Komatsu Wheel Loader WA900L Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA900L-3 avance, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA900L-3 avance workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,341 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEAM010400 - Wheel Loader WA900-1, WA900-1L Operation & Maintenance Manual.pdf
SEBM035704 - Wheel Loader WA900L-3 avance Shop Manual.pdf
TEN00009-02 - Wheel Loader WA900L-3 avance Operation & Maintenance Manual.pdf
MAIN SECTIONS
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 ...44
POWER TRAIN...45
POWER TRAIN SYSTEM...46
ENGINE CONTROL...47
RADIATOR AND COOLER...48
DAMPER...50
TORQUE CONVERTER AND TRANSMISSION PIPING...51
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...53
TORQUE CONVERTER...54
TRANSMISSION...59
TRANSFER...67
TRANSMISSION CONTROL VALVE...68
TORQUE CONVERTER OIL COOLER...84
DRIVE SHAFT...85
CENTER SUPPORT...86
AXLE...87
DIFFERENTIAL...89
FINAL DRIVE...92
CENTER HINGE PIN...93
AXLE MOUNT...94
TIRE AND WHEEL...96
STEERING PIPING...97
JOYSTICK STEERING LINKAGE...98
STEERING PUMP...99
SWITCH PUMP...101
STEERING DEMAND VALVE...109
EPC VALVE...120
ROTARY VALVE...121
TWO-WAY RESTRICTOR VALVE...123
DIVERTER VALVE...124
BRAKE PIPING...128
BRAKE CIRCUIT DIAGRAM...129
BRAKE VALVE...131
CHARGE VALVE...136
ACCUMULATOR (FOR BRAKE)...140
SLACK ADJUSTER...141
BRAKE...144
PARKING BRAKE...145
SPRING CYLINDER...147
PARKING BRAKE SOLENOID VALVE...148
HYDRAULIC PIPING...149
WORK EQUIPMENT LEVER LINKAGE...152
HYDRAULIC TANK...153
MAIN PISTON PUMP...156
ES VALVE (ENGINE SENSING VALVE)...164
SERVO VALVE...166
PPC VALVE (PROPORTIONAL PRESSURE VALVE)...169
PPC RELIEF VALVE...173
ACCUMULATOR (FOR PPC VALVE)...174
MAIN CONTROL VALVE...175
LUBRICATION OF WORK EQUIPMENT...188
WORK EQUIPMENT LINKAGE...191
BUCKET POSITIONER AND BOOM KICK-OUT...193
OPERATION OF PROXIMITY SWITCH...195
CRB AND ROPS CANOPY...199
AIR CONDITIONER...200
MACHINE MONITOR SYSTEM...204
MAIN MONITOR...205
MAINTENANCE MONITOR...209
ENGINE STARTING CIRCUIT...212
ENGINE STOP CIRCUIT...215
PREHEATING CIRCUIT...216
ELECTRICAL TRANSMISSION CONTROL...217
KICK-DOWN, HOLD SWITCH...218
AUTOMATIC TRANSMISSION (ATM) SYSTEM...219
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)...229
ELECTRIC PARKING BRAKE CONTROL...234
20 TESTING AND ADJUSTING...243
STANDARD VALVE TABLE FOR ENGINE...244
STANDARD VALVE TABLE FOR CHASSIS...245
STANDARD VALVE TABLE FOR ELECTRICAL PARTS...249
TESTING AND ADJUSTING...259
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...260
MEASURING ENGINE SPEED...262
MEASURING EXHAUST GAS COLOR...263
ADJUSTING VALVE CLEARANCE...264
MEASURING COMPRESSION PRESSURE...264
MEASURING BLOW-BY PRESSURE...264
TESTING AND ADJUSTING FUEL INJECTION TIMING...264
MEASURING ENGINE OIL PRESSURE...264
MEASURING EXHAUST TEMPERATURE...264
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...264
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...265
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...266
MEASURING ACCELERATOR PEDAL...267
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE...268
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS...270
TESTING AND ADJUSTING STEERING OIL PRESSURE...272
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE...273
BLEEDING AIR FROM STEERING CIRCUIT...275
TESTING AND ADJUSTING STEERING STOPPER BOLT...276
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR...277
TESTING WHEEL BRAKE PERFORMANCE...278
TESTING WHEEL BRAKE OIL PRESSURE DROP...279
MEASURING WEAR OF WHEEL BRAKE DISC...281
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...282
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT...284
TESTING PARKING BRAKE PERFORMANCE...285
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE...286
CHECKING AND ADJUSTING PARKING BRAKE PAD...287
TESTING AND ADJUSTING PPC PRESSURE...289
ADJUSTING PPC VALVE LINKAGE...290
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...291
BLEEDING AIR FROM PISTON PUMP...293
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT...294
ADJUSTING WORK EQUIPMENT LEVER LINKAGE...295
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...296
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH...297
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH...297
TESTING PROXIMITY ACTUATION PILOT LAMP...298
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR...299
TROUBLESHOOTING...300
POINTS TO REMEMBER WHEN TROUBLESHOOTING...301
SEQUENCE OF EVENTS IN TROUBLESHOOTING...302
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...303
CHECKS BEFORE TROUBLESHOOTING...311
TYPES AND LOCATIONS OF CONNECTORS...312
CONNECTOR LOCATION STEREOGRAM...318
WIRING TABLE FOR CONNECTOR PIN NUMBERS...324
T-ADAPTER BOX AND T-ADAPTER TABLE...357
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM...360
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE...364
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION...366
TRANSMISSION CONTROLLER LED DISPLAY...368
METHOD OF USING JUDGEMENT TABLE...369
METHOD OF USING TROUBLESHOOTING CHARTS...370
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...372
TROUBLESHOOTING OF ENGINE (S MODE)...374
METHOD OF USING TROUBLESHOOTING CHARTS...375
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...379
S-2 ENGINE DOES NOT START...380
(1) ENGINE DOES NOT TURN...380
(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)...381
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...382
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...383
S-4 ENGINE STOPS DURING OPERATIONS (FOR V TYPE ENGINE, INCLUDING CASES WHERE ONE BANK STOPS)...384
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...385
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)...386
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...387
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...388
S-9 OIL BECOMES CONTAMINATED QUICKLY...389
S-10 FUEL CONSUMPTION IS EXCESSIVE...390
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...391
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...392
S-13 OIL LEVEL RISES...393
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...394
S-15 ABNORMAL NOISE IS MADE...395
S-16 VIBRATION IS EXCESSIVE...396
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)...397
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS...398
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...399
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...403
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED...405
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...406
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED...407
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED...408
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED...409
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED...410
T-7 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVEL SWITCH SYSTEM) IS DISPLAYED...411
T-8 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED...412
T-9 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED...413
T-10 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...414
T-11 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM ...415
T-12 TRANSMISSION CUT-OFF SIGNAL SYSTEM...416
T-13 NEUTRALIZER SIGNAL SYSTEM...417
T-14 BUZZER SIGNAL SYSTEM...418
T-15 NETWORK SYSTEM...419
T-16 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM...420
T-17 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM ...421
T-18 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS...422
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...423
TROUBLE DATA DISPLAY...425
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM...427
M-1 MAIN MONITOR DOES NOT WORK...429
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP...430
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...431
M-4 ABNORMALITY IN SHIFT INDICATOR...432
a) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT F...432
b) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT R...432
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL SWITCH IS AT N (DISPLAY 1ST-3RD)...432
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...434
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP...434
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP...434
M-6 ABNORMALITY IN PARKING DISPLAY...436
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP...436
b) PARKING LAMP DISPLAY STAYS LIGHT UP...436
M-7 NIGHT LIGHTING DOES NOT LIGHT UP...437
M-8 ABNORMALITY IN FRONT WORKING LAMP...439
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP...439
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...439
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP ...439
M-9 ABNORMALITY IN REAR WORKING LAMP...441
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP ...441
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP ...441
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP...441
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF...443
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE...443
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED...443
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED...443
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)...443
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED...444
M-11 ABNORMALITY IN LOW IDLE SELECTION...445
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLE SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE ...445
b) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLE SPEED DOES NOT RISE...445
c) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLE SPEED DOES NOT LOWER...446
M-12 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY...447
M-13 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY...448
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP...448
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP...448
M-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...449
a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL SWITCH IS AT N...449
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...449
M-15 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED...450
a) ACTUATED CONTINUOUSLY...450
b) NOT ACTUATED...450
M-16 ABNORMALITY IN BUZZER...451
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)...451
b) BUZZER ALWAYS SOUNDS...451
M-17 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...452
M-18 ABNORMALITY IN FAILURE DISPLAY MODE...453
a) DOES NOT ENTER FAILURE DISPLAY MODE...453
b) COUNT FOR TIME ELAPSED SINCE FAILURE DISPLAY MODE DOES NOT ADVANCE...453
M-19 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER...454
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM...455
a) FORCED GREASING CANNOT BE CARRIED OUT...455
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...455
c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...455
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY...456
e) MONITOR DISPLAY GOES OUT...456
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...457
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...458
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM...459
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...461
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...461
b) SOME LAMPS DO NOT LIGHT UP...461
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)...462
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT...463
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH...465
a) ENGINE OIL LEVEL DISPLAY FLASHES...465
b) ENGINE WATER LEVEL DISPLAY FLASHES...466
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH...467
a) ENGINE OIL PRESSURE DISPLAY FLASHES...467
b) BATTERY CHARGE LEVEL DISPLAY FLASHES...468
c) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE BRAKE OIL PRESSURE IS CORRECT)...469
d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (R.H.) IS NOT CLOGGED)...471
e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (L.H.) IS NOT CLOGGED)...472
f) TRANSMISSION OIL FILTER DISPLAY FLASHES (THE TRANSMISSION OIL FILTER MUST NOT BE CLOGGED)...473
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND...474
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS...475
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES...476
a) CHECK LAMP...476
b) CAUTION LAMP...476
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP ...477
a) CHECK LAMP...477
b) CAUTION LAMP...477
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON...478
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF...479
K-12 SERVICE METER DOES NOT WORK...480
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED...480
K-14 ABNORMALITY IN GAUGE DISPLAY...482
a) ABNORMALITY IN FUEL GAUGE...482
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...483
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...484
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...485
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING...486
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE...488
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER...489
E-1 ENGINE DOES NOT START...490
a) STARTING MOTOR DOES NOT TURN...490
b) STARTING MOTOR TURNS...494
E-2 ENGINE DOES NOT STOP...495
E-3 ABNORMALITY IN PREHEATING SYSTEM...498
a) DOES NOT CARRY OUT PREHEATING...498
b) ONLY MONITOR DISPLAY LIGHTS UP ...498
c) MONITOR DISPLAY DOES NOT LIGHT UP WHEN PREHEATING IS COMPLETED...499
d) MONITOR DISPLAY KEEPS LIGHTING UP WHEN PREHEATING IS NOT COMPLETED...499
E-4 PARKING BRAKE DOES NOT HAVE EFFECT...501
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON...501
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)...501
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...502
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNDED ON...504
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)...504
E-8 KICK-DOWN SWITCH DOES NOT WORK...506
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY...506
b) KICK-DOWN CANNOT BE CANCELED...507
E-9 BOOM KICK-OUT DOES NOT WORK...508
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION...511
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP...514
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP ...514
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF...514
E-14 ABNORMALITY IN LOW IDLING SELECTION...514
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ...514
E-16 ABNORMALITY IN BUZZER ...514
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...515
H-1 MACHINE DOES NOT MOVE...516
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)...517
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...518
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ...519
H-5 STEERING DOES NOT TURN...520
H-6 TURNING,RESPONSE OF STEERING IS POOR...521
H-7 JOYSTICK LEVEL IS HEAVY...522
H-8 STEERING WHEEL SHAKES OR JERKS...523
H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT...524
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...525
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...526
H-12 BOOM DOES NOT RISE...527
H-13 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...528
H-14 WHEN RAISING BOOM,BECOMES SLOW AT CERTAIN HEIGHT...529
H-15 BOOM CYLINDER CANNOT HOLD DOWN BUCKET...529
H-16 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT...529
H-17 BOOM FLUCTUATES WHILE WORKING ...530
H-18 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE...530
H-19 BUCKET DOES NOT TILT BACK...531
H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...532
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...533
H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET...533
H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT...533
H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE ?HOLD")...534
H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT...534
H-26 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY...535
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)...536
JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM...537
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY ...538
ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL...542
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED...544
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED...545
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGEL SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED...546
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED...547
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED...548
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED...549
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...550
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT...551
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)...552
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE...553
30 DISASSEMBLY AND ASSEMBLY...554
METHOD OF USING MANUAL...556
STANDARD TIGHTENING TORQUE TABLE...558
PRECAUTIONS WHEN CARRYING OUT OPERATION...562
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER...565
COATING MATERIALS LIST...568
SPECIAL TOOL LIST...572
SKETCHES OF SPECIAL TOOLS...578
ENGINE RELATED PARTS...586
STARTING MOTOR...586
ALTERNATOR...586
ENGINE OIL COOLER...586
FUEL INJECTION PUMP FOR LEFT BANK...586
FUEL INJECTION PUMP FOR RIGHT BANK...586
WATER PUMP...586
NOZZELE HODLER...586
TURBOCHARGER...586
ENGINE FRONT SEAL...586
ENGINE REAR SEAL...586
CYLINDER HEAD...586
REMOVAL AND INSTALLATION OF RADIATOR...587
REMOVAL AND INSTALLATION OF ENGINE...590
REMOVAL AND INSTALLATION OF DAMPER...595
DISASSEMBLY AND ASSEMBLY OF DAMPER...596
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...600
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER...607
DISASSEMBLY AN ASSEMBLY OF TORQUE CONVERTER VALVE...614
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION...615
REMOVAL AND INSTALLATION OF TRANSMISSION VALVE...639
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE...640
DISASSEMBLY AND ASSEMBLY OF TRANSFER...644
DISASSEMBLY AND ASSEMBLY OF PTO...656
REMOVAL AND INSTALLATION OF CENTER SUPPORT...661
DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT...663
DISASSEMBLY AND ASSEMBLY OF DRIVE SHAFT...667
REMOVAL AND INSTALLATION OF FRONT AXLE...670
REMOVAL AND INSTALLATION OF REAR AXLE...672
REMOVAL AND INSTALLATION OF DIFFERENTIAL...677
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL...679
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE...687
REMOVAL AND INSTALLATION OF ROTARY VALVE...692
REMOVAL AND INSTALLATION OF EMERGENCY STEERING PUMP...693
REMOVAL AND INSTALLATION OF DIVERTER VALVE...694
DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE...695
REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE...697
DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE...698
REMOVAL AND INSTALLATION OF STEERING CYLINDER...700
REMOVAL AND INSTALLATION OF STEERING VALVE...702
REMOVAL AND INSTALLATION OF BRAKE VALVE...704
REMOVAL AND INSTALLATION OF SLACK ADJUSTER...705
DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER...706
REMOVAL AND INSTALLATION OF BRAKE...708
DISASSEMBLY AND ASSEMBLY OF BRAKE...709
REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS...713
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS...714
REMOVAL AND INSTALLATION OF PARKING BRAKE PAD...716
REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER...717
REMOVAL AND INSTALLATION OF BRAKE OIL TANK...718
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP...719
REMOVAL AND INSTALLATOIN OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY...721
REMOVAL AND INSTALLATION OF PPC VALVE...723
DISASSEMBLY AND ASSEMBLY OF PPC VALVE...725
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...726
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE...728
REMOVAL AND INSTALLATION OF CAB...731
REMOVAL AND INSTALLATION OF FLOOR FRAME...733
REMOVAL AND INSTALLATION OF CENTER HINGE PIN...736
REMOVAL AND INSTALLATION OF WORK EQUIPMENT...743
REPLACEMENT OF BOOM FRONT END BUSH...748
REMOVAL AND INSTALLATION OF BUCKET CYLINDER...749
REMOVAL AND INSTALLATION OF LIFT CYLINDER...750
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER...752
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT...756
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR...758
REMOVAL AND INSTALLATION OF RECEIVER TANK...759
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER...760
REMOVAL AND INSTALLATION OF TRANSMISSION AND JOYSTICK STEERING CONTROLLER...761
REMOVAL AND INSTALLATION OF MAIN MONITOR...762
REMOVAL AND INSTALLATION OF FUEL TANK...764
REMOVAL AND INSTALLATION OF COUNTERWEIGHT...766
40 MAINTENANCE STANDARD...767
ENGINE MOUNT...768
TRANSMISSION MOUNT...769
DAMPER...770
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP...772
TORQUE CONVERTER ...774
TORQUE CONVERTER REGULATOR VALVE...775
TRANSMISSION (1/2)...776
TRANSMISSION (2/2)...778
TRANSFER...779
TRANSMISSION CONTROL VALVE...780
DRIVE SHAFT...785
CENTER SUPPORT...786
DIFFERENTIAL (1/2)...787
DIFFERENTIAL (2/2)...788
FINAL DRIVE...790
AXLE MOUNT...792
CENTER HINGE PIN...794
STEERING DEMAND VALVE...796
DIVERTER VALVE...798
STEERING CYLINDER MOUNT...799
EMERGENCY STEERING PUMP...800
BRAKE VALVE...801
SLACK ADJUSTER...804
BRAKE...805
PARKING BRAKE...807
PPC VALVE...809
PPC RELIEF VALVE...811
CONTROL PUMP...812
STEERING PUMP...813
SWITCH PUMP...814
MAIN PISTON PUMP...815
MAIN CONTROL VALVE...816
HYDRAULIC CYLINDER...818
WORK EQUIPMENT LINKAGE...819
BUCKET POSITIONER AND BOOM KICK-OUT...821
ROPS CANOPY...822
90 OTHERS...823
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...824
ELECTRIC CIRCUIT DIAGRAM (1/5)...825
ELECTRIC CIRCUIT DIAGRAM (2/5)...826
ELECTRIC CIRCUIT DIAGRAM (3/5)...827
ELECTRIC CIRCUIT DIAGRAM (4/5)...828
ELECTRIC CIRCUIT DIAGRAM (5/5)...829
ELECTRIC CIRCUIT DIAGRAM (ENGINE SHUT-DOWN)...830
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING)...831
