Komatsu Wheel Loader WA900-LC avance Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA900-3LC avance, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA900-3LC 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
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MAIN SECTIONS
MAIN MENU...0
COVER PAGE...1
CONTENTS...2
00 FOREWORD...13
SAFETY...13
SAFETY NOTICE...13
IMPORTANT SAFETY NOTICE...13
GENERAL PRECAUTIONS...13
PREPARATIONS FOR WORK...13
PRECAUTIONS DURING WORK...13
GENERAL...15
HOW TO READ THE SHOP MANUAL...16
VOLUMES...16
DISTRIBUTION AND UPDATING...16
FILING METHOD...16
REVISED EDITION MARK...16
REVISIONS...16
SYMBOLS...16
HOISTING INSTRUCTIONS...17
HOISTING...17
WIRE ROPES...17
COATING MATERIALS...18
STANDARD TIGHTENING TORQUE...20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...20
TIGHTENING TORQUE OF HOSE NUTS...21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...21
TIGHTENING TORQUE FOR FLARED NUTS...21
ELECTRIC WIRE CODE...22
CLASSIFICATION BY THICKNESS...22
CLASSIFICATION BY COLOR AND CODE...22
CONVERSION TABLES...23
METHOD OF USING THE CONVERSION TABLE...23
01 GENERAL...29
SPECIFICATION DRAWING...30
SPECIFICATIONS...31
WEIGHT TABLE...34
FUEL, COOLANT AND LUBRICANTS...35
ENGINE OIL SPECIFICATIONS...36
NORMAL OPERATION...36
ARCTIC OPERATION...36
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM....37
FINAL DRIVE OIL SPECIFICATIONS...37
DRIVE AXLE OIL SPECIFICATIONS...37
DIESEL FUEL SPECIFICATIONS...37
COOLANT SPECIFICATIONS...38
SUPPLEMENTAL COOLANT ADDITIVES...40
COOLING SYSTEM TEST KIT...44
10 STRUCTURE AND FUNCTION...45
POWER TRAIN...50
OUTLINE...50
ENGINE CONTROL...52
OUTLINE...52
RADIATOR AND HYDRAULIC OIL COOLER...53
DAMPER...54
TORQUE CONVERTER AND TRANSMISSION PIPING...55
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...56
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...57
TORQUE CONVERTER...58
RELIEF VALVE...61
OUTLINE...61
FUNCTION...61
REGULATOR VALVE...62
OPERATION...62
TRANSMISSION...63
CLUTCH...66
OUTLINE...66
OPERATION...66
FORWARD 1st...67
FORWARD 2ND...68
FORWARD 3RD...69
REVERSE 1ST...70
TRANSFER...71
OUTLINE...71
TRANSMISSION PATH...71
CONTROL VALVE...72
SOLENOID VALVE...73
TRANSMISSION SOLENOID VALVE...74
UPPER VALVE...76
LINE OIL FILTER...77
PILOT OIL FILTER...77
MAIN RELIEF VALVE...78
PILOT REDUCING VALVE...79
PRIORITY VALVE...80
MODULATING VALVE AND QUICK RETURN VALVE...81
OPERATION...81
REDUCING VALVE...83
EMERGENCY MANUAL SPOOL...84
LUBRICATION VALVE...85
HYDRAULIC CIRCUIT SCHEMATICS...86
FORWARD 1st...86
OPERATION...87
TORQUE CONVERTER OIL COOLER...88
OUTLINE...88
DRIVE SHAFT...89
OUTLINE...89
CENTER SUPPORT...90
FUNCTION...90
AXLE...91
FRONT AXLE...91
FRONT DIFFERENTIAL...92
REAR AXLE...93
REAR DIFFERENTIAL...94
OUTLINE...95
FINAL DRIVE...96
OUTLINE...96
OPERATION...96
MEMORANDA...97
AXLE MOUNT...98
FRONT AXLE...99
REAR AXLE...99
CENTER HINGE PIN...100
OUTLINE...100
TIRE AND WHEEL...101
OUTLINE...101
STEERING...102
PIPING...102
STEERING COLUMN...103
STEERING PUMP...104
OUTLINE...104
MEMORANDA...106
SWITCH PUMP...107
OUTLINE...107
SWITCH PUMP (HPV 90 + 90)...108
CO - NC VALVE...110
CO VALVE...112
FUNCTION...112
OPERATION...112
NC VALVE...114
OPERATION...114
STEERING DEMAND VALVE...115
OVERLOAD RELIEF VALVE...116
FUNCTION...116
OPERATION...116
MAIN RELIEF VALVE...118
OPERATION OF DEMAND VALVE...120
WHEN STEERING SPOOL IS OPERATED...121
OPERATION OF STEERING VALVE...123
ORBIT-ROLL VALVE...126
OUTLINE...127
STRUCTURE...127
OPERATION...128
TWO-WAY RESTRICTOR VALVE...129
FUNCTION...129
OPERATION...129
DIVERTER VALVE...130
FUNCTION...130
GROUND DRIVEN STEERING...131
RELIEF VALVE...131
FUNCTION...131
OPERATION...131
HYDRAULIC CIRCUIT SCHEMATICS...132
PUMP, ENGINE WORKING NORMALLY...132
FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING...133
BRAKE...134
PIPING...134
BRAKE CIRCUIT DIAGRAM...136
BRAKE VALVE...138
OUTLINE...138
OPERATION...139
CHARGE VALVE...142
FUNCTION...142
OPERATION...144
ACCUMULATOR...146
FUNCTION...146
SLACK ADJUSTER...147
FUNCTION...147
OPERATION...148
BRAKE...150
OPERATION...150
FUNCTION...150
PARKING BRAKE...151
OUTLINE...151
OPERATION...152
SPRING CYLINDER...153
OUTLINE...153
PARKING BRAKE SOLENOID VALVE...154
FUNCTION...154
HYDRAULIC PIPING...156
MACHINE WITH JOYSTICK STEERING...158
WORK EQUIPMENT LEVER LINKAGE...162
HYDRAULIC TANK...163
OUTLINE...163
OIL FILTER BYPASS VALVE...164
BREATHER...165
FUNCTION...165
MAIN PISTON PUMP...166
OUTLINE...166
PISTON PUMP (HPV90 + 90)...167
FUNCTION...169
STRUCTURE...169
OPERATION...170
CONTROL PUMP (BAR025)...172
RELIEF VALVE...173
ES (ENGINE SENSING) VALVE...174
FUNCTION...174
OPERATION...175
SERVO VALVE...176
OPERATION...177
PPC VALVE...179
OPERATION...181
PPC RELIEF VALVE...183
FUNCTION...183
OPERATION...183
ACCUMULATOR (PPC VALVE)...184
FUNCTION...184
OPERATION...184
MAIN CONTROL VALVE...185
FUNCTION...186
RELIEF VALVE...187
FUNCTION...187
OPERATION...187
SAFETY VALVE (with suction valve)...188
FUNCTION...188
OPERATION...188
SUCTION VALVE...189
OPERATION...189
FLOAT SELECTOR VALVE AND UNLOADER VALVE...190
FUNCTION...190
OPERATION...190
OPERATION OF HYDRAULIC CIRCUIT...192
BOOM AND DUMP SPOOLS IN ?HOLD?...192
LIFT SPOOL IN ?RAISE?...193
LIFT SPOOL IN ?LOWER?...194
BOOM SPOOL IN ?FLOAT?...195
DUMP SPOOL IN ?DUMP?...196
DUMP SPOOL IN ?TILT BACK?...197
WORK EQUIPMENT...198
LUBRICATION...198
LINKAGE...200
BUCKET POSITIONER AND BOOM KICKOUT...202
BUCKET POSITIONER...203
BOOM KICK-OUT...203
OPERATION OF PROXIMITY SWITCH...204
BOOM RAISE...204
BUCKET TILT...206
CAB...208
ROPS CANOPY...209
AIR CONDITIONER...210
AIR CONDITIONER PIPING...210
AIR CONDITIONER CONDENSER...211
AIR CONDITIONER COMPRESSOR...211
DRY RESERVOIR...212
ELECTRIC CIRCUIT DIAGRAM...215
MACHINE MONITOR SYSTEM...233
OUTLINE...233
MAIN MONITOR...234
OUTLINE...234
DISPLAY FUNCTION...235
SWITCH FUNCTION...236
TROUBLE DATA DISPLAY MODE...237
MAINTENANCE MONITOR...238
OUTLINE...238
DISPLAY FUNCTION...239
ENGINE START AND STOP CIRCUIT...241
SAFETY RELAY...243
FUNCTION...244
ENGINE START...244
ENGINE STOP...244
PREHEATING CIRCUIT...245
OUTLINE...245
ELECTRICAL TRANSMISSION CONTROL...246
FUNCTION...246
COMBINATION SWITCH...247
OUTLINE...247
OPERATION...248
KICK-DOWN, HOLD SWITCH...249
KICK-DOWN SWITCH...249
OPERATION...249
CANCELLATION (or not actuated)...249
HOLD SWITCH...249
PARKING BRAKE...250
ELECTRIC CONTROL...250
OUTLINE...250
FUNCTION...251
PARKING BRAKE SWITCH...251
PARKING BRAKE SOLENOID VALVE...252
PARKING SAFETY RELAY...252
NEUTRALIZER RELAY...252
EMERGENCY BRAKE SWITCH...252
OPERATION...253
STARTING SWITCH OFF...253
STARTING SWITCH ON...254
PARKING BRAKE SWITCH OFF (RELEASED)...256
PARKING BRAKE SWITCH ON (actuated)...257
WHEN MAIN BRAKE OIL PRESSURE DROPS (emergency brake actuated)...258
20 TESTING, ADJUSTING AND TROUBLESHOOTING...259
STANDARD VALUE TABLE FOR ENGINE...260
STANDARD VALUE TABLE FOR CHASSIS...261
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...267
TESTING AND ADJUSTING ...277
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...278
MEASURING ENGINE SPEED...280
ADJUSTING VALVE CLEARANCE...282
MEASURING COMPRESSION PRESSURE...283
MEASURING BLOW-BY PRESSURE...284
FUEL INJECTION TIMING...285
MEASURING ENGINE OIL PRESSURE...287
MEASURING EXHAUST TEMPERATURE...288
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...289
ALTERNATOR BELT TENSION...290
AIR CONDITIONER COMPRESSOR BELT TENSION...291
MEASURING ACCELERATOR PEDAL...292
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE...293
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL...296
STEERING OIL PRESSURE...298
GROUND DRIVEN STEERING OIL PRESSURE...299
BLEEDING AIR FROM STEERING CIRCUIT...301
STEERING STOP VALVE...302
TESTING WHEEL BRAKE PERFORMANCE...303
TESTING WHEEL BRAKE OIL PRESSURE DROP...304
MEASURING WEAR OF WHEEL BRAKE DISC...306
ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...307
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT...309
TESTING PARKING BRAKE PERFORMANCE...310
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE...311
PARKING BRAKE PAD...312
PPC PRESSURE...314
ADJUSTING PPC VALVE LINKAGE...316
WORK EQUIPMENT HYDRAULIC PRESSURE...317
BLEEDING AIR FROM PISTON PUMP...319
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT...320
ADJUSTING WORK EQUIPMENT LEVER LINKAGE...321
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...323
BUCKET PROXIMITY SWITCH...324
BOOM PROXIMITY SWITCH...325
TESTING PROXIMITY ACTUATION PILOT LAMP...326
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR...327
ADJUSTING JOYSTICK LEVER POTENTIOMETER...328
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH...330
TROUBLESHOOTING...331
POINTS TO REMEMBER WHEN TROUBLESHOOTING...332
SEQUENCE OF EVENTS IN TROUBLESHOOTING...333
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...334
POINTS TO REMEMBER WHEN HANDLING ELECTRICAL EQUIPMENT...334
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS...339
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...340
CHECKS BEFORE TROUBLESHOOTING...342
CONNECTOR TYPES AND MOUNTING LOCATIONS...343
CONNECTOR ARRANGEMENT DIAGRAM ...347
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...352
EXPLANATION OF FUNCTION OF ELECTRICAL CONTROL MECHANISM...365
TRANSMISSION CONTROL SYSTEM...365
MAIN MONITOR SYSTEM...366
MAINTENANCE MONITOR SYSTEM...367
JOYSTICK STEERING ...368
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE...369
CHART OF ACTION CODES AND FAILURE CODES AND RE-ENACTION...371
TRANSMISSION CONTROLLER LED DISPLAY...373
METHOD OF USING JUDGEMENT TABLE...374
METHOD OF USING TROUBLESHOOTING CHARTS...375
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...377
METHOD OF USING TROUBLESHOOTING ENGINE RELATED CHARTS...379
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...383
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKE TIME)...384
S-2 ENGINE DOES NOT START...385
(1) ENGINE DOES NOT TURN...385
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)...386
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START...387
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...388
S-4 ENGINE STOPS DURING OPERATION...389
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...390
S-6 ENGINE LACKS OUTPUT (NO POWER)...391
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...392
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...393
S-9 OIL BECOMES CONTAMINATED QUICKLY...394
S-10 FUEL CONSUMPTION IS EXCESSIVE...395
S-11 OIL IN COOLANT WATER, OR WATER SPURTS BACK OR WATER LEVEL GOES DOWN...396
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...397
S-13 OIL LEVEL RISES...398
S-14 COOLANT WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...399
S-15 ABNORMAL NOISE IS MADE...400
S-16 VIBRATION IS EXCESSIVE...401
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T-MODE)...403
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS...404
ACTION TAKEN BY CONTROLLERS WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...406
ELECTRICAL DIAGRAM FOR TANSMISSION CONTROLLER SYSTEM...411
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK UP LAMP RELAY) IS DISPLAYED...412
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...413
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED...414
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED...415
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED...416
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED...417
T-7 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...418
T-8 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...420
T-9 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED...424
T-10 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED...427
T-11 FAIURE CODE [23] (SHORT CIRCUIT, DISCONNECTION, ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...428
T-12 SHIFT-UP SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) AND HOLD SIGNAL SYSTEM (AUTO-SHIFT (OP) ...429
T-13 KICK-DOWN SIGNAL SYSTEM AND SHIFT DOWN SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT)...429
T-14 TRANSMISSION CUT-OFF SIGNAL SYSTEM...430
T-15 NEUTRALIZER SIGNAL SYSTEM...431
T-16 BUZZER SIGNAL SYSTEM...432
T-17 NETWORK SYSTEM...433
T-18 TRANSMISSION CONTROLLER POWER SOURCE...434
T-19 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...435
T-20 ABNORMALITY IN MACHINE SELECTION WIRE HARNESS...436
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)...437
TROUBLE DATA DISPLAY...439
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM...441
M-1 MAIN MONITOR DOES NOT WORK BACKUP LAMP RELAY) IS DISPLAYED...442
M-2 WHEN STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT UP...443
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...444
M-4 ABNORMALITY IN SHIFT INDICATOR...445
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP...448
M-6 TURN SIGNAL DISPLAY NOT LIGHT UP...449
M-7 ABNORMALITY IN PARKING DISPLAY...450
M-8 ABNORMALITY IN PREHEATING SYSTEM...451
M-9 NIGHT LIGHTING DOES NOT LIGHT UP...455
M-10 ABNORMALITY IN FRONT WORKING LAMP...456
M-11 ABNORMALITY IN REAR WORKING LAMP...458
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...460
M-13 ABNORMALITY IN LOW IDLE SELECTION...462
M-14 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY...464
M-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...465
M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP)...467
M-17 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR NOT ACTUATED...469
M-18 ABNORMALITY IN BUZZER...470
M-19 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...471
M-20 ABNORMALITY IN FAILURE DISPLAY MODE...472
M-21 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER...473
M-22 ABNORMALITY IN AUTO-GREASING SYSTEM (OP)...474
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP)...476
TROUBLEHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...477
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR...479
K-1 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO...480
K-2 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)...481
K-3 WHEN ENGINE IS STARTED IMMEDIATLY AFTER STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE GO OUT...482
K-4 WHEN STARTER SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH...483
K-5 WHEN STARTER SWITCH IS TURNED ON (ENGINE STARTED), CAUTION) ITEMS FLASH...485
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND...492
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS...493
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES...494
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHT UP...495
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHT SWITCH IS TURNED ON...496
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHT SWITCH IS TURNED OFF...497
K-12 SERVICE METER DOES NOT WORK...498
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED...498
K-14 ABNORMALITY IN GAUGE DISPLAY...499
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...503
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING...505
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING ...506
ENGINE PRE-LUBRICATION SYSTEM...507
ELECTRICAL DIA. - BOOM KICK-OUT / BUCKET POSITIONER...511
E-1 ENGINE DOES NOT START...512
E-2 ENGINE DOES NOT STOP (STD SPEC.)...517
E-3 ABNORMALITY IN PREHEATING SYSTEM...519
E-4 PARKING BRAKE DOES NOT HAVE EFFECT...523
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...524
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH TURNED ON...526
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED...526
E-8 KICK-DOWN SWITCH DOES NOT WORK...528
E-9 BOOM KICK-OUT DOES NOT WORK...530
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION...534
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP ...537
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP...537
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF...537
E-14 ABNORMALITY IN LOW IDLE SELECTION...537
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...537
E-16 ABNORMALITY IN BUZZER...537
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...539
H-1 MACHINE DOES NOT MOVE...540
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)...541
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...542
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...543
H-5 STEERING DOES NOT TURN...544
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK (OP)]...545
H-7 TURNING, RESPONSE OF STEERING IS POOR...546
H-8 TURNING RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK(OP)]...547
H-9 STEERING IS HEAVY...548
H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK(OP)] ...548
H-11 STEERING WHEEL SHAKES OR JERKS...549
H-12 STEERING WHEEL SHAKES OR JERKS SHOCK [MACHINE WITH JOYSTICK (OP)]...550
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING...550
H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...551
H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...552
H-16 BOOM DOES NOT RISE...553
H-17 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...554
H-18 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT...555
H-19 BOOM CYLINDER CANNOT HOLD DOWN BUCKET...555
H-20 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT...555
H-21 BOOM FLUCTUATES WHILE WORKING...556
H-22 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE...556
H-23 BUCKET DOES NOT TILT BACK...557
H-24 BUCKET MOVES SLOWLY AND HAS INSUFFICIENT TILT BACK POWER...558
H-25 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...559
H-26 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET...559
H-27 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT...559
H-28 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD...560
H-29 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT...560
H-30 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY...561
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J-MODE)...563
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM...564
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS...566
ELECTRIC DIAGRAM FOR JOYSTICK STEERING SYSTEM...570
J-1 FAILURE CODE [56] (SHORT CIRCUIT, 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, DISCONNECTION IN STEERING RIGHT SOLENOID CUT RELAY OUTPUT) IS DISPLAYED...577
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED...578
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED...579
J-9 ABNORMALITY IN POWER SUPPLY, 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...589
PRECAUTIONS DURING OPERATION...590
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...590
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...591
PRECAUTIONS WHEN COMPLETING THE OPERATIONS...592
OTHER PRECAUTIONS...592
SPECIAL TOOL LIST...593
SKETCHES OF SPECIAL TOOLS...601
ENGINE...609
ALTERNATOR...609
CYLINDER HEAD...609
DAMPER...609
ENGINE OIL COOLER...609
ENGINE FRONT SEAL...609
ENGINE REAR SEAL...609
FUEL INJECTION PUMP FOR LEFT BANK...609
FUEL INJECTION PUMP FOR RIGHT BANK...609
NOZZLE HOLDER...609
STARTING MOTOR...609
TURBOCHARGER...609
WATER PUMP...609
RADIATOR...610
REMOVAL...610
INSTALLATION...613
ENGINE...614
REMOVAL...614
INSTALLATION...620
TORQUE CONVERTER AND TRANSMISSION...621
REMOVAL...621
INSTALLATION...629
TORQUE CONVERTER...631
DISASSEMBLY...631
ASSEMBLY...635
TORQUE CONVERTER VALVE...640
DISASSEMBLY...640
ASSEMBLY...640
TRANSMISSION...641
DISASSEMBLY...641
ASSEMBLY...657
TRANSMISSION VALVE...673
REMOVAL...673
INSTALLATION...673
UPPER VALVE...674
DISASSEMBLY...674
ASSEMBLY...675
LOWER VALVE...676
DISASSEMBLY...676
ASSEMBLY...676
RELIEF VALVE...677
DISASSEMBLY...677
ASSEMBLY...677
TRANSFER...678
DISASSEMBLY...678
ASSEMBLY...686
PTO...696
DISASSEMBLY...696
ASSEMBLY...698
CENTER SUPPORT...701
REMOVAL...701
INSTALLATION...702
DISASSEMBLY...703
ASSEMBLY...705
DRIVE SHAFT...708
DISASSEMBLY...708
ASSEMBLY...710
FRONT AXLE...712
REMOVAL...712
INSTALLATION...714
REAR AXLE...715
REMOVAL...715
INSTALLATION...721
DIFFERENTIAL...723
REMOVAL...723
INSTALLATION...725
DISASSEMBLY...726
ASSEMBLY...730
FINAL DRIVE...736
DISASSEMBLY...736
ASSEMBLY...739
ORBIT-ROLL...742
REMOVAL...742
INSTALLATION...743
GROUND DRIVEN STEERING PUMP...744
REMOVAL...744
INSTALLATION...744
DIVERTER VALVE...745
REMOVAL...745
INSTALLATION...745
DISASSEMBLY...746
ASSEMBLY...747
ACCUMULATOR CHARGE VALVE...749
REMOVAL...749
INSTALLATION...749
DISASSEMBLY...750
ASSEMBLY...751
STEERING STOP VALVE...753
REMOVAL...753
INSTALLATION...753
STEERING CYLINDER...754
REMOVAL...754
INSTALLATION...755
STEERING VALVE...756
REMOVAL...756
INSTALLATION...757
BRAKE VALVE...758
REMOVAL...758
INSTALLATION...758
SLACK ADJUSTER...759
REMOVAL...759
INSTALLATION...759
DISASSEMBLY...760
ASSEMBLY...761
BRAKE...762
REMOVAL...762
INSTALLATION...763
DISASSEMBLY...764
ASSEMBLY...767
PARKING BRAKE CALIPERS...771
REMOVAL...771
INSTALLATION...772
DISASSEMBLY...773
ASSEMBLY...774
PARKING BRAKE PAD...776
REMOVAL...776
INSTALLATION...777
PARKING BRAKE SPRING CYLINDER...778
REMOVAL...778
INSTALLATION...778
BRAKE OIL TANK...779
REMOVAL...779
INSTALLATION...779
HYDRAULIC PUMP...780
REMOVAL...780
INSTALLATION...782
HYDRAULIC TANK AND FILTER CASE...783
REMOVAL...783
INSTALLATION...784
PPC VALVE...785
REMOVAL...785
INSTALLATION...786
DISASSEMBLY...787
ASSEMBLY...787
WORK EQUIPMENT CONTROL VALVE...788
REMOVAL...788
INSTALLATION...789
DISASSEMBLY...790
ASSEMBLY...792
CAB...794
REMOVAL...794
INSTALLATION...797
FLOOR FRAME...798
REMOVAL...798
INSTALLATION...801
CENTER HINGE PIN...802
REMOVAL...802
INSTALLATION...808
WORK EQUIPMENT...812
REMOVAL...812
INSTALLATION...817
BOOM FRONT END BUSHING...818
REPLACEMENT...818
BUCKET CYLINDER...819
REMOVAL...819
INSTALLATION...819
LIFT CYLINDER...821
REMOVAL...821
INSTALLATION...822
HYDRAULIC CYLINDER...823
DISASSEMBLY...823
ASSEMBLY...825
AIR CONDITIONER UNIT...827
REMOVAL...827
INSTALLATION...828
AIR CONDITIONER COMPRESSOR...829
REMOVAL...829
INSTALLATION...829
RECEIVER TANK...830
REMOVAL...830
INSTALLATION...830
AIR CONDITIONER CONDENSER...831
REMOVAL...831
INSTALLATION...832
TRANSMISSION AND STEERING CONTROLLER...833
REMOVAL...833
INSTALLATION...833
MAIN MONITOR...834
REMOVAL...834
INSTALLATION...835
FUEL TANK...836
REMOVAL...836
INSTALLATION...837
COUNTERWEIGHT - STANDARD...838
REMOVAL...838
INSTALLATION...839
COUNTERWEIGHT - HIGH-LIFT...840
REMOVAL...840
INSTALLATION...841
40 MAINTENANCE STANDARD...843
ENGINE MOUNT...844
TRANSMISSION MOUNT...845
DAMPER...846
HYDRAULIC PUMPS...848
TORQUE CONVERTER CHARGING, PPC AND BRAKE...848
TORQUE CONVERTER...850
REGULATOR VALVE...851
TRANSMISSION...852
CLUTCH...852
GEAR...854
TRANSMISSION CONTROL VALVE...856
UPPER VALVE...856
LOWER VALVE...858
DRIVE SHAFT...861
CENTER SUPPORT...862
DIFFERENTIAL...863
Assembly Torques...863
Gears...864
FINAL DRIVE...866
AXLE MOUNT...868
CENTER HINGE PIN...870
STEERING COLUMN...872
STEERING DEMAND VALVE...873
DIVERTER VALVE...875
STEERING CYLINDER MOUNT...876
GROUND DRIVEN STEERING PUMP...877
BRAKE VALVE...878
SLACK ADJUSTER...881
BRAKE...882
PARKING BRAKE...884
PPC VALVE...886
PPC RELIEF VALVE...888
CONTROL PUMP (BAR025)...889
MAIN CONTROL VALVE...891
HYDRAULIC CYLINDER...893
BUCKET LINKAGE...895
BUCKET POSITIONER AND BOOM KICK-OUT...897
90 OTHERS (SHOP MANUAL FOLDOUTS)...899
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 1 OF 6)...901
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 2 OF 6)...903
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 3 OF 6)...905
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 4 OF 6)...907
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 5 OF 6)...909
FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 6 OF 6)...911
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 1 OF 4)...913
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 2 OF 4)...915
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 3 OF 4)...917
FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 4 OF 4)...919
FOLDOUT 20-217 CONNECTOR ARRANGEMENT DIAGRAM (1 OF 3)...921
FOLDOUT 20-219 CONNECTOR ARRANGEMENT DIAGRAM (2 OF 3)...923
FOLDOUT 20-409 ELECTRICAL DIAGRAM FOR TRANSMISSION CONTROLLER...925
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 1 OF 4)...927
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 2 OF 4)...929
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 3 OF 4)...931
FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 4 OF 4)...933
FOLDOUT 20-603 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM...935
FOLDOUT 20-703 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING, AND PREHEATING...937
