Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD
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Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD
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Pages : 928
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Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD
MACHINE MODEL SERIAL NO.
WA600-3 50363 and up
GENERAL PRECAUTIONS:
PREPARATIONS FOR WORK:
- 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
- 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
- 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
- 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
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 judgeme~ts. 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.
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• to •causes• are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting 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.
TABLE OF CONTENTS:
Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD
COVER 1
CONTENTS 2
List of revised pages 3
SAFETY 9
SAFETY NOTICE 9
FOREWORD
11
GENERAL
11
HOW TO READ THE SHOP MANUAL
12
HOISTING INSTRUCTIONS
13
COATING MATERIALS
14
STANDARD TIGHTENING TORQUE
16
ELECTRIC WIRE CODE
19
CONVERSION TABLE 20
01 GENERAL 27
GENERAL ASSEMBLY DRAWING 28
SPECIFICATIONS 29
WEIGHT TABLE 32
LIST OF LUBRICANT AND WATER 33
10 STRUCTURE AND FUNCTION 35
POWER TRAIN 36
POWER TRAIN SYSTEM 38
RADIATOR,HYDRAULIC OIL COOLER 40
TORQUE CONVERTER AND TRANSMISSION PIPING 41
HYDRAULIC CIRCUIT FOR POWER TRAIN 42
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 44
TORQUE CONVERTER 46
TRANSMISSION 49
TRANSMISSION CONTROL VALVE 58
TORQUE CONVERTER OIL COOLER 80
TORQUE CONVERTER OIL FILTER 81
TRANSFER 83
DRIVE SHAFT 84
CENTER SUPPORT 85
AXLE 86
DIFFERENTIAL 88
LIMITED SLIP DIFFERENTIAL 91
FINAL DRIVE 95
AXLE MOUNT 98
CENTER HINGE PIN 100
STEERING PIPING 101
STEERING COLUMN 102
STEERING UNIT(ORBIT-ROLL VALVE) 103
STEERING VALVE 106
TWO-WAY RESTRICTION VALVE 117
STOP VALVE 118
EMERGENCY STEERING PIPING 119
DIVERTER VALVE(FOR EMERGENCY STEERING) 120
BRAKE PIPING 124
BRAKE CIRCUIT DIAGRAM 126
BRAKE VALVE 128
CHARGE VALVE 133
ACCUMULATOR(FOR BRAKE) 137
SLACK ADJUSTER 138
BRAKE 141
PARKING BRAKE 143
SPRING CYLINDER 145
PARKING BRAKE SOLENOID VALVE 146
HYDRAULIC PIPING 148
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 150
WORK EQUIPMENT LEVER LINKAGE 152
HYDRAULIC TANK 153
ACCUMULATOR(FOR PPC VALVE) 155
PPC VALVE 156
PPC RELIEV VALVE 160
CUT-OFF VALVE 161
MAIN CONTROL VALVE 164
LUBRICATION OF WORK EQUIPMENT 178
WORK EQUIPMENT LINKAGE 180
BUCKET 182
BUCKET POSITIONER AND BOOM KICK-OUT 183
OPERATION OF PROXIMITY SWITCH 185
ROPS CANOPY 189
CAB 190
CAB HEATER 191
AIR CONDITIONER 193
ELECTRIC CIRCUIT DIAGRAM 196
MACHINE MONITOR SYSTEM 202
MAIN MONITOR 203
MAINTENAMCE MONITOR 208
MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL 210
ENGINE STARTING CIRCUIT 226
ENGINE STOP CIRCUIT 228
5-AUTO PRIMING SYSTEM(APS) 229
ELECTRIC TRANSMISSION CONTROL 233
KICK-DOWN,HOLD SWITCH 236
KICK-DOWN ELECTRICAL CIRCUIT 237
ELECTRIC PARKING BRAKE CONTROL 243
20 TESTING AND ADJUSTING 253
STANDARD VALUE TABLE FOR ENGINE 254
STANDARD VALUE TABLE FOR CHASSIS 255
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 260
TESTING AND ADJUSTING 273
TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING 274
MEASURING ENGINE SPEED 275
MEASURING EXHAUST GAS COLOR 277
ADJUSTIN VALVE CLEARANCE 278
MEASURING COMPRESSION PRESSURE 279
MEASURING BLOW-BY PRESSURE 280
MEASURING ENGINE OIL PRESSURE 281
TESTING AND ADJUSTING FUEL INJECTION TIMING 282
REPLACING FAN BELT ADJUSTING AUTO-TENSIONER 284
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 285
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 285
MEASURING EXHAUST TEMPERATURE 286
MEASURING AIR SUPPLY PRESSURE(BOOST PRESSURE) 287
ADJUSTING SPEED SENSOR 288
ADJUSTING FUEL CONTROL CABLE 289
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 290
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE 292
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT 297
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 298
TESTING AND ADJUSTING STEERING OIL PRESSURE 300
TESTING AND ADJUSTING STEERING STOP VALVE 302
TESTING BRAKE OIL PRESSURE 303
MEASURING WEAR OF BRAKE DISC 304
MEASURING BRAKE PERFORMANCE 305
TESTING AND ADJUSTING PARKING BRAKE 306
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE 308
TESTING AND ADJUSTING PPC OIL PRESSURE 309
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 311
ADJUSTING WORK EQUIPMENT LEVER LINKAGE 313
TESTING AND ADJUSTING OF BUCKET POSITIONER 315
TESTING AND ADJUSTING OF BOOM KICK-OUT 316
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP 317
ADJUSTING MAIN MONITOR(SPEEDOMETER MODULE) 318
BLEEDING AIR 319
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 320
TROUBLESHOOTING 321
POINTS TO REMEMBER WHEN TROUBLESHOOTING 322
SEQUENCE OF EVENTS IN TROUBLESHOOTING 323
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 324
CHECKS BEFORE TROUBLESHOOTING 332
CONNECTOR TYPES AND MOUNTING LOCATIONS 333
CONNECTOR ARRANGEMENT DIAGRAM 336
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 340
METHOD OF USING TROUBLESHOOTING CHARTS 349
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 351
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 353
METHOD OF USING TROUBLESHOOTING CHARTS 354
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME) 358
S-2 ENGINE DOES NOT START 360
(1) ENGINE DOES NOT START 360
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED) 361
(3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 362
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY(FOLLOW-UP IS POOR) 363
S-4 ENGINE STOPS DURING OPERATIONS 364
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) 365
S-6 ENGINE LACKS OUTPUT 366
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION) 367
S-8 OIL COMSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE) 368
S-9 OIL BECOMES CONTAMINATED QUICKLY 369
S-10 FUEL CONSUMPTION IS EXCESSIVE 370
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN 371
S-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE) 372
S-13 OIL LEVEL RISES 373
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) 374
S-15 ABNORMAL NOISE IS MADE 375
S-16 VIBRATION IS EXCESSIVE 376
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 377
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR 380
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN 382
M-1 MAIN MONITOR DOES NOT WORK 383
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP 384
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 385
M-4 ABNORMALITY IN SHIFT INDICATOR 386
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F 386
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R 386
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N 386
d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST 387
e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND 387
f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD 387
g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH 387
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP 389
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 390
a) L H TURN SIGNAL DISPLAY DOES NOT LIGHT UP 390
b) R H TURN SIGNAL DISPLAY DOES NOT LIGHT UP 390
M-7 ABNORMALITY IN PARKING LAMP DISPLAY 391
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP 391
b) PARKING LAMP DISPLAY STAYS LIGHTED UP 391
M-8 ABNORMALITY IN PREHEATING SYSTEM 392
a) PREHEATING DISPLAY DOES NOT LIGHT UP 392
b) PREHEATING DISPLAY STAYS LIGHTED UP 392
M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP 393
M-10 ABNORMALITY IN FRONT WORKING LAMP 394
a) NEITHER MONITOR DISPLAY NOR FRONG WORKIGN LAMP LIGHT UP 394
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 394
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP 394
M-11 ABNORMALITY IN REAR WORKIGN LAMP 396
a) NEITHER MONITOR DISPLAY NOR RERA WORKING LAMP LIGHT UP 396
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 396
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP 396
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 398
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE 398
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED 398
c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON,BUT CUT-OFF FUNCTION IS NOT ACTUATED 399
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN 400
a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N 400
b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N 400
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED 401
a) ACTUATED CONTINUOUSLY 401
b) NOT ACTUATED 401
M-15 ABNORMALITY IN BUZZER 402
a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON 402
b) BUZZER ALWAYS SOUNDS 402
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 403
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 404
a) FAILURE DISPLAY MODE DOES NOT WORK 404
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE 404
M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY 405
a) EMERGENCY STEERING DISPLAY DOES NOT FLASH 405
b) EMERGENCY STEERING DISPLAY STAYS FLASHED 405
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 407
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR 408
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 410
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP 410
b) SOME LAMPS DO NOT LIGHT UP 410
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SECONDS 411
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT 412
K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES 413
a) ENGINE OIL LEVEL DISPLAY FLASHES 413
b) ENGINE WATER LEVEL DISPLAY FLASHES 414
K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES 415
a) ENGINE OIL PRESSURE DISPLAY FLASHES 415
b) BATTERY CHARGE DISPLAY FLASHES 416
c) BRAKE OIL PRESSURE DISPLAY FLASHES 417
d) AIR CLEANER CLOGGED DISPLAY FLASHES 418
K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND 419
K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS 420
K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH 421
a) CHECK LAMP 421
b) CAUTION LAMP 421
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP 422
a) CHECK LAMP 422
b) CAUTION LAMP 422
K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON 423
K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF 424
K-12 SERVICE METER DOES NOT WORK 425
K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED 425
K-14 ABNORMALITY IN GAUGES 426
a) ABNORMALITY IN FUEL GAUGE 426
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 427
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 428
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 429
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM 431
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE 432
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN 433
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER 434
E-1 ENGINE DOES NOT START 436
a) STARTING MOTOR DOES NOT TURN 436
b) STARTING MOTOR TURNS 442
E-2 ENGINE DOES NOT STOP 446
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 446
E-4 ABNORMALITY IN APS SYSTEM 448
a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP 450
b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL 451
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL 452
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 453
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 453
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 454
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 454
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 455
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL 455
j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP 456
E-5 PARKING BRAKE DOES NOT HAVE EFFECT 457
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON 457
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS 457
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 458
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 460
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY 460
E-9 TRANSMISSION DOES NOT WORK PROPERLY 462
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT 464
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT 468
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT 470
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT 472
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT 478
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT 481
E-10 KICK-DOWN SWITCH DOES NOT WORK 486
E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON 489
E-12 KICK-DOWN ALWAYS WORKS 490
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND 492
E-14 BOOM KICK-OUT DOES NOT WORK 494
E-15 DEFECTIVE BUCKET POSITIONER 498
E-16 POWER WINDOW DOES NOT WORK 501
a) POWER WINDOW DOES NOT RISE 501
b) POWER WINDOW DOES NOT LOWER 502
E-17 ABNORMALITY IN FRONT WORKING LAMP 504
E-18 ABNORMALITY IN REAR WORKING LAMP 504
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF 504
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 504
E-21 ABNORMALITY IN BUZZER 504
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 505
H-1 MACHINE DOES NOT START 506
H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES 507
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 508
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 509
H-5 STEERING DOES NOT TURN 510
H-6 TURNING,RESPONSE OF STEERING IS POOR 511
H-7 STEERING IS HEAVY 512
H-8 STEERING WHEEL SHAKES OR JERKS 513
H-9 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING 513
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 514
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 516
H-12 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR 517
H-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 518
H-14 NEITHER BOOM NOR BUCKET MOVE 519
H-15 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER 520
H-16 BOOM DOES NOT MOVE 521
H-17 BOOM IS SLOW OR BOOM LACKS POWER 522
H-18 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT 523
H-19 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 523
H-20 EXCESSIVE HYDRAULIC DRIFT OF BOOM 524
H-21 BUCKET DOES NOT MOVE 525
H-22 BUCKET IS SLOW OR LACKS POWER 526
H-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 527
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)(ONLY FOR MACHINE WIGH JOYSTICK AND AUTOMATIC SHIFT CONTROL) 529
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM 530
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE 532
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM 536
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED 538
T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED 539
T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED 540
T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED 541
T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED 542
T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED 543
T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED 544
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED 545
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED 546
T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED 550
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED 553
T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED 554
T-13 SHIFT-UP DOES NOT WORK 555
T-14 SHIFT-DOWN DOES NOT WORK 555
T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING 556
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING 557
T-17 BUZZER DOES NOT WORK 558
T-18 ABNORMALITY IN NETWORK SYSTEM 559
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY 560
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 561
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS 562
TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE)(ONLY FOR MACHINE WIGH JOYSTICK AND AUTOMATIC SHIFT CONTROL) 563
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM 564
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 566
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM 570
J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED 572
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED 573
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED 574
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED 575
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED 576
J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED 577
J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED 578
J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED 579
J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE 580
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT 581
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 582
J-12 DISCONNECTION IN STEERING LEFT SOLENOID 583
30 DISASSEMBLY AND ASSEMBLY 585
METHOD OF USING MANUAL 587
PRECAUTIONS WHEN CARRYING OUT OPERATION 588
SPECIAL TOOL LIST 590
SKETCHES OF SPECIAL TOOLS 598
STARTING MOTOR 607
REMOVAL AND INSTALLATION 607
ALTERNATOR 608
REMOVAL AND INSTALLATION 608
ENGINE OIL COOLER 609
REMOVAL AND INSTALLATION 609
FUEL INJECTION PUMP 610
REMOVAL AND INSTALLATION 610
WATER PUMP 611
REMOVAL AND INSTALLATION 611
NOZZLE HOLDER 612
REMOVAL AND INSTALLATION 612
TURBOCHARGER 613
REMOVAL 613
INSTALLATION 614
ENGINE FRONT SEAL 615
REPLACEMENT 615
ENGINE REAR SEAL 617
REPLACEMENT 617
CYLINDER HEAD 619
REMOVAL 619
INSTALLATION 624
THERMOSTAT 626
REMOVAL AND INSTALLATION 626
AFTERCOOLER CORE 627
REMOVAL 627
INSTALLATION 628
RADIATOR 629
REMOVAL 629
INSTALLATION 631
ENGINE AND TORQUE CONVERTER ASSEMBLY 632
REMOVAL 632
INSTALLATION 634
TORQUE CONVERTER 635
REMOVAL AND INSTALLATION 635
DISASSEMBLY 636
ASSEMBLY 641
TRANSMISSION 647
REMOVAL 647
INSTALLATION 649
DISASSEMBLY 650
ASSEMBLY 665
TRANSMISSION VALVE 681
REMOVAL AND INSTALLATION 681
TRANSFER 682
DISASSEMBLY 682
ASSEMBLY 691
CENTER SUPPORT 702
REMOVAL AND INSTALLATION 702
DISASSEMBLY 704
ASSEMBLY 706
DRIVE SHAFT 709
DISASSEMBLY 709
ASSEMBLY 712
FRONT AXLE 715
REMOVAL 715
INSTALLATION 716
FRONT DIFFERENTIAL 717
REMOVAL 717
INSTALLATION 718
REAR AXLE 719
REMOVAL 719
INSTALLATION 722
REAR DIFFERENTIAL 723
REMOVAL 723
INSTALLATION 724
DIFFERENTIAL GEAR 725
DISASSEMBLY 725
ASSEMBLY 729
FINAL DRIVE AND BRAKE 737
DISASSEMBLY 737
ASSEMBLY 745
ORBIT-ROLL 756
REMOVAL AND INSTALLATION 756
STEERING CYLINDER 757
REMOVAL 757
INSTALLATION 758
DISASSEMBLY 759
ASSEMBLY 761
STEERING VALVE 763
REMOVAL 763
INSTALLATION 764
CUT-OFF VALVE 765
REMOVAL AND INSTALLATION 765
BRAKE VALVE 766
REMOVAL AND INSTALLATION 766
BRAKE VALVE(R H ) 767
DISASSEMBLY 767
ASSEMBLY 769
BRAKE VALVE(L H ) 771
DISASSEMBLY 771
ASSEMBLY 773
SLACK ADJUSTER 775
REMOVAL AND INSTALLATION 775
DISASSEMBLY 776
ASSEMBLY 777
HYDRAULIC PUMP 778
REMOVAL 778
INSTALLATION 779
HYDRAULIC TANK 780
REMOVAL 780
INSTALLATION 781
HYDRAULIC FILTER 782
REMOVAL AND INSTALLATION 782
PPC VALVE 783
REMOVAL AND INSTALLATION 783
DISASSEMBLY AND ASSEMBLY 784
WORK EQUIPMENT VALVE 785
REMOVAL 785
INSTALLATION 786
MAIN CONTROL VALVE 788
DISASSEMBLY 788
ASSEMBLY 792
DUMP CYLINDER 795
REMOVAL 795
INSTALLATION 796
LIFT CYLINDER 797
REMOVAL 797
INSTALLATION 798
LIFT CYLINDER AND DUMP CYLINDER 799
DISASSEMBLY 799
ASSEMBLY 801
CENTER HINGE PIN 804
REMOVAL 804
INSTALLATION 809
WORK EQUIPMENT 812
REMOVAL 812
INSTALLATION 816
BULCKHEAD 818
REMOVAL 818
INSTALLATION 819
FLOOR FRAME 820
REMOVAL 820
INSTALLATION 822
COUNTERWEIGHT 823
REMOVAL AND INSTALLATION 823
FUEL TANK 824
REMOVAL 824
INSTALLATION 825
CAB 826
REMOVAL 826
INSTALLATION 828
STOP VALVE 829
REMOVAL AND INSTALLATION 829
ACCUMULATOR 830
REMOVAL 830
INSTALLATION 831
ACCUMULATOR CHARGE VALVE 833
REMOVAL AND INSTALLATION 833
PARKING BRAKE SOLENOID VALVE 834
REMOVAL AND INSTALLATION 834
DIVERTER VALVE 835
REMOVAL AND INSTALLATION 835
EMERGENCY STEERIGN PUMP 836
REMOVAL AND INSTALLATION 836
PARKING BRAKE 837
REMOVAL 837
INSTALLATION 838
PARKING BRAKE CALIPERS 840
DISASSEMBLY 840
ASSEMBLY 841
PARKING BRAKE PAD 842
REMOVAL AND INSTALLATION 842
REAR TIRES 843
REMOVAL AND INSTALLATION 843
AIR CONDITIONER COMPRESSOR 844
REMOVAL AND INSTALLATION 844
AIR CONDITIONER CONDENSER 845
REMOVAL AND INSTALLATION 845
RECEIVER TANK 846
REMOVAL AND INSTALLATION 846
AIR CONDITIONER UNIT 847
REMOVAL 847
INSTALLATION 848
MONITOR 849
REMOVAL AND INSTALLATION 849
40 MAINTENANCE STANDARD 851
ENGINE MOUNT 852
TRANSMISSION MOUNT 853
TORQUE CONVERTER 854
TRANSMISSION 856
TRANSFER 860
TRANSMISSION CONTROL VALVE 862
DRIVE SHAFT 869
CENTER SUPPORT 870
DIFFERENTIAL 872
FINAL DRIVE 876
AXLE MOUNT 878
CENTER HINGE PIN 880
STEERING COLUMN 882
STEERING VALVE 883
EMERGENCY STEERING PUMP 884
DIVERTER VALVE 885
STEERING CYLINDER MOUNT 886
BRAKE VALVE 887
SLACK ADJUSTER 890
BRAKE 892
PARKING BRAKE 894
HYDRAULIC PUMP 896
PPC VALVE 898
CUT-OFF VALVE 900
MAIN CONTROL VALVE 902
HYDRAULIC CYLINDER 904
WORK EQUIPMENT LINKAGE 906
BUCKET 908
BUCKET POSITIONER AND BOOM KICK-OUT 909
ROPS CANOPY 910
90 OTHERS 911
FOR STANDARD MACHINE 913
ELECTRIC CIRCUIT DIAGRAM(1/4) 913
ELECTRIC CIRCUIT DIAGRAM(2/4) 915
ELECTRIC CIRCUIT DIAGRAM(3/4) 917
ELECTRIC CIRCUIT DIAGRAM(4/4) 919
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL 921
ELECTRIC CIRCUIT DIAGRAM(1/4) 921
ELECTRIC CIRCUIT DIAGRAM(2/4) 923
ELECTRIC CIRCUIT DIAGRAM(3/4) 925
ELECTRIC CIRCUIT DIAGRAM(4/4) 927
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