Komatsu WA900L-3 Avance Loader Shop Manual SEBM035708 – PDF DOWNLOAD 

Description

Komatsu WA900L-3 Avance Loader Shop Manual SEBM035708 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA900L-3 Avance Loader Shop Manual SEBM035708 – PDF DOWNLOAD 

Language : English
Pages : 886
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA900L-3 Avance Loader Shop Manual SEBM035708 – PDF DOWNLOAD 

MACHINE MODEL          SERIAL NUMBER
WA900L-3                         52001 and up

FOREWORD
GENERAL:

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
  accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service
  workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu WA900L-3 Avance Loader Shop Manual SEBM035708 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 34
LIST OF LUBRICANT AND WATER 36
10 STRUCTURE AND FUNCTION 45
POWER TRAIN 46
POWER TRAIN SYSTEM 47
ENGINE CONTROL 48
RADIATOR AND COOLER 50
DAMPER 52
TORQUE CONVERTER AND TRANSMISSION PIPING 53
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 54
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 55
TORQUE CONVERTER 56
TRANSMISSION 61
TRANSFER 69
TRANSMISSION CONTROL VALVE 70
TORQUE CONVERTER OIL COOLER 86
DRIVE SHAFT 87
CENTER SUPPORT 88
AXLE 89
DIFFERENTIAL 91
FINAL DRIVE 94
CENTER HINGE PIN 95
AXLE MOUNT 96
TIRE AND WHEEL 98
STEERING PIPING 99
JOYSTICK STEERING LINKAGE 100
STEERING PUMP 102
SWITCH PUMP 105
STEERING DEMAND VALVE 113
EPC VALVE 124
ROTARY VALVE 125
TWO-WAY RESTRICTOR VALVE 127
DIVERTER VALVE 128
BRAKE PIPING 132
BRAKE CIRCUIT DIAGRAM 134
BRAKE VALVE 136
CHARGE VALVE 141
ACCUMULATOR (FOR BRAKE) 145
SLACK ADJUSTER 146
BRAKE 149
PARKING BRAKE 150
SPRING CYLINDER 152
PARKING BRAKE SOLENOID VALVE 153
HYDRAULIC PIPING 154
WORK EQUIPMENT LEVER LINKAGE 157
HYDRAULIC TANK 158
MAIN PISTON PUMP 161
ES VALVE (ENGINE SENSING VALVE) 169
SERVO VALVE 171
PPC VALVE (PROPORTIONAL PRESSURE VALVE) 174
PPC RELIEF VALVE 178
ACCUMULATOR (FOR PPC VALVE) 179
MAIN CONTROL VALVE 180
LUBRICATION OF WORK EQUIPMENT 193
WORK EQUIPMENT LINKAGE 196
BUCKET POSITIONER AND BOOM KICK-OUT 198
OPERATION OF PROXIMITY SWITCH 200
CRB AND ROPS CANOPY 204
AIR CONDITIONER 206
MACHINE MONITOR SYSTEM 210
MAIN MONITOR 211
MAINTENANCE MONITOR 215
ENGINE STARTING CIRCUIT 218
ENGINE STOP CIRCUIT 221
PREHEATING CIRCUIT 222
ELECTRICAL TRANSMISSION CONTROL 223
KICK-DOWN, HOLD SWITCH 224
AUTOMATIC TRANSMISSION (ATM) SYSTEM 225
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) 235
ELECTRIC PARKING BRAKE CONTROL 240
20 TESTING AND ADJUSTING 249
STANDARD VALVE TABLE FOR ENGINE 250
STANDARD VALVE TABLE FOR CHASSIS 251
STANDARD VALVE TABLE FOR ELECTRICAL PARTS 257
TESTING AND ADJUSTING 267
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 268
MEASURING ENGINE SPEED 270
MEASURING EXHAUST GAS COLOR 271
ADJUSTING VALVE CLEARANCE 272
MEASURING COMPRESSION PRESSURE 272
MEASURING BLOW-BY PRESSURE 272
TESTING AND ADJUSTING FUEL INJECTION TIMING 272
MEASURING ENGINE OIL PRESSURE 272
MEASURING EXHAUST TEMPERATURE 272
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 272
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 273
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 274
MEASURING ACCELERATOR PEDAL 275
TESTING OF UPPER DRIVE SHAFT SLIDING PART 276
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE 278
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS 280
TESTING AND ADJUSTING STEERING OIL PRESSURE 282
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE 283
BLEEDING AIR FROM STEERING CIRCUIT 285
TESTING AND ADJUSTING STEERING STOPPER BOLT 286
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR 287
TESTING WHEEL BRAKE PERFORMANCE 288
TESTING WHEEL BRAKE OIL PRESSURE DROP 289
MEASURING WEAR OF WHEEL BRAKE DISC 291
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE 292
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS 294
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT 302
TESTING PARKING BRAKE PERFORMANCE 303
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE 304
CHECKING AND ADJUSTING PARKING BRAKE PAD 305
TESTING AND ADJUSTING PPC PRESSURE 307
ADJUSTING PPC VALVE LINKAGE 308
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 309
BLEEDING AIR FROM PISTON PUMP 311
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT 312
ADJUSTING WORK EQUIPMENT LEVER LINKAGE 313
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 314
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH 315
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH 315
TESTING PROXIMITY ACTUATION PILOT LAMP 316
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR 317
TROUBLESHOOTING 319
POINTS TO REMEMBER WHEN TROUBLESHOOTING 320
SEQUENCE OF EVENTS IN TROUBLESHOOTING 321
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 322
CHECKS BEFORE TROUBLESHOOTING 330
TYPES AND LOCATIONS OF CONNECTORS 331
CONNECTOR LOCATION STEREOGRAM 338
WIRING TABLE FOR CONNECTOR PIN NUMBERS 344
T-ADAPTER BOX AND T-ADAPTER TABLE 377
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM 380
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 384
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION 386
TRANSMISSION CONTROLLER LED DISPLAY 388
METHOD OF USING JUDGEMENT TABLE 389
METHOD OF USING TROUBLESHOOTING CHARTS 390
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 392
TROUBLESHOOTING OF ENGINE (S MODE) 395
METHOD OF USING TROUBLESHOOTING CHARTS 396
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 400
S-2 ENGINE DOES NOT START 401
(1) ENGINE DOES NOT TURN 401
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES UOT (FUEL IS NOT BEING INJECTED) (INCLUDING CASES WITH V-TYPE ENGINE WHERE THERE IS NO FUEL INJECTION FOR THE BANK ON ONE SIDE) 402
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 403
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 404
S-4 ENGINE STOPS DURING OPERATIONS (FOR V TYPE ENGINE, INCLUDING CASES WHERE ONE BANK STOPS) 405
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 406
S-6 ENGINE LACKS UOTPUT (NO POWER) (WITH V-TYPE ENGINE, FOR CASES WHERE THERE IS INJECTION FOR ONLY BANK,GO TO TROUBLESHOOTING S-2-(2)OR S-4) 407
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 408
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 409
S-9 OIL BECOMES CONTAMINATED QUICKLY 410
S-10 FUEL CONSUMPTION IS EXCESSIVE 411
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 412
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 413
S-13 OIL LEVEL RISES 414
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 415
S-15 ABNORMAL NOISE IS MADE 416
S-16 VIBRATION IS EXCESSIVE 417
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) 419
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS 420
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 422
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM 426
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED 428
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED 429
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED 430
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED 431
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED 432
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED 433
T-7 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVEL SWITCH SYSTEM) IS DISPLAYED 434
T-8 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED 435
T-9 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED 436
T-10 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 437
T-11 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM 438
T-12 TRANSMISSION CUT-OFF SIGNAL SYSTEM 439
T-13 NEUTRALIZER SIGNAL SYSTEM 440
T-14 BUZZER SIGNAL SYSTEM 441
T-15 NETWORK SYSTEM 442
T-16 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM 443
T-17 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 444
T-18 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS 445
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 447
TROUBLE DATA DISPLAY 449
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM 452
M-1 MAIN MONITOR DOES NOT WORK 454
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP 455
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 456
M-4 ABNORMALITY IN SHIFT INDICATOR 457
a) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT F 457
b) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT R 457
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL SWITCH IS AT N (DISPLAY 1ST-3RD) 457
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 459
a) L H TURN SIGNAL DISPLAY DOES NOT LIGHT UP 459
b) R H TURN SIGNAL DISPLAY DOES NOT LIGHT UP 459
M-6 ABNORMALITY IN PARKING DISPLAY 461
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP 461
b) PARKING LAMP DISPLAY STAYS LIGHT UP 461
M-7 NIGHT LIGHTING DOES NOT LIGHT UP 462
M-8 ABNORMALITY IN FRONT WORKING LAMP 464
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 464
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 464
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP 464
M-9 ABNORMALITY IN REAR WORKING LAMP 466
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 466
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 466
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP 466
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF 468
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE 468
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED 468
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED 468
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF) 468
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED 469
M-11 ABNORMALITY IN LOW IDLE SELECTION 470
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLE SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE 470
b) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLE SPEED DOES NOT RISE 470
c) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLE SPEED DOES NOT LOWER 471
M-12 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY 472
M-13 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY 473
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP 473
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP 473
M-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 474
a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL SWITCH IS AT N 474
b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL SWITCH IS AT POSITION OTHER THAN N 474
M-15 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED 475
a) ACTUATED CONTINUOUSLY 475
b) NOT ACTUATED 475
M-16 ABNORMALITY IN BUZZER 476
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK) 476
b) BUZZER ALWAYS SOUNDS 476
M-17 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 477
M-18 ABNORMALITY IN FAILURE DISPLAY MODE 478
a) DOES NOT ENTER FAILURE DISPLAY MODE 478
b) COUNT FOR TIME ELAPSED SINCE FAILURE DISPLAY MODE DOES NOT ADVANCE 478
M-19 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER 479
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM 480
a) CHECK POWER SUPPLY SYSTEM 1 (RELAY G1) 480
b) CHECK POWER SUPPLY SYSTEM 2 (RELAY G2) 480
c) FORCED GREASING DOES NOT START 481
d) MONITOR DOES NOT FLASH WHILE GREASE IS BEING SUPPLIED 481
e) MONITOR IS STILL FLASHING AFTER GREASING IS FINISHED, OR IT FLASHES FOR PERIOD SET WITH TIMER WHEN STARTING SWITCH IS TURNED TO ON POSITION 482
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 484
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 485
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM 486
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 488
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP 488
b) SOME LAMPS DO NOT LIGHT UP 488
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) 489
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT 490
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 492
a) ENGINE OIL LEVEL DISPLAY FLASHES 492
b) ENGINE WATER LEVEL DISPLAY FLASHES 493
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 494
a) ENGINE OIL PRESSURE DISPLAY FLASHES 494
b) BATTERY CHARGE LEVEL DISPLAY FLASHES 495
c) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE BRAKE OIL PRESSURE IS CORRECT) 496
d) AIR CLEANER (R H ) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (R H ) IS NOT CLOGGED) 498
e) AIR CLEANER (L H ) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (L H ) IS NOT CLOGGED) 499
f) TRANSMISSION OIL FILTER DISPLAY FLASHES (THE TRANSMISSION OIL FILTER MUST NOT BE CLOGGED) 500
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND 501
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS 502
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES 503
a) CHECK LAMP 503
b) CAUTION LAMP 503
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP 504
a) CHECK LAMP 504
b) CAUTION LAMP 504
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON 505
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF 506
K-12 SERVICE METER DOES NOT WORK 507
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 507
K-14 ABNORMALITY IN GAUGE DISPLAY 509
a) ABNORMALITY IN FUEL GAUGE 509
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 510
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 511
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 513
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING 514
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE 516
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER 517
E-1 ENGINE DOES NOT START 518
a) STARTING MOTOR DOES NOT TURN 518
b) STARTING MOTOR TURNS 522
E-2 ENGINE DOES NOT STOP 523
E-3 ABNORMALITY IN PREHEATING SYSTEM 526
a) DOES NOT CARRY OUT PREHEATING 526
b) ONLY MONITOR DISPLAY LIGHTS UP 526
c) MONITOR DISPLAY DOES NOT LIGHT UP WHEN PREHEATING IS COMPLETED 527
d) MONITOR DISPLAY KEEPS LIGHTING UP WHEN PREHEATING IS NOT COMPLETED 527
E-4 PARKING BRAKE DOES NOT HAVE EFFECT 529
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON 529
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE) 529
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 530
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNDED ON 532
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY) 532
E-8 KICK-DOWN SWITCH DOES NOT WORK 534
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY 534
b) KICK-DOWN CANNOT BE CANCELED 535
E-9 BOOM KICK-OUT DOES NOT WORK 536
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION 540
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP 543
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP 543
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF 543
E-14 ABNORMALITY IN LOW IDLING SELECTION 543
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 543
E-16 ABNORMALITY IN BUZZER 543
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 545
H-1 MACHINE DOES NOT MOVE 546
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE) 547
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 548
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 549
H-5 STEERING DOES NOT TURN 550
H-6 TURNING,RESPONSE OF STEERING IS POOR 551
H-7 JOYSTICK LEVEL IS HEAVY 552
H-8 STEERING WHEEL SHAKES OR JERKS 553
H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT 554
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 555
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 556
H-12 BOOM DOES NOT RISE 557
H-13 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER 558
H-14 WHEN RAISING BOOM,BECOMES SLOW AT CERTAIN HEIGHT 559
H-15 BOOM CYLINDER CANNOT HOLD DOWN BUCKET 559
H-16 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT 559
H-17 BOOM FLUCTUATES WHILE WORKING 560
H-18 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE 560
H-19 BUCKET DOES NOT TILT BACK 561
H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER 562
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK 563
H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET 563
H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT 563
H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE “HOLD”) 564
H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT 564
H-26 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY 565
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE) 567
JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM 568
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY 570
ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL 574
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED 576
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED 577
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGEL SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED 578
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED 579
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED 580
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED 581
A-7 FAILURE CODE [63] (DISCONNECTION,SHORT CIRCUIT WITH CHASSIS GROUND, OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED 582
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT 583
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE) 584
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE 585
30 DISASSEMBLY AND ASSEMBLY 587
METHOD OF USING MANUAL 589
STANDARD TIGHTENING TORQUE TABLE 591
PRECAUTIONS WHEN CARRYING OUT OPERATION 595
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER 598
COATING MATERIALS LIST 601
SPECIAL TOOL LIST 605
SKETCHES OF SPECIAL TOOLS 611
ENGINE RELATED PARTS 619
STARTING MOTOR 619
ALTERNATOR 619
ENGINE OIL COOLER 619
FUEL INJECTION PUMP FOR LEFT BANK 619
FUEL INJECTION PUMP FOR RIGHT BANK 619
WATER PUMP 619
NOZZELE HODLER 619
TURBOCHARGER 619
ENGINE FRONT SEAL 619
ENGINE REAR SEAL 619
CYLINDER HEAD 619
REMOVAL AND INSTALLATION OF RADIATOR 620
REMOVAL AND INSTALLATION OF ENGINE 623
REMOVAL AND INSTALLATION OF DAMPER 628
DISASSEMBLY AND ASSEMBLY OF DAMPER 629
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 633
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER 640
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE 647
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION 648
REMOVAL AND INSTALLATION OF TRANSMISSION VALVE 672
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE 673
DISASSEMBLY AND ASSEMBLY OF TRANSFER 677
DISASSEMBLY AND ASSEMBLY OF PTO 691
REMOVAL AND INSTALLATION OF CENTER SUPPORT 696
DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT 698
DISASSEMBLY AND ASSEMBLY OF DRIVE SHAFT 702
REMOVAL AND INSTALLATION OF FRONT AXLE 705
REMOVAL AND INSTALLATION OF REAR AXLE 707
REMOVAL AND INSTALLATION OF DIFFERENTIAL 712
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL 714
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE 722
REMOVAL AND INSTALLATION OF ROTARY VALVE 727
REMOVAL AND INSTALLATION OF EMERGENCY STEERING PUMP 728
REMOVAL AND INSTALLATION OF DIVERTER VALVE 729
DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE 730
REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE 732
DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE 733
REMOVAL AND INSTALLATION OF STEERING CYLINDER 735
REMOVAL AND INSTALLATION OF STEERING VALVE 737
REMOVAL AND INSTALLATION OF BRAKE VALVE 739
REMOVAL AND INSTALLATION OF SLACK ADJUSTER 740
DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER 741
REMOVAL AND INSTALLATION OF BRAKE 743
DISASSEMBLY AND ASSEMBLY OF BRAKE 744
REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS 750
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS 751
REMOVAL AND INSTALLATION OF PARKING BRAKE PAD 753
REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER 754
REMOVAL AND INSTALLATION OF BRAKE OIL TANK 755
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP 756
REMOVAL AND INSTALLATOIN OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY 758
REMOVAL AND INSTALLATION OF PPC VALVE 760
DISASSEMBLY AND ASSEMBLY OF PPC VALVE 762
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY 763
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE 765
REMOVAL AND INSTALLATION OF CAB 768
REMOVAL AND INSTALLATION OF FLOOR FRAME 770
REMOVAL AND INSTALLATION OF CENTER HINGE PIN 773
REMOVAL AND INSTALLATION OF WORK EQUIPMENT 780
REPLACEMENT OF BOOM FRONT END BUSH 785
REMOVAL AND INSTALLATION OF BUCKET CYLINDER 786
REMOVAL AND INSTALLATION OF LIFT CYLINDER 787
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER 789
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT 793
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR 795
REMOVAL AND INSTALLATION OF RECEIVER TANK 796
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER 797
REMOVAL AND INSTALLATION OF TRANSMISSION AND JOYSTICK STEERING CONTROLLER 798
REMOVAL AND INSTALLATION OF MAIN MONITOR 799
REMOVAL AND INSTALLATION OF FUEL TANK 801
REMOVAL AND INSTALLATION OF COUNTERWEIGHT 803
REMOVAL AND INSTALLATION OF AJSS LEVER SWITCH ASSEMBLY 804
40 MAINTENANCE STANDARD 809
ENGINE MOUNT 810
TRANSMISSION MOUNT 811
DAMPER 812
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP 814
TORQUE CONVERTER 816
TORQUE CONVERTER REGULATOR VALVE 817
TRANSMISSION (1/2) 818
TRANSMISSION (2/2) 820
TRANSFER 821
TRANSMISSION CONTROL VALVE 822
DRIVE SHAFT 827
CENTER SUPPORT 828
DIFFERENTIAL (1/2) 829
DIFFERENTIAL (2/2) 830
FINAL DRIVE 832
AXLE MOUNT 834
CENTER HINGE PIN 836
STEERING DEMAND VALVE 838
DIVERTER VALVE 840
STEERING CYLINDER MOUNT 841
EMERGENCY STEERING PUMP 842
BRAKE VALVE 844
SLACK ADJUSTER 847
BRAKE 848
PARKING BRAKE 850
PPC VALVE 852
PPC RELIEF VALVE 854
CONTROL PUMP 855
STEERING PUMP 856
SWITCH PUMP 857
MAIN PISTON PUMP 858
MAIN CONTROL VALVE 860
HYDRAULIC CYLINDER 862
WORK EQUIPMENT LINKAGE 864
BUCKET POSITIONER AND BOOM KICK-OUT 866
ROPS CANOPY 867
90 OTHERS 869
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 871
ELECTRIC CIRCUIT DIAGRAM (1/5) 873
ELECTRIC CIRCUIT DIAGRAM (2/5) 875
ELECTRIC CIRCUIT DIAGRAM (3/5) 877
ELECTRIC CIRCUIT DIAGRAM (4/5) 879
ELECTRIC CIRCUIT DIAGRAM (5/5) 881
ELECTRIC CIRCUIT DIAGRAM (ENGINE SHUT-DOWN) 883
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING) 885

IMAGES PREVIEW OF THE MANUAL:

S.V  17/12/24