Komatsu Wheel Loader WA700-3 Shop Manual SEBM032802 – PDF DOWNLOAD

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Komatsu Wheel Loader WA700-3 Shop Manual SEBM032802 – PDF DOWNLOAD

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Komatsu Wheel Loader WA700-3 Shop Manual SEBM032802 – PDF DOWNLOAD

Language : English
Pages :809
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Wheel Loader WA700-3 Shop Manual SEBM032802 – PDF DOWNLOAD

MACHINE MODEL SERIAL NO.
WA700-3 51005 and up

FOREWORD
GENERAL

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

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

TABLE OF CONTENTS:

Komatsu Wheel Loader WA700-3 Shop Manual SEBM032802 – PDF DOWNLOAD

MACHINE MODEL SERIAL NO.
WA700-3 51005 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 8
SAFETY NOTICE 8
FOREWORD 10
GENERAL 10
HOW TO READ THE SHOP MANUAL 11
HOISTING INSTRUCTIONS 12
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 13
COATING MATERIALS 15
STANDARD TIGHTENING TORQUE 17
ELECTRIC WIRE CODE 20
CONVERSION TABLE 21
UNITS 27
01 GENERAL 28
GENERAL ASSEMBLY DRAWING 29
SPECIFICATIONS 30
WEIGHT TABLE 33
LIST OF LUBRICANT AND WATER 35
10 STRUCTURE AND FUNCTION 38
OUTLINE 39
POWER TRAIN SYSTEM 41
DAMPER 43
RADIATOR AND OIL COOLER 44
TORQUE CONVERTER AND TRANSMISSION PIPING 45
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 47
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 49
TORQUE CONVERTER AND PTO 51
TORQUE CONVERTER REGULATOR VALVE 54
TRANSMISSION 56
TRANSMISSION CONTROL VALVE 65
TORQUE CONVERTER OIL COOLER 85
TRANSMISSION OIL FILTER 86
TRANSFER 88
AXLE 89
DIFFERENTIAL 91
FINAL DRIVE 94
AXLE MOUNT 97
CENTER HINGE PIN 99
JOYSTICK STEERING LINKAGE100
STEERING AND SWITCH PUMP101
SWITCH PUMP CUT-OFF SOLENOID103
STEERING DEMAND VALVE104
EPC VALVE115
ROTARY VALVE116
TWO WAY RESTRICTOR VALVE119
DIVERTER VALVE120
BRAKE PIPING124
BRAKE CIRCUIT DIAGRAM125
BRAKE VALVE127
CHARGE VALVE133
ACCUMULATOR (FOR BRAKE)137
SLACK ADJUSTER138
BRAKE141
PARKING BRAKE143
SPRING CYLINDER145
PARKING BRAKE SOLENOID VALVE146
HYDRAULIC PIPING147
HYDRAULIC CIRCUIT DIAGRAM149
MAIN PISTON PUMP152
ES • CO VALVE160
SERVO VALVE161
PRESSURE DIFFERENTIAL VALVE162
PPC VALVE (PROPORTIONAL PRESSURE VALVE)163
PPC RELIEF VALVE167
ACCUMULATOR (FOR PPC VALVE)168
MAIN CONTROL VALVE169
LUBRICATION OF WORK EQUIPMENT183
WORK EQUIPMENT LINKAGE185
BUCKET POSITIONER AND BOOM KICK-OUT187
OPERATION OF PROXIMITY SWITCH189
AIR CONDITIONER193
ELECTRIC CIRCUIT DIAGRAM196
MACHINE MONITOR SYSTEM196
MAIN MONITOR197
MAINTENANCE MONITOR201
AUTOMATIC TRANSMISSION SYSTEM (ATM)203
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)214
TRANSMISSION AND JOYSTICK CONTROLLER219
ENGINE STARTING CIRCUIT221
ENGINE STOP CIRCUIT222
PREHEATING CIRCUIT223
FUEL SYSTEM224
KICK-DOWN, HOLD SWITCH225
ELECTRIC PARKING BRAKE CONTROL226
ELECTRIC CIRCUIT OF ACTIVE POWER MAXIMIZING FUNCITON235
[RELATED TO VHMS CONTROLLER]241
VHMS CONTROLLER241
BLOW-BY PRESSURE SENSOR241
ENGINE OIL TEMPERATURE SENSOR242
EXHAUST TEMPERATURE SENSOR/AMP243
AMBIENT TEMPERATURE SENSOR243
TRANSMISSION PUMP OIL PRESSURE SENSOR244
BRAKE OIL TEMPERATURE SENSOR AND HYDRAULIC OIL TEMPERATURE SENSOR245
BRAKE OIL PRESSURE SENSOR, STEERING OIL PRESSURE SENSOR AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR246
COMMUNICATIONS (ORB: ORBCOMM) CONTROLLER/ANTENNA247
20 TESTING AND ADJUSTING249
STANDARD VALUE TABLE FOR ENGINE250
STANDARD VALUE TABLE FOR CHASSIS251
STANDARD VALUE TABLE FOR ELECTRICAL PARTS256
TESTING AND ADJUSTING265
TABLE OF TOOLS FOR TESING, ADJUSTING, AND TROUBLESHOOTING266
ADJUSTING VALVE CLEARANCE268
MEASURING COMPRESSION PRESSURE269
MEASURING BLOW-BY PRESSURE271
MEASURING EXHAUST GAS COLOR272
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)273
MEASURING EXHAUST TEMPERATURE274
MEASURING ENGINE SPEED276
ADJUSTING SET LOAD OF INJECTOR278
TROUBLESHOOTING OF INJECTOR280
MEASURING FUEL CIRCUIT PRESSURE281
HANDLING EQUIPMENT IN FUEL CIRCUIT283
BLEEDING AIR FROM FUEL CIRCUIT284
ADJUSTING SPEED SENSORS286
TESTING AND ADJUSTING ALTERNATOR BELT TENSION287
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION288
MEASURING ACCELERATOR PEDAL289
ADJUSTING ACCELERATOR PEDAL TRAVEL, POTENTIOMETER290
ADJUSTING ACCELERATOR PEDAL MICRO SWITCH292
MEASURING TORQUE CONVERTER, TRANSMISSION HYDRAULIC PRESSURE293
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL295
TESTING AND ADJUSTING STEERING OIL PRESSURE297
ADJUSTING STEERING STOPPER BOLT298
ADJUSTING JOYSTICK STEERING299
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH300
TESTING BRAKE OIL PRESSURE301
MEASURING WEAR OF BRAKE DISC302
MEASURING BRAKE PERFORMANCE303
TESTING AND ADJUSTING PARKING BRAKE304
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE306
MEASURING PPC RELIEF VALVE HYDRAULIC PRESSURE307
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE309
BLEEDING AIR FROM THE PISTON PUMP311
ADJUSTING WORK EQUIPMENT LEVER LINKAGE312
TESTING AND ADJUSTING BUCKET POSITIONER314
TESTING AND ADJUSTING BOOM KICK-OUT315
TESTING AND ADJUSTING PROXIMITY SWITCH FOR ACTIVE POWER MAXIMIZING FUNCTION316
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP317
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)318
BLEEDING AIR319
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT320
PM CLINIC INSPECTION TABLE321
BASIC PRECAUTIONS323
OUTLINE326
SETTING UP VHMS CONTROLLER332
COLLECTION, TRANSMISSION OF DATA334
INSPECTION AND MAINTENANCE339
REPLACING PARTS339
TROUBLESHOOTING340
POINTS TO REMEMBER WHEN TROUBLESHOOTING 341
SEQUENCE OF EVENTS IN TROUBLESHOOTING342
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE343
CHECKS BEFORE TROUBLESHOOTING351
CONNECTOR TYPES AND MOUNTING LOCATIONS352
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS356
T-BRANCH BOX AND T-BRANCH TABLE379
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE381
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION383
TRANSMISSION CONTROLLER LED DISPLAY385
METHOD OF USING TROUBLESHOOTING CHARTS386
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)388
METHOD OF USING TROUBLESHOOTING CHARTS389
S-1 Starting performance is poor (starting always takes time)393
S-2 Engine does not start395
a) Engine does not turn395
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)397
c) Exhaust smoke comes out but engine does not start (fuel is being injected)399
S-3 Engine does not pick up smoothly (follow-up is poor)401
S-4 Engine stops during operations403
S-5 Engine does not rotate smoothly (hunting)405
S-6 Engine lacks output (or lacks power)407
S-7 Exhaust smoke is black (incomplete combustion)409
S-8 Oil consumption is excessive (or exhaust smoke is blue)411
S-9 Oil becomes contaminated quickly412
S-10 Fuel consumption is excessive413
S-11 Oil is in cooling water, or water spurts back, or water level goes down414
S-12 Oil pressure caution lamp lights up (drop in oil pressure)415
S-13 Oil level rises416
S-14 Water temperature becomes too high (overheating)417
S-15 Abnormal noise is made418
S-16 Vibration is excessive419
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)420
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM423
M-1 Main monitor does not work425
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up426
M-3 Speedometer display does not work properly427
M-4 Abnormality in shift indicator428
a) displays N even when directional lever is at F428
b) Displays N even when directional lever is at R428
c) Does not display N even when directional lever is at N, and displays R when directional lever is at F428
d) Does not display N even when directional lever is at N, and displays F when directional lever is at R429
e) Does not display 1st even when speed lever is at 1 (directional lever at F or R)429
f) Does not display 2nd even when speed lever is at 2 (directional lever at F or R)429
g) Does not display 3rd even when speed lever is at 3 (directional lever at F or R)430
h) Does not display 4th even when speed lever is at 4 (directional lever at F or R)430
M-5 Turn signal display does not light up432
a) LH turn signal display does not light up432
b) RH turn signal display does not light up432
M-6 Abnormality in parking display433
a) Parking lamp display does not light up433
b) Parking lamp display stays lighted up433
M-7 Night lighting does not light up434
M-8 Abnormality in front working lamp435
a) Neither monitor display nor front working lamp light up435
b) Working lamp lights up but monitor display does not light up435
c) Monitor display lights up but working lamp does not light up435
M-9 Abnormality in rear working lamp437
a) Neither monitor display nor rear working lamp light up437
b) Working lamp lights up but monitor display does not light up437
c) Monitor display lights up but working lamp does not light up437
M-10 Abnormality in transmission cut-off438
a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not change438
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated438
c) Transmission cut-off switch turned ON, but cut-off function is not actuated439
Auto-shift specification440
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change440
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off funciton is actuated when pedal is depressed440
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated440
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF)440
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated441
M-11 Abnormality in parking brake dragging warning442
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N442
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 N442
M-12 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated444
a) Actuated continuously 444
b) Not actuated444
M-13 Abnormality in buzzer445
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)445
b) Buzzer always sounds445
M-14 Condition of monitor switched is not stored in memory446
M-15 Abnormality in failure display mode447
a) Does not enter failure display mode447
b) Count for time elapsed since failure display mode does not advance447
M-16 Abnormality in emergency steering actuation display448
a) Emergency steering actuation display does not light up448
b) Emergency steering actuation display stays lighted up448
M-17 Abnormality in auto-greasing system449
a) Forced greasing cannot be carried out449
b) Monitor display flashes rapidly (2 times/sec)449
c) When no more grease remains, monitor display flashes rapidly (2 times/sec)449
d) Monitor display flashes slowly (1 time/sec)450
e) Monitor display goes out450
M-18 Abnormality in low idling select system451
a) Display does not change when switch is pressed451
b) Monitor display lights up but low idling select function does not work451
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)452
ELECTRICAL CIRCUIT DIAGRAM FOR K MODE SYSTEM453
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does not work454
a) No lamps on maintenance monitor light up454
b) Some lamps do not light up454
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds)455
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out456
K-4 When starting switch is turned ON (engine stopped), CHECK items flash457
a) Engine oil level display flashes457
b) Engine water level display flashes458
K-5 When starting switch is turned ON (engine started), CAUTION items flash459
a) Engine oil pressure display flashes (Check that the engine oil pressure is correct)459
b) Battery charge level display flashes460
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct)461
d) Air cleaner display flashes (Check that there is no clogging of the air cleaner)462
K-6 CAUTION items are flashing but caution buzzer does not sound463
K-7 There is no abnormality in monitor display but caution buzzer sounds464
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash465
a) CHECK lamp465
b) CAUTION lamp465
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up466
a) CHECK lamp466
b) CAUTION lamp466
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)467
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up468
K-12 Service meter does not work469
K-13 Service meter is running even when engine is stopped469
K-14 Abnormality is gauge items471
a) Abnormality is fuel gauge471
b) Abnormality in engine water temperature gauge472
c) Abnormality in torque converter oil temperature gauge473
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)474
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM475
ELECTRICAL CIRCUIT DIAGRAM FOR ACTIVE POWER UP SYSTEM477
E-1 Engine does not start479
E-2 Defective preheating484
E-3 Parking brake does not have effect486
a) Parking brake has no effect when parking brake switch is turned ON486
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure drops486
E-4 Parking brake is applied when machine is traveling487
E-5 Parking brake is released when starting switch is turned ON489
E-6 Transmission does not change to neutral when parking brake is applied, but parking brake works normally489
E-7 Transmission does not work properly492
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit493
b) No continuity in travel FORWARD solenoid circuit497
c) No continuity in travel REVERSE solenoid circuit499
d) Short circuit to chassis ground in directional solenoid circuit501
e) Abnormality in shift solenoid circuit507
f) Short circuit to chassis ground in shift solenoid circuit510
E-8 Kick-down switch does not work (shift works correctly during normal gear shift operations F1 – F4)515
E-9 Kick-down works only when kick-down switch is being turned ON (kick-down switch does not carry out self-hold operation)518
E-10 Kick-down always works519
E-11 Kick-down switch works even when traveling FORWARD in 2nd521
E-12 Boom Kick-out does not work523
E-13 Defective bucket positioner525
E-14 Power window does not work527
a) Window does not go up527
b) Window does not go down528
E-15 Defective operation of solenoid for power maximizing function531
a) Inspection of timer 1 and no-load relay system531
b) Inspection of neutral relay 1 and neutral relay 2 (Power supply system)533
c) Inspection of solenoid (U11) drive system)535
E-16 Abnormality in front working lamp540
E-17 Abnormality in rear working lamp540
E-18 Abnormality in transmission cut-off540
E-19 Abnormality in parking brake dragging warning540
E-20 Abnormality in buzzer540
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)542
METHOD OF USING MATRIX TROUBLESHOOTING TABLES543
H-1 Machine does not start545
H-2 Machine lacks power or speed when traveling (all speed ranges)546
H-3 Time lag is excessive when starting or shifting gear547
H-4 Torque converter oil temperature is high548
H-5 Steering does not turn549
H-6 Steering does not turn (machine with joystick)550
H-7 Turning, response of steering is poor551
H-8 Turning, response of steering is poor (machine with joystick)553
H-9 Steering is heavy555
H-10 Steering wheel shakes or jerks556
H-11 Steering shakes or there is excessive shock (machine with joystick)557
H-12 Turning radius is different between left and right at maximum steering557
H-13 Wheel brakes do not work or braking effect is poor559
H-14 Wheel brakes are not released or brakes drag561
H-15 Parking brake does not work or braking effect is poor562
H-16 Parking brake is not released or brake drags563
H-17 Neither boom nor bucket move564
H-18 Both boom and bucket are slow or lack power565
H-19 Boom does not move566
H-20 Boom is slow or boom lacks power567
H-21 Boom cannot be set to FLOAT or cannot be released from FLOAT568
H-22 Boom drops momentarily when control lever is operated from HOLD to RAISE568
H-23 Excessive hydraulic drift of boom569
H-24 Bucket does not move570
H-25 Bucket is slow or lacks power571
H-26 Excessive hydraulic drift of bucket572
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)574
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS575
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE577
ELECTRICAL CIRCUIT DIAGRAM FOR T MODE SYSTEM583
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed585
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed586
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed587
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed588
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed589
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed590
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed591
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed592
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed593
T-10 Failure code [21] (Short circuit, disconnection in range switch system) is displayed597
T-11 Failure code [22] (Disconnection in travelspeed sensor system) is displayed600
T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed601
T-13 Hold switch system602
T-14 Kick-down switch system602
T-15 Transmission cut-off signal system603
T-16 Neutralizer relay signal system604
T-17 Buzzer signal system605
T-18 Network system606
T-19 Transmission controller power source system607
T-20 Short circuit in travel speed sensor system608
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM CONTROL SYSTEM) (J MODE)610
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM611
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY613
ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL617
J-1 Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed619
J-2 Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed620
J-3 Error code [58] (Deviation of steering lever angle sensor and frame sensor signals) is displayed621
J-4 Error code [59] (Disconnection or short circuit with chassis ground in frame angle sensor system) is displayed622
J-5 Error code [60] (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed623
J-6 Error code [62] (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed624
J-7 Error code [63] (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed625
J-8 Steering speeds in both directions are different626
J-9 Abnormality in console switch (adjustment of steering lever angle sensor and frame angle sensor is impossible)627
J-10 Abnormality in power source and voltage628
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (EA MODE)630
METHOD OF ERROR CODE DISPLAY632
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED635
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROL SYSTEM643
EA-1 Error code [111] (Abnormality in controller memory)645
EA-2 Error code [112] (Abnormality in timing rail actuator)645
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)646
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system)647
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)649
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system)650
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system)651
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)652
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system)653
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system)654
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system)655
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system)656
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system)657
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system)658
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)659
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))660
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)661
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system)662
EA-19 Error code [151] (Abnormal rise in water temperature)662
EA-20 Error code [153] (Abnormality [high level] in intake air temperature sensor system)663
EA-21 Error code [154] (Abnormality [low level] in intake air temperature sensor system)663
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure sensor system)664
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure sensor system)665
EA-24 Error code [234] (Overspeed)667
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)668
EA-26 Error code [259] (Abnormality in fuel shut-off valve)669
EA-27 Error code [261] (Abnormal rise in fuel temperature)669
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)670
EA-29 Error code [265] (Abnormality [low level] in fuel temperature sensor system)670
EA-30 Error code [316] (Abnormality in fuel pump actuator system current)671
EA-31 Error code [318] (Abnormality in fuel pump actuator)672
EA-32 Error code [343] (Abnormality in controller internal communication)672
EA-33 Error code [346] (Abnormality in controller power down)673
EA-34 Error code [384] (Abnormality in preheating heater control system)674
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))675
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system)675
EA-37 Error code [431] (Abnormality [1] in idling validation switch system)677
EA-38 Error code [432] (Idling validation process error)679
EA-39 Error code [441] (Abnormality [low level] in battery voltage)681
EA-40 Error code [442] (Abnormality [high level] in battery voltage)681
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system)682
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)683
EA-43 Error code [455] (Abnormality in fuel rail actuator system current)684
EA-44 Error code [467] (Abnormality in timing rail actuator control)685
EA-45 Error code [468] (Abnormality in fuel rail actuator control)685
EA-46 Error code [514] (Abnormality in fuel rail actuator)685
EA-47 Error code [527] (Abnormality in dual output solenoid A system)686
EA-48 Error code [551] (Abnormality [2] in idling validation switch system)686
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor)687
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)689
ELECTRICAL SYSTEM DIAGRAM RELATED TO VHMS CONTROLLER692
INFORMATION GIVEN IN TROUBLESHOOTING CHART694
PHENOMENON TYPE CODE LIST695
[DBB0KK] (OR VHMS_LED INDICATES [N901]) ABNORMALITY IN SOURCE VOLTAGE696
[DBB5KP] (OR VHMS_LED INDICATES [N904]) ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM698
[DBB6KP] (OR VHMS_LED INDICATES [N902]) ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM700
[DBBRKR] (OR VHMS_LED DISPLAYS [N801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)702
[DGE1KB] (OR VHMS_LED DISPLAYS [N242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE)704
[DGE1KY] (OR VHMS_LED DISPLAYS [N242]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)705
[DGE5KX] (OR VHMS_LED DISPLAYS [N401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)706
[DGT4KA] (OR VHMS_LED DISPLAYS [N312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO 1, 2 , 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)708
[DGT4KB] (OR VHMS_LED DISPLAYS [N311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO 1, 2, 3 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)710
[DGT5KA] (OR VHMS_LED DISPLAYS [N322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) 712
[DGT5KB] (OR VHMS_LED DISPLAYS [N321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)714
[DHE5KB] (OR VHMS_LED DISPLAYS [N332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)716
[DHE5KY] (OR VHMS_LED DISPLAYS [N331]) SHORT CIRCUIT WIRTH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)718
[DHT3KX] (OR VHMS_LED DISPLAYS [N614]) TROUBLE IN TRANSMISSION OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)720
[DHP2KX] (OR VHMS_LED DISPLAYS [N531]) TROUBLE IN MAIN PUMP OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)722
[DHT8KX] (OR VHMS_LED DISPLAYS [N533]) TROUBLE IN STEERING OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIIGNAL RANGE (KX)724
[DGH2KX] (OR VHMS_LED DISPLAYS [N537]) TROUBLE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)726
[DHU2KX] (OR VHMS_LED DISPLAYS [N711]) TROUBLE IN FRONT BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)728
[DHU3KX] (OR VHMS_LED DISPLAYS [N712]) TROUBLE IN REAR BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)730
[DGR4KX] OR VHMS_LED DISPLAYS [N717]) TROUBLE IN FRONT BRAKE OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)732
[F@BBZL] (OR VHMS_LED DISPLAYS [N338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL) 733
[F@BYNR] (OR VHMS_LED DISPLAYS [N362]) NO 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (2): (NR)734
[F@BYNS] (OR VHMS_LED DISPLAYS [N361]) NO 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (1): (NS)735
[F@BZNR] (OR VHMS_LED DISPLAYS {N372]) NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (2): (NR)736
[F@BZNS] (OR VHMS_LED DISPLAYS [N371]) NO 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (1): (NS)737
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION738
A SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED738
B ABNORMALITY IN DOWNLOADING INTO PC OR SETTING PC742
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)744
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRTUMENT IS NORMAL)746
40 MAINTENANCE STANDARD747
ENGINE AND TRANSMISSION MOUNT749
DAMPER750
TORQUE CONVERTER AND PTO752
TORQUE CONVERTER REGULATOR VALVE753
TRANSMISSION754
TRANSMISSION CONTROL VALVE758
TRANSFER764
DRIVE SHAFT766
CENTER SUPPORT767
DIFFERENTIAL768
FINAL DRIVE770
AXLE MOUNT772
CENTER HINGE PIN774
STEERING DEMAND VALVE776
DIVERTER VALVE778
STEERING CYLINDER MOUNT779
EMERGENCY STEERING PUMP780
BRAKE VALVE781
SLACK ADJUSTER783
BRAKE784
PARKING BRAKE786
CONTROL PUMP787
STEERING AND SWITCH PUMP788
MAIN PISTON PUMP789
MAIN CONTROL VALVE790
PPC VALVE792
PPC RELIEF VALVE794
HYDRAULIC CYLINDER795
WORK EQUIPMENT LINKAGE796
BUCKET798
BUCKET POSITIONER AND BOOM KICK-OUT799
90 OTHERS801
ELECTRIC CIRCUIT DIAGRAM (1/7)802
ELECTRIC CIRCUIT DIAGRAM (2/7)803
ELECTRIC CIRCUIT DIAGRAM (3/7)804
ELECTRIC CIRCUIT DIAGRAM (4/7)805
ELECTRIC CIRCUIT DIAGRAM (5/7)806
ELECTRIC CIRCUIT DIAGRAM (6/7)807
ELECTRIC CIRCUIT DIAGRAM (7/7)808

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24