................................................1014 REMOVAL..............................................................................................................................................................................1014 INSTALLATION.........................................................................................................................................................................1015 HYDRAULIC CYLINDER.......................................................................................................................................................................1016 DISASSEMBLY..........................................................................................................................................................................1016 ASSEMBLY.............................................................................................................................................................................1018 AIR CONDITIONER UNIT.....................................................................................................................................................................1020 REMOVAL..............................................................................................................................................................................1020 INSTALLATION.........................................................................................................................................................................1021 AIR CONDITIONER COMPRESSOR...............................................................................................................................................................1022 REMOVAL AND INSTALLATION.............................................................................................................................................................1022 RECEIVER TANK............................................................................................................................................................................1023 REMOVAL AND INSTALLATION.............................................................................................................................................................1023 AIR CONDITIONER CONDENSER................................................................................................................................................................1024 REMOVAL AND INSTALLATION.............................................................................................................................................................1024 TRANSMISSION AND STEERING CONTROLLER.....................................................................................................................................................1025 REMOVAL AND INSTALLATION.............................................................................................................................................................1025 MAIN MONITOR.............................................................................................................................................................................1026 REMOVAL..............................................................................................................................................................................1026 INSTALLATION.........................................................................................................................................................................1027 FUEL TANK................................................................................................................................................................................1028 REMOVAL..............................................................................................................................................................................1028 INSTALLATION.........................................................................................................................................................................1029 COUNTERWEIGHT............................................................................................................................................................................1030 REMOVAL AND INSTALLATION.............................................................................................................................................................1030 40 MAINTENANCE STANDARD......................................................................................................................................................................1031 ENGINE MOUNT.............................................................................................................................................................................1032 TRANSMISSION MOUNT.......................................................................................................................................................................1033 DAMPER...................................................................................................................................................................................1034 TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP............................................................................................................................................1036 TORQUE CONVERTER.........................................................................................................................................................................1038 TORQUE CONVERTER REGULATOR VALVE.........................................................................................................................................................1039 TRANSMISSION.............................................................................................................................................................................1040 TRANSFER.................................................................................................................................................................................1043 TRANSMISSION CONTROL VALVE...............................................................................................................................................................1045 DRIVE SHAFT..............................................................................................................................................................................1050 CENTER SUPPORT...........................................................................................................................................................................1051 DIFFERENTIAL.............................................................................................................................................................................1052 FINAL DRIVE..............................................................................................................................................................................1055 AXLE MOUNT...............................................................................................................................................................................1057 CENTER HINGE PIN.........................................................................................................................................................................1059 STEERING COLUMN..........................................................................................................................................................................1061 STEERING DEMAND VALVE....................................................................................................................................................................1062 DIVERTER VALVE...........................................................................................................................................................................1064 STEERING CYLINDER MOUNT..................................................................................................................................................................1065 EMERGENCY STEERING PUMP..................................................................................................................................................................1066 BRAKE VALVE..............................................................................................................................................................................1067 SLACK ADJUSTER...........................................................................................................................................................................1070 BRAKE....................................................................................................................................................................................1071 PARKING BRAKE............................................................................................................................................................................1073 PPC VALVE................................................................................................................................................................................1075 PPC RELIEF VALVE.........................................................................................................................................................................1077 STEERING PUMP............................................................................................................................................................................1078 SWITCH PUMP..............................................................................................................................................................................1080 MAIN PISTON PUMP.........................................................................................................................................................................1082 CONTROL PUMP (BAR025)....................................................................................................................................................................1084 COOLING FAN MOTOR........................................................................................................................................................................1085 MAIN CONTROL VALVE.......................................................................................................................................................................1086 HYDRAULIC CYLINDER.......................................................................................................................................................................1090 BUCKET LINKAGE ..........................................................................................................................................................................1091 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................................................................1093 BRAKE COOLING PUMP.......................................................................................................................................................................1094 90 OTHERS....................................................................................................................................................................................1095 ELECTRIC CIRCUIT DIAGRAM [1/22]..........................................................................................................................................................1096 ELECTRIC CIRCUIT DIAGRAM [2/22]..........................................................................................................................................................1097 ELECTRIC CIRCUIT DIAGRAM [3/22]..........................................................................................................................................................1098 ELECTRIC CIRCUIT DIAGRAM [4/22]..........................................................................................................................................................1099 ELECTRIC CIRCUIT DIAGRAM [5/22]..........................................................................................................................................................1100 ELECTRIC CIRCUIT DIAGRAM [6/22]..........................................................................................................................................................1101 ELECTRIC CIRCUIT DIAGRAM [7/22]..........................................................................................................................................................1102 ELECTRIC CIRCUIT DIAGRAM [8/22]..........................................................................................................................................................1103 ELECTRIC CIRCUIT DIAGRAM [9/22]..........................................................................................................................................................1104 ELECTRIC CIRCUIT DIAGRAM [10/22].........................................................................................................................................................1105 ELECTRIC CIRCUIT DIAGRAM [11/22].........................................................................................................................................................1106 ELECTRIC CIRCUIT DIAGRAM [12/22].........................................................................................................................................................1107 ELECTRIC CIRCUIT DIAGRAM [13/22].........................................................................................................................................................1108 ELECTRIC CIRCUIT DIAGRAM [14/22].........................................................................................................................................................1109 ELECTRIC CIRCUIT DIAGRAM [15/22].........................................................................................................................................................1110 ELECTRIC CIRCUIT DIAGRAM [16/22].........................................................................................................................................................1111 ELECTRIC CIRCUIT DIAGRAM [17/22].........................................................................................................................................................1112 ELECTRIC CIRCUIT DIAGRAM [18/22].........................................................................................................................................................1113 ELECTRIC CIRCUIT DIAGRAM [19/22].........................................................................................................................................................1114 ELECTRIC CIRCUIT DIAGRAM [20/22].........................................................................................................................................................1115 ELECTRIC CIRCUIT DIAGRAM [21/22].........................................................................................................................................................1116 ELECTRIC CIRCUIT DIAGRAM [22/22].........................................................................................................................................................1117 WITH ELECTRONIC GOVERNOR.................................................................................................................................................................1118 TROUBLESHOOTING OF ELECTRONIC GOVERNOR SYSTEM (G MODE)...............................................................................................................................1119 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS...................................................................................................................1120 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS......................................................................................................1122 ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS..................................................................................................1130 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM.................................................................................................1131 JUDGEMENT TABLE FOR ENGINE CONTROLLER............................................................................................................................................1133 G-1 [90] [OFF OR 10] ABNORMALITY IN POWER SOURCE SYSTEM..........................................................................................................................1134 G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM...................................................................................................................................1134 G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR...................................................................................................................................1135 G-4 [90] [56] ABNORMALITY IN RIGHT BANK SOLENOID POWER SOURCE SYSTEM.............................................................................................................1135 G-5 [90] [57] ABNORMALITY IN LEFT BANK SOLENOID POWER SOURCE SYSTEM..............................................................................................................1135 G-6 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM.........................................................................................................................1136 G-7 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM..........................................................................................................................1137 G-8 [91] [14] ABNORMALITY IN RIGHT BANK GOVERNOR SOLENOID SYSTEM.................................................................................................................1138 G-9 [91] [15] ABNORMALITY IN LEFT BANK GOVERNOR SOLENOID SYSTEM..................................................................................................................1139 G-10 [91] [16] ABNORMALITY IN RIGHT BANK GOVERNOR CUT RELAY SYSTEM...............................................................................................................1140 G-11 [91] [17] ABNORMALITY IN LEFT BANK GOVERNOR CUT RELAY SYSTEM................................................................................................................1141 G-12 [91] [19] ABNORMALITY IN RIGHT BANK GOVERNOR SERVO SYSTEM...................................................................................................................1142 G-13 [91] [1A] ABNORMALITY IN LEFT BANK GOVERNOR SERVO SYSTEM....................................................................................................................1143 G-14 [91] [1d] ABNORMALITY IN RIGHT BANK PRE-STROKE SOLENOID SYSTEM..............................................................................................................1144 G-15 [91] [1E] ABNORMALITY IN LEFT BANK PRE-STROKE SOLENOID SYSTEM...............................................................................................................1145 G-16 [92] [12] ABNORMALITY IN RIGHT BANK RACK SENSOR SYSTEM......................................................................................................................1146 G-17 [92] [13] ABNORMALITY IN LEFT BANK RACK SENSOR SYSTEM.......................................................................................................................1147 G-18 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM....................................................................................................................1148 G-19 [93] [1b] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM.......................................................................................................................1149 G-20 [94] [1c] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM.......................................................................................................................1150 G-21 [93, 94] [1b, 1c] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM............................................................................................................1151 G-22 [95] [40] ABNORMALITY IN ENGINE WATER TEMPERATURE SENSOR SYSTEM.............................................................................................................1151 G-23 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM..........................................................................................................................1152 G-24 [98] [18] ABNORMALITY IN MODEL SELECTION....................................................................................................................................1154 G-25 [99] [22] ENGINE OVERRUN....................................................................................................................................................1155 G-26 ENGINE DOES NOT START.......................................................................................................................................................1155 G-27 ENGINE DOES NOT STOP........................................................................................................................................................1159
KOMATSU WA900-3 AVANCE LOADER WHEEL LOADER SHOP MANUAL 50001 AND UP – PDF DOWNLOAD:
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