Komatsu Wheel Loader WA500LK Series avance plus Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA500-3LK avance plus, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA500-3LK avance plus 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: 1,441 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM008101 - Wheel Loader WA500-3LK avance plus Operation & Maintenance Manual.pdf
CEBM005403 - Wheel Loader WA500-3LK avance plus Shop Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...15
SAFETY NOTICE...15
IMPORTANT SAFETY NOTICE...15
GENERAL PRECAUTIONS...15
PREPARATIONS FOR WORK...15
PRECAUTIONS DURING WORK...15
GENERAL...17
HOW TO READ THE SHOP MANUAL...18
VOLUMES...18
DISTRIBUTION AND UPDATING...18
FILING METHOD...18
REVISED EDITION MARK...18
REVISIONS...18
SYMBOLS...18
HOISTING INSTRUCTIONS...19
HOISTING...19
WIRE ROPES...19
PUSH-PULL TYPE COUPLER...20
COATING MATERIALS...23
STANDARD TIGHTENING TORQUE...25
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...25
TIGHTENING TORQUE OF HOSE NUTS...26
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...26
TIGHTENING TORQUE FOR FLARED NUTS...26
ELECTRIC WIRE CODE...27
CLASSIFICATION BY THICKNESS...27
CLASSIFICATION BY COLOR AND CODE...27
CONVERSION TABLES...28
METHOD OF USING THE CONVERSION TABLE...28
01 GENERAL...35
DIMENSIONS...36
SPECIFICATIONS...38
WEIGHT TABLE...41
FUEL, COOLANT AND LUBRICATNTS...42
ENGINE OIL...43
NORMAL OPERATION...43
ARCTIC OPERATION...45
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL...45
AXLE OIL...45
GREASE...46
DIESEL FUEL...46
COOLANT SPECIFICATIONS...47
GENERAL...47
WATER...47
ANTIFREEZE...47
SUPPLEMENTAL COOLANT ADDITIVES...49
10 STRUCTURE AND FUNCTION...51
GENERAL...55
RADIATOR AND OIL COOLER...58
DAMPER...60
TORQUE CONVERTER AND TRANSMISSION PIPING...62
HYDRAULIC CIRCUIT FOR POWER TRAIN...64
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...65
TORQUE CONVERTER AND PTO...66
TRANSMISSION...68
TRANSMISSION CUTAWAY...70
OPERATION OF CLUTCH...72
FORWARD 1ST...73
FORWARD 2ND...74
FORWARD 3RD...75
FORWARD 4TH...76
REVERSE 1ST...77
TRANMISSION CONTROL VALVE...78
ECMV (ELECTRONIC CONTROL MODULATION VALVE)...80
OUTLINE OF ECMV...82
ECMV AND PROPORTIONAL SOLENOID...82
ECMV AND FILL SWITCH...82
ACTUATION OF ECMV...83
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE...86
MAIN RELIEF VALVE...87
TORQUE CONVERTER RELIEF VALVE...87
LUBRICATING RELIEF VALVE...88
TORQUE CONVERTER OIL FILTER...89
PILOT FILTER...90
TRANSFER...91
DRIVE SHAFT...92
CENTER SUPPORT...93
AXLE...94
FRONT...94
REAR...95
DIFFERENTIAL...96
NORMAL - (STANDARD)...96
FRONT...96
REAR...97
LIMITED SLIP (OPTION)...99
FRONT...99
REAR...99
FINAL DRIVE...104
AXLE MOUNT...106
CENTER HINGE PIN...108
TIRE AND WHEEL...109
STEERING PIPING...110
STEERING COLUMN...111
STEERING VALVE...112
DEMAND VALVE OPERATION...113
STEERING SPOOL AT NEUTRAL...113
STEERING SPOOL OPERATED - ENGINE AT LOW SPEED...114
STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED...115
FLOW AMP...116
FLOW AMP OPERATION...116
STEERING VALVE OPERATION...119
STEERING RELIEF VALVE...122
RELIEF VALVE OPERATION...123
SAFETY VALVE (WITH SUCTION)...124
ORBIT-ROLL VALVE...126
STOP VALVE...130
DIVERTER VALVE...131
BRAKE...134
BRAKE PIPING...134
BRAKE CIRCUIT DIAGRAM...136
BRAKE VALVE...138
RIGHT BRAKE VALVE...138
LEFT BRAKE VALVE...139
CHARGE VALVE...144
ACCUMULATOR (FOR BRAKE)...148
SLACK ADJUSTER...149
BRAKE...151
PARKING BRAKE...153
PARKING BRAKE CONTROL...153
PARKING BRAKE...154
PARKING BRAKE SOLENOID VALVE...155
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE...156
HYDRAULIC...157
HYDRAULIC PIPING...157
HYDRAULIC CIRCUIT DIAGRAM...159
MACHINES WITH STANDARD SPECIFICATIONS...159
WORK EQUIPMENT LEVER LINKAGE...162
HYDRAULIC TANK...163
OIL FILTER BY-PASS VALVE...164
BREATHER...164
ACCUMULATOR (FOR PPC VALVE)...165
PPC VALVE...166
FOR BUCKET / BOOM...166
FOR OPTIONAL ATTACHMENT...168
PPC VALVE NEUTRAL POSITION...170
PPC VALVE POSITIONS FUNCTIONS...171
PPC RELIEF VALVE...173
CUT-OFF VALVE...174
ECSS CONTROL VALVE...176
MAIN CONTROL VALVE...178
2-SPOOL...178
3-SPOOL...180
RELIEF VALVE...183
SAFETY VALVE (WITH SUCTION)...184
FLOAT SELECTOR VALVE AND UNLOAD VALVE...186
BOOM AND DUMP SPOOLS AT HOLD POSITION...187
BOOM SPOOL AT RAISE POSITION...188
BOOM SPOOL AT LOWER POSITION...189
BOOM SPOOL AT FLOAT POSITION...190
BUCKET SPOOL AT DUMP POSITION...191
BUCKET SPOOL AT TILT POSITION...192
WORK EQUIPMENT...194
WORK EQUIPMENT LINKAGE...194
BUCKET...196
BUCKET POSITIONER AND BOOM KICK-OUT...198
BUCKET POSITIONER...199
BOOM KICK-OUT...199
PROXIMITY SWITCH...200
CAB...205
ROPS CANOPY...206
AIR CONDITIONER...207
AIR CONDITIONER PIPING...207
AIR CONDITIONING (GENERAL)...208
BASIC INFORMATION ON AIR CONDITIONERS...208
HEAT...208
TEMPERATURE...209
PRESSURE...210
HUMIDITY...211
PRINCIPLE OF COOLING...211
REFRIGERANTS...216
FREON-TYPE GASES...216
SAFETY PRECAUTIONS...216
REFRIGERATOR OIL (LUBE OIL)...217
AIR CONDITONING CONDENSER...218
AIR CONDITIONER COMPRESSOR...221
RECEIVER WITH SIGHT GLASS (LIQUID TANK)...222
AIR CONDITIONER UNIT...224
MONITOR SYSTEMS...225
MACHINE MONITOR SYSTEM...225
MAIN MONITOR...226
MAIN MONITOR DISPLAY FUCTION...227
MAIN MONITOR SWITCH FUNCTION...228
TROUBLE DATA DISPLAY MODE...229
MAINTENANCE MONITOR...230
MAINTENANCE MONITOR DISPLAY FUNCTION...231
MAINTENANCE MONITOR SWITCH FUNCTION...232
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM...233
SYSTEM STRUCTURE DIAGRAM...234
FUNCTION...235
TRANSMISSION CONTROLLER POWER SOURCE...240
INPUT SIGNALS...240
OUTPUT SIGNALS...242
LED DISPLAY...243
JOYSTICK TRANSMISSION SYSTEM...245
REMOTE POSITION, JOYSTICK STEERING CONTROLLER...246
ECSS SYSTEM...247
TRANSMISSION CONTROLLER...252
CONNECTOR SIGNALS...253
SENSORS...254
SPEEDOMETER SENSOR...254
ENGINE SPEED SENSOR...255
ENGINE OIL PRESSURE SENSOR...255
RADIATOR WATER LEVEL SENSOR...256
ENGINE OIL LEVEL SENSOR...256
FUEL LEVEL SENSOR...257
ENGINE WATER TEMPERATURE SENSOR...258
TORQUE CONVERTER OIL TEMPERATURE SENSOR...258
ELECTRICAL...259
ENGINE STARTING CIRCUIT...259
ENGINE STOP CIRCUIT...260
PREHEATING CIRCUIT...261
ELECTRICAL TRANSMISSION CONTROL...263
COMBINATION SWITCH...264
KICK-DOWN / HOLD SWITCH...266
KICK-DOWN SWITCH...266
HOLD SWITCH...266
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS...267
NORMAL OPERATION...267
WHEN KICK-DOWN SWITCH IS OPERATED...268
KICK-DOWN SWITCH OPERATION CANCELED...269
ELECTRIC PARKING BRAKE CONTROL...271
PARKING BRAKE EMERGENCY RELEASE SWITCH...273
EMERGENCY BRAKE SWITCH...273
PARKING SAFETY RELAY...274
NEUTRALIZER RELAY...274
ELECTRICAL DIAGRAM...283
ECSS WIRING DIAGRAM - FOLDOUT 10-225-1...283
JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-4, (Sheet 1) (Part 2 of 5)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-5, (Sheet 1) (Part 3 of 5)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-6, (Sheet 1) (Part 4 of 5)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-7, (Sheet 1) (Part 5 of 5)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-8, (Sheet 2) (Part 1 of 4)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-9, (Sheet 2) (Part 2 of 4)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-10, (Sheet 2) (Part 3 of 4)...283
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-11, (Sheet 2) (Part 4 of 4)...283
ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12...283
CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13...283
ENGINE HARNESS DIAGRAM...284
ENGINE - FRAME - FLOOR HARNESS DIAGRAM...285
A. The standard values in tables are those established for a new machine and are given as referen...289
B. Permissible values shown in the tables are estimations based on the results of test performed ...289
C. These standard values do not form a basis for judging claims...289
20 TESTING, ADJUSTING AND TROUBLESHOOTING...287
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS...291
STANDARD VALUE TABLE FOR CHASSIS...292
SKETCHES OF SPECIAL TOOLS...313
ENGINE...314
COMPONETS...314
BLEEDING AIR FROM FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)...314
BLOW-BY PRESSURE (REFER TO ENGINE SHOP MANUAL)...314
COMPRESSION PRESSURE (REFER TO ENGINE SHOP MANUAL)...314
EXHAUST TEMPERATURE (REFER TO ENGINE SHOP MANUAL)...314
FUEL PRESSURE (REFER TO ENGINE SHOP MANUAL)...314
HANDLING EQUIPMENT IN FUEL CIRCUIT (REFER TO ENGINE SHOP MANUAL)...314
INTAKE AIR PRESSURE (BOOST PRESSURE) (REFER TO ENGINE SHOP MANUAL)...314
LEAKAGE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)...314
OIL PRESSURE (REFER TO ENGINE SHOP MANUAL)...314
PERFORMANCE TEST STANDARDS (REFER TO ENGINE SHOP MANUAL)...314
RELEASING REMAINING PRESSURE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)...314
RUN-IN STANDARD (REFER TO ENGINE SHOP MANUAL)...314
SPEED SENSOR (REFER TO ENGINE SHOP MANUAL)...314
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (REFER TO ENGINE SHOP MANUAL)...314
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (REFER TO ENGINE SHOP MANUAL)...314
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (REFER TO ENGINE SHOP MANUAL)...314
VALVE CLEARANCE (REFER TO ENGINE SHOP MANUAL)...314
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT...315
REDUCED CYLINDER MODE...316
ALTERNATOR BELT TENSION...319
FAN BELT TENSION...320
AIR CONDITIONER BELT...321
TORQUE CONVERTER STALL SPEEDS...322
SHIFT LEVERS...323
OPERATING FORCE OF SPEED LEVER...323
TRAVEL OF SPEED LEVER...323
ACCELERATOR PEDAL...324
OPERATING FORCE...324
OPERATING ANGLE...325
TORQUE CONVERTER AND TRANSMISSION...326
OIL PRESSURE...326
HYDRAULIC CIRCUIT FLUSHING...329
TRANSMISSION VALVE FAILS - MOVING MACHINE...331
STEERING WHEEL...333
MEASURING PLAY...333
MEASURING OPERATING FORCE...333
MEASURING OPERATING TIME...334
STEERING OIL PRESSURE...335
MEASURING...335
ADJUSTING...336
STEERING STOP VALVE...337
TESTING...337
ADJUSTING...337
BRAKE PEDAL...338
OPERATING FORCE...338
TRAVEL...338
PEDAL PLAY...338
BRAKE PERFORMANCE...339
TESTING BRAKE OIL PRESSURE...340
BRAKE DISC WEAR...341
PARKING BRAKE...342
OIL PRESSURE...343
DISC WEAR...345
MANUAL RELEASE METHOD...346
PPC VALVE...347
OIL PRESSURE...347
MEASURING...347
ADJUSTING...348
ADJUSTING LINKAGE...349
ACCUMULATOR...350
CHARGE PRESSURE...350
MEASURING...350
ADJUSTING...350
WORK EQUIPMENT...351
HYDRAULIC PRESSURE...351
ADJUSTING...352
CUT-OFF VALVE...353
TESTING FUNCTION...353
PROCEDURE...353
LEVER LINKAGE...355
ADJUSTING...355
BUCKET POSITIONER...356
TESTING...356
ADJUSTING...356
BOOM KICK-OUT POSITIONER...357
TESTING...357
ADJUSTING...357
TRANSMISSION CONTROLLER...359
INITIAL TEACHING METHOD...359
MAIN MONITOR...361
ADJUSTMENT PROCEDURE...361
BLEEDING AIR...363
RELEASING REMAINING HYDRAULIC OIL PRESSURE...364
ADJUSTING JOYSTICK LEVER POTENTIOMETER...365
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH...367
TROUBLESHOOTING GENERAL...369
POINTS TO REMEMBER WHEN TROUBLEHSOOTING...371
SEQUENCE OF EVENTS IN TROUBLESHOOTING...373
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...374
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...374
HANDLING CONTROL BOX...379
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...380
CHECKS BEFORE TROUBLESHOOTING...382
JUDGEMENT OF POWER TRAIN...383
PRECAUTIONS WHEN TROUBLESHOOTING...384
SAFETY...384
METHODS FOR TROUBLESHOOTING...384
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING...386
PREVENTING RECURRENCE OF TROUBLE...387
HYDRAULIC EQUIPMENT...387
OIL CHECKS...387
CLEANING FRAGMENTS OF DAMAGED PARTS...387
METHOD OF USING TROUBLESHOOTING CHARTS...388
CATEGORY OF TROUBLESHOOTING CODE NUMBER...388
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...388
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...390
METHOD OF USING ENGINE RELATED CHARTS...392
TROUBLESHOOTING CONNECTORS...397
CONNECTOR ARRANGEMENT DIAGRAM...399
CONNECTOR NUMBERS, TYPES AND PINS...400
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...409
TROUBLESHOOTING EXPLANATION OF FUNCTION OF ECM (ELECTRIC CONTROL MECHANISM)...421
EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL MECHANISM)...422
TRANSMISSION CONTROL SYSTEM...422
MAIN MONITOR SYSTEM...426
MAINTENANCE MONITOR SYSTEM...430
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) CONTROL SYSTEM...434
JOYSTICK STEERING CONTROL SYSTEM...438
METHOD OF DISPLAYING ACTION AND FAILURE CODE...441
CONTROLLERS AND FAILURE CODES...443
RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM...446
MAIN MONITOR FAILURE DISPLAY...446
TRANSMISSION CONTROLLER LED DISPLAY...449
ERROR CODE DISPLAYS...450
TROUBLESHOOTING OF ECSS (D MODE)...453
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM...454
D-1 ECSS DOES NOT WORK...456
A. ERROR CODE (D0) IS DISPLAYED...456
B. NO ABNORMALITY DISPLAY IS GIVEN...458
1. DOES NOT WORK AT ALL...458
D-2 ECSS CANNOT BE CANCELLED...459
TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE)...461
E-1 ENGINE DOES NOT START...462
A. STARTING MOTOR DOES NOT TURN...462
B. STARTING MOTOR TURNS...466
E-2 ENGINE DOES NOT STOP...470
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING...472
E-5 PARKING BRAKE DOES NOT HAVE EFFECT...474
A. PARKING BRAKE HAS NOT EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (ACTUATED)...474
B. PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE)...474
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...476
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...480
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)...482
E-9 KICK-DOWN SWITCH DOE NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)...484
A. KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)...484
B. KICK-DOWN IS NOT CANCELLED...484
E-10 BOOM KICK-OUT CANNOT BE USED...486
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION...490
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP...493
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP...493
E-14 ABNORMALITY IN TRANMISSION CUT-OFF...493
E-15 ABNORMALITY IN PAKING BRAKE DRAGGING WARNING...493
E-16 ABNORMALITY IN BUZZER...493
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...495
POWER TRAIN...496
H-1 MACHINE DOES NOT START...496
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES, DOES NOT SHIFT GEAR...500
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR...505
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...508
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...511
STEERING SYSTEM...512
H-6 STEERING WHEEL DOES NOT TURN...512
H-7 STEERING DOES NOT TURN (MACHINE WITH JOYSTICK)...513
H-8 TURNING, RESPONSE OF STEERING IS POOR...514
H-9 TURNING, RESPONSE OF STEERING IS POOR (MACHINE WITH JOYSTICK)...515
H-10 STEERING IS HEAVY...516
H-11 JOYSTICK STEERING IS HEAVY (MACHINES EQUIPPED WITH JOYSTICK)...517
H-12 STEERING WHEEL SHAKES OR JERKS...518
H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK)...519
H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING...520
BRAKE SYSTEM...522
H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...522
H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...524
H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR...525
H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)...526
WORK EQUIPMENT...527
H-19 NEITHER BOOM NOR BUCKET MOVE...527
H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER...528
H-21 BOOM DOES NOT MOVE...529
H-22 NOT USED...529
H-23 BOOM IS SLOW OR BOOM LACKS POWER...530
H-24 NOT USED...530
H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT...531
H-26 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...532
H-27 NOT USED...532
H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM...533
H-29 BUCKET DOES NOT MOVE...534
H-30 BUCKET IS SLOW OR LACKS POWER...535
H-31 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...536
H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]...537
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)...539
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS...541
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR...542
JOYSTICK CONTROLLER SYSTEM...542
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED...546
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED...547
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED...548
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END) IS DISPLAYED...549
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END) IS DISPLAYED...550
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DIS...551
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPL...552
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYST...553
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE...554
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM...555
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID...556
J-12 DISCONNECTION IN STEERING LEFT SOLENOID...557
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...559
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC...561
A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...561
B. SOME LAMPS DO NOT LIGHT UP...561
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OU...562
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO ...563
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH...564
A. ENGINE OIL LEVEL DISPLAY FLASHES...564
B. ENGINE WATER LEVEL DISPLAY FLASHES...565
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH...566
A. ENGINE OIL PRESSURE DISPLAY FLASHES...566
B. BATTERY CHARGE LEVEL DISPLAY FLASHES...567
C. BRAKE OIL PRESSURE DISPLAY FLASHES...568
D. AIR CLEANER DISPLAY FLASHES...569
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND...570
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS...571
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH...572
A. CHECK LAMP...572
B. CAUTION LAMP...572
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION ...573
A. CHECK LAMP...573
B. CAUTION LAMP...573
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON...574
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF...575
K-12 SERVICE METER DOES NOT WORK...576
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED...577
K-14 ABNORMALITY IN GAUGE ITEMS...578
A. ABNORMALITY IN FUEL GAUGE...578
B) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE...579
C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...580
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...581
M-1 MAIN MONITOR DOES NOT WORK...583
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP...584
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...585
M-4 ABNORMALITY IN SHIFT INDICATOR...586
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F...586
B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R...586
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R WHEN DIRECTIONAL LEVER ...586
D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAY F WHEN DIRECTIONAL LEVER I...587
E. DOES NOT DISPLAY 1ST - 4TH...587
M-5 HIGH BEAM DOES NOT LIGHT UP...588
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...589
A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP...589
B. RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP...589
M-7 ABNORMALITY IN PARKING DISPLAY...590
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP...590
B. PARKING LAMP DISPLAY STAYS LIT UP...590
M-8 NOT USED...591
M-9 NIGHT LIGHTING DOES NOT LIGHT UP...592
M-10 ABNORMALITY IN FRONT WORKING LAMP...594
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP...594
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP...594
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP...594
M-11 ABNORMALITY IN REAR WORKING LAMP...596
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...596
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP...596
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP...596
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...598
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED...598
B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT, BUT CUT-OF...598
C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION ...598
D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH...598
E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURN ON), BUT CUT-OFF FUNCTION IS NOT A...599
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...600
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN W...600
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W...600
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU...602
A. ACTUATED CONTINOUSLY...602
B. NOT ACTUATED...602
M-15 ABNORMALITY IN BUZZER...603
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)...603
B. BUZZER ALWAYS SOUNDS...603
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...604
M-17 ABNORMALITY IN FAILURE DISPLAY MODE...605
A. DOES NOT ENTER FAILURE DISPLAY MODE...605
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE...605
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER...606
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY...607
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP...607
B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP...607
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY...608
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP...608
B. EMERGENCY STEERING DISPLAY STAYS LIT UP...608
M-21 NOT USED...609
M-22 ABNORMALITY IN ECSS SYSTEM...705
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED...610
B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK...610
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...718
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)...613
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS...616
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...618
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP L...624
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI...626
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI...628
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN...630
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLEN...632
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN...634
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN...636
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS...638
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...640
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED...644
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED...648
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...650
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED...652
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED...653
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL SWITCH SYSTEM) IS DISPLAYED...654
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED...655
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED...656
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED...657
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED...658
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED...659
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED...660
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED...662
T-23 HOLD SWITCH SYSTEM...665
T-24 KICK-DOWN SWITCH SYSTEM...666
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM...667
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM...668
T-27 BUZZER SIGNAL SYSTEM...669
T-28 NETWORK SYSTEM...670
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM...671
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...672
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM...673
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM...674
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM...675
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM...676
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM...677
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM...678
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM...679
TROUBLESHOOTING AIR CONDITIONING (DENSO)...681
AIR CONDITIONER / HEATER (DENSO)...682
VISUAL AND AUDIBLE INSPECTION...682
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)...683
NORMAL CONDITIONS...683
INSUFFICIENT REFRIGERANT...683
REFRIGERANT FAILS TO CIRCULATE (SYSTEM CLOGGED)...684
MOISTURE IN SYSTEM...684
COMPRESSOR FAILURE...684
EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING...685
AIR IN THE SYSTEM...685
EXPANSION VALVE OPENS TOO FAR...685
TROUBLESHOOTING THE ELECTRICAL CIRCUIT...686
BLOWER TROUBLESHOOTING...686
ELECTRICAL CIRCUIT CHECKS...688
HEATER RELAY...688
BLOWER SWITCH...688
COOLER CIRCUIT TROUBLESHOOTING...690
AIR CONDITIONER SWITCH...690
MAGNETIC CLUTCH RELAY...690
CONDENSER FAN OPERATION CIRCUIT...691
ERROR MESSAGE TABLES...694
A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER...694
B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER...694
C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS...695
D. PROBLEM - NO HEAT...695
E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF, WHEN THE POWER IS TURNED ON...695
F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS DEFROST BUTTON IS PUSHED...696
WIRING DIAGRAM...698
WIRE CHART...699
INSPECTION AREAS...700
30 DISASSEMBLY AND ASSEMBLY...701
METHOD OF USING MANUAL...705
PRECAUTIONS DURING OPERATION...706
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...706
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...707
PRECAUTIONS WHEN COMPLETING THE OPERATIONS...708
OTHER PRECAUTIONS...708
SPECIAL TOOL LIST...709
SKETCHES OF SPECIAL TOOLS...713
ENGINE...716
COMPONENTS...716
ALTERNATOR (REFER TO THE ENGINE SHOP MANUAL)...716
CYLINDER HEAD (REFER TO THE ENGINE SHOP MANUAL)...716
ENGINE FRONT SEAL (REFER TO THE ENGINE SHOP MANUAL)...716
ENGINE OIL COOLER (REFER TO THE ENGINE SHOP MANUAL)...716
ENGINE REAR SEAL (REFER TO THE ENGINE SHOP MANUAL)...716
FUEL INJECTION PUMP (REFER TO THE ENGINE SHOP MANUAL)...716
NOZZLE HOLDER (REFER TO THE ENGINE SHOP MANUAL)...716
STARTING MOTOR (REFER TO THE ENGINE SHOP MANUAL)...716
THERMOSTAT (REFER TO THE ENGINE SHOP MANUAL)...716
TURBOCHARGER (REFER TO THE ENGINE SHOP MANUAL)...716
WATER PUMP (REFER TO THE ENGINE SHOP MANUAL)...716
REMOVAL...716
INSTALLATION...720
RADIATOR...722
REMOVAL...722
INSTALLATION...723
DAMPER...724
REMOVAL...724
INSTALLATION...725
DISASSEMBLY...726
ASSEMBLY...729
TORQUE CONVERTER AND TRANSMISSION...734
REMOVAL...734
INSTALLATION...737
DISCONNECTION...738
CONNECTION...738
TORQUE CONVERTER...739
DISASSEMBLY...739
ASSEMBLY...743
TRANSMISSION...750
DISASSEMBLY...750
ASSEMBLY...767
TRANSFER...784
DISASSEMBLY...784
ASSEMBLY...788
PARKING BRAKE...793
DISASSEMBLY...793
ASSEMBLY...796
TRANSMISSION CONTROL VALVE (ECMV)...800
REMOVAL...800
INSTALLATION...800
CENTER SUPPORT...801
REMOVAL...801
INSTALLATION...802
DISASSEMBLY...803
ASSEMBLY...805
DRIVE SHAFT...808
DISASSEMBLY...808
ASSEMBLY...811
FRONT AXLE...814
REMOVAL...814
INSTALLATION...815
REAR AXLE...816
REMOVAL...816
INSTALLATION...820
DIFFERENTIAL...822
REMOVAL (FRONT)...822
INSTALLATION (FRONT)...824
REMOVAL (REAR)...825
INSTALLATION (REAR)...826
DISASSEMBLY DIFFERENTIAL GEAR ASSEMBLY...827
FINE DISASSEMBLY OF PINION ASSEMBLY...829
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY...830
FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY...831
FINE ASSEMBLY OF PINION ASSEMBLY...832
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...833
DISSASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY...839
FINE DISASSEMBLY OF PINION ASSEMBLY...841
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY...842
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY...843
FINE ASSEMBLY OF PINION ASSEMBLY...845
ASSEMBLY OF DIFFERENTIAL ASSEMBLY...846
DISASSEMBLY OF FINAL DRIVE ASSEMBLY...853
ASSEMBLY OF FINAL DRIVE ASSEMBLY...856
STEERING ORBITAL VALVE...860
REMOVAL...860
INSTALLATION...860
DISASSEMBLY...861
ENSURE A CLEAN WORKING ENVIRONMENT...861
PREPARATORY WORK...861
ASSEMBLY...866
STEERING CYLINDER...874
REMOVAL...874
INSTALLATION...875
DISASSEMBLY...876
ASSEMBLY...878
STEERING VALVE...880
REMOVAL...880
INSTALLATION...882
BRAKE VALVE...884
REMOVAL...884
INSTALLATION...885
SLACK ADJUSTER...886
REMOVAL...886
INSTALLATION...886
DISASSEMBLY...887
ASSEMBLY...888
BRAKE ASSEMBLY (FRONT AND REAR)...889
REMOVAL...889
INSTALLATION...889
DISASSEMBLY...890
ASSEMBLY...893
HYDRAULIC PUMP...898
REMOVAL...898
INSTALLATION...899
HYDRAULIC TANK...900
REMOVAL...900
INSTALLATION...901
HYDRAULIC FILTER...902
REMOVAL...902
INSTALLATION...902
PPC VALVE...903
REMOVAL...903
INSTALLATION...903
DISASSEMBLY...904
ASSEMBLY...904
MAIN CONTROL VALVE...905
REMOVAL...905
INSTALLATION...907
DISASSEMBLY...908
ASSEMBLY...912
BUCKET CYLINDER...915
REMOVAL...915
INSTALLATION...916
DISASSEMBLY...917
ASSEMBLY...919
BOOM CYLINDER...922
REMOVAL...922
INSTALLATION...923
DISASSEMBLY...924
ASSEMBLY...926
CENTER HINGE PIN...929
REMOVAL...929
INSTALLATION...935
WORK EQUIPMENT...938
REMOVAL...938
INSTALLATION...942
BULKHEAD...944
REMOVAL...944
INSTALLATION...945
ENGINE HOOD...946
REMOVAL...946
INSTALLATION...948
CAB...950
REMOVAL...950
INSTALLATION...952
FLOOR FRAME...953
REMOVAL...953
INSTALLATION...955
COUNTERWEIGHT...956
REMOVAL...956
INSTALLATION...956
FUEL TANK...958
REMOVAL...958
INSTALLATION...959
AIR CONDITIONER UNIT...960
REMOVAL...960
INSTALLATION...961
CONDENSER...962
REMOVAL...962
INSTALLATION...962
RECEIVER TANK...963
REMOVAL...963
INSTALLATION...963
COMPRESSOR ASSEMBLY...964
REMOVAL...964
INSTALLATION...965
MAIN MONITOR...966
REMOVAL...966
INSTALLING...967
40 MAINTENANCE STANDARD...969
ENGINE MOUNT...971
TRANSMISSION MOUNT...972
TORQUE CONVERTER CHARGING PUMP...974
DAMPER...976
TORQUE CONVERTER AND PTO...978
TRANSMISSION...980
TRANSFER...984
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE...986
LUBRICATION RELIEF VALVE...987
DRIVE SHAFT...988
CENTER SUPPORT...990
DIFFERENTIAL, NORMAL - (STANDARD)...992
DIFFERENTIAL, LIMITED SLIP...996
FINAL DRIVE...998
AXLE MOUNT...1000
CENTER HINGE PIN...1002
STEERING COLUMN...1006
STEERING PUMP...1008
STEERING VALVE...1009
STEERING CYLINDER MOUNT...1010
BRAKE VALVE...1012
RIGHT...1012
LEFT...1014
SLACK ADJUSTER...1016
BRAKE...1018
PARKING BRAKE...1020
HYDRAULIC PUMP...1021
SAR(4)-160...1021
SWITCH, PPC PUMP...1022
SAR(3)-63 + SAR(1)-28...1022
PPC VALVE...1023
FOR BUCKET AND BOOM...1023
FOR AUXILIARY ATTACHMENT...1024
CUT-OFF VALVE...1025
MAIN CONTROL VALVE...1026
2 SPOOL VALVE...1026
3-SPOOL...1028
HYDRAULIC CYLINDERS...1030
BUCKET LINKAGE...1032
BUCKET...1034
BUCKET POSITIONER AND BOOM KICK-OUT...1035
ROPS CAB...1036
90 OTHERS...1037
ELECTRICAL DIAGRAMS...1039
ECSS WIRING DIAGRAM...1039
JOYSTICK STEERING WIRING DIAGRAM...1041
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 OF 5)...1043
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 2 OF 5)...1045
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 3 OF 5)...1047
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 4 OF 5)...1049
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 5 OF 5)...1051
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 1 OF 4)...1053
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 2 OF 4)...1055
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 3 OF 4)...1057
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 4 OF 4)...1059
ENGINE FLOOR HARNESS DIAGRAM...1061
CAB ELECTRICAL DIAGRAM...1063
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5)...1065
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 2 OF 5)...1067
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5)...1069
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 4 OF 5)...1071
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 5 OF 5)...1073
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2)...1075
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2)...1077
PARKING BRAKE CONTROL DIAGRAM...1079
HYDRAULIC...1081
CIRCUIT DIAGRAM...1081
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)...1083
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)...1085
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)...1087
STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)...1089
STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)...1091
STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)...1093
HYDRAULIC LINE ASSEMBLY (PART 1 OF 3)...1095
HYDRAULIC LINE ASSEMBLY (PART 2 OF 3)...1097
HYDRAULIC LINE ASSEMBLY (PART 3 OF 3)...1099
COVER....1
INTRODUCTION....3
FOREWORD....4
SAFETY INFORMATION....5
APPROVED AND NON-APPROVED USES....6
Approved Functions....6
Non-Approved Functions....6
VISIBILITY STANDARD....7
Visibility in Immediate Area....7
12-M Radius Visibility....7
PRODUCT IDENTIFICATION....8
Directions of Machine....8
Machine Serial Number....9
Engine Serial Number, EPA Regulations....9
Service Meter Location....10
SERIAL NUMBERS AND DEALER INFORMATION....11
Model: WA500-3LK....11
TABLE OF CONTENTS....13
SAFETY....25
SAFETY AND WARNING DECALS....26
Location of the Safety Decals....26
Safety Labels....27
Additional Safety Decals....32
GENERAL SAFETY RULES AND PRECAUTIONS....34
General Safety Rules....34
Unauthorized Modifications....34
General Safety at Job Site....35
Working on Loose Ground....35
Safety Features....35
Personal Protective Equipment....36
Fire and Explosion Prevention....36
Fire Caused by Fuel or Oil....36
Fire Caused by Accumulation of Flammable Material....37
Fire Coming from Electrical Wiring....37
Fire Coming from Hydraulic Line....37
Windshield Washer Fluid....37
Action if Fire Occurs....37
Fire Extinguisher and First Aid Kit....38
Mounting and Dismounting....39
Inside Operator?s Compartment....40
Precautions When Standing Up from Operator?s Seat....40
Precautions When Using ROPS....41
Emergency Escape from Operator?s Cab....41
Leaving Operator?s Compartment....42
Asbestos Hazard Alert....43
Crush or Pinch-Point Dangers....43
Precautions for Ventilation Exhaust Gas....43
PRECAUTIONS BEFORE STARTING OPERATIONS....44
Pre-Operational Checks....44
Ensure Good Visibility....44
Confirmation of Marks....44
Precaution for Warning Tag....45
Checks Before Starting Engine, Adjustments....46
Precautions When Starting....47
Work Site Hazards....47
Avoiding Dangerous Situations....48
Working Clearances....49
Working Near High Voltage Cables....50
RULES FOR ROAD TRAVEL....51
Traveling in Reverse....51
Working on Loose or Unstable Ground....52
Operating on Snow or Frozen Surfaces....52
Travel on Slopes....53
Parking the Machine....55
PRECAUTIONS DURING MAINTENANCE OPERATIONS....56
Warning Tags....56
Equipment Storage....56
Working Under the Machine....57
Using Drop Lamps....57
Keeping the Machine Clean....57
Running the Machine During Maintenance....58
Rules for Refueling the Machine....59
Cooling System Precautions....59
Battery Precautions....59
Battery Hazard Prevention....60
Using Jumper Cables....61
Starting the Machine....61
High-Pressure Hoses....62
Safe Handling of High-Pressure Hoses....62
Precautions for High-Pressure Fuel....62
High-Temperature Areas....63
Disposal of Waste Materials....63
Inflating Tires....64
Accumulator....64
Critical Parts....64
High Voltage....65
Maintenance of Air Conditioner....65
OPERATION....67
GENERAL VIEW....68
General View of Machine....68
Controls and Gauges....69
Main Monitor....70
Maintenance Monitor....71
EXPLANATION OF COMPONENTS....72
Machine Monitor System....72
Warning Display....74
Central Check Lamp (CHECK)....75
Central Caution Lamp (CAUTION)....75
Engine Water Level Caution Pilot Lamp....76
Engine Oil Level Caution Pilot Lamp....76
Brake Oil Pressure Caution Pilot Lamp....77
Engine Oil Pressure Caution Pilot Lamp....77
Battery Charge Caution Pilot Lamp....77
Air Cleaner Clogging Caution Pilot Lamp....78
Emergency Steering Pilot Lamp (if equipped)....78
Front Axle Oil Temperature Warning Lamp (if equipped)....78
Meter Display Portion....79
Parking Brake Pilot Lamp....80
Engine Preheating Pilot Lamp....80
Front Working Lamp Pilot Lamp....80
Rear Working Lamp Pilot Lamp....80
Transmission Cutoff Pilot Lamp....81
Turn Signal Pilot Lamp....81
High Beam Pilot Lamp....81
Transmission Auto-Shift/Manual Selector Pilot Lamp....81
Fuel Gauge....82
Engine Water Temperature Gauge....82
Torque Converter Oil Temperature Gauge....82
Service Meter....83
Speedometer....83
Transmission Shift Indicator....83
Switches....84
Starting Switch....85
Transmission Cutoff Switch....85
Front Working Lamp Switch....86
Rear Working Lamp Switch....86
Transmission Auto-Shift/Manual Selector Switch....86
Lamp Switch....87
Turn Signal Lever....87
Dimmer Switch....87
Horn Button....87
Hazard Lamp Switch....88
Kickdown Switch....88
Front Wiper Switch....88
Rear Wiper Switch....89
Cigarette Lighter (if equipped)....89
Room Lamp Switch....89
Parking Brake Switch....90
Power Window Switch....90
Hold Switch....91
Control Levers, Pedals....92
Gearshift Lever....93
Directional Lever....94
Gearshift Lever Stopper....95
Safety Lock Lever (for Work Equipment Lever)....95
Bucket Control Lever....96
Lift Arm Control Lever....96
Brake Pedals....97
Accelerator Pedal....97
SECURITY LOCKS AND SAFETY FEATURES....98
Steering Column Tilt Lever....98
Cap with Lock....98
Opening the Cap....98
Locking the Cap....99
Safety Bar....99
Towing Pin....100
Backup Alarm....100
MACHINE FEATURES....101
Cab Door....101
Emergency Escape Right Door....101
Left Cab Door, Opening Lock....103
Left Cab Door, Opening Knob....104
Left Cab Window (Open, Lock, Cancel Knob)....104
Cab Wiper....105
Grease Pump....105
Dust Indicator....105
ELECTRICAL....106
Fuses....106
Fuse Capacity and Circuits....106
Slow-Blow Fuses....107
Power Outlet....107
WORK OPERATIONS....108
Walk-Around Check....108
Precautions Before Starting Work Operations....108
Check Before Starting Engine....111
Check Machine Monitor....111
Check Dust Indicator....111
Check Coolant Level, Add Coolant....112
Check Oil Level in Engine Oil Pan, Add Oil....113
Check Fuel Level, Add Fuel....114
Check Electric Wiring....115
Check Inflation Pressure of Tires....115
Check Parking Brake....115
Check Brake Pedal....115
Check Waterproof/Fireproof Dividing Walls....116
Adjust Seat....117
Adjust Seat Belt....118
Adjust Wrist Rest Height....119
Adjust Rearview Mirrors....119
Final Checks Before Starting Engine....120
Starting Engine....122
Normal Starting....122
Automatic Warming-Up Operation....124
Operations and Checks After Starting Engine....125
Breaking in the Machine....125
Checks After Starting Engine....125
Normal Operation....127
Stopping Engine....128
Check After Stopping Engine....128
Moving the Machine (Directional, Speed), Stopping the Machine....129
Moving the Machine....129
Changing Gear Speed....132
Changing Direction....133
Stopping the Machine....134
Turning....135
Operation of Work Equipment....136
Lift Arm Operation....136
Bucket Operation....137
Work Possible Using Wheel Loader....138
Digging Operations....138
Loading Piled Soil or Blasted Rock....138
Digging and Loading on Level Ground....140
Leveling Operations....141
Pushing Operations....141
Load-and-Carry Operations....141
Loading Operations....142
Cross-Drive Loading....142
V-Shape Loading....142
Preparations for Loading, Gathering Rocks....143
Approaching Facing....143
Digging....144
Traveling in Reverse After Excavation....146
Approaching Dump Truck....147
Loading Dump Truck....147
Reversing Away From Dump Truck....148
Precautions....150
When Piling Up Loads....150
When Handling Blasted Rock....150
During Cutting Face Operations....154
When Switching Between Forward and Reverse....154
When Turning When Tires Are Stationary....154
Permissible Water Depth....155
When Wheel Brake Does Not Work....155
When Driving Up or Down Slopes....155
When Driving the Machine....156
Adjusting Work Equipment....157
Adjusting Boom Kickout....157
Adjusting Bucket Positioner....158
Bucket Level Indicator....158
Removing the Bucket....159
Installing the Bucket....160
Parking the Machine....162
Checks After Completion of Operation....164
Before Stopping Engine....164
After Stopping Engine....164
Locking the Machine....164
HANDLING TIRES....165
Precautions When Handling Tires....165
Tire Pressure....166
Precautions for Using Load-and-Carry Method....167
Precautions when Storing Tires....167
TRANSPORTATION....168
Transportation Procedure....168
Loading and Unloading Trailers....168
Loading Machine....168
Securing Machine....169
Unloading Machine....170
LIFTING MACHINE....171
Lifting Position Marks....172
Lifting Procedure....173
COLD WEATHER OPERATION....175
Precautions for Low Temperature....175
Fuel and Lubricants....175
Coolant....175
Battery....176
Warming-Up Operation for Steering Hydraulic Circuit....177
Precautions After Completion of Work....177
When Cold Weather Ends....177
LONG-TERM STORAGE....178
Before Storage....178
During Storage....178
After Storage....179
TROUBLESHOOTING....180
When Machine Runs Out of Fuel....180
Bleeding Air from Fuel Line....180
Towing the Machine....182
When Engine Can Be Used....183
When Engine Cannot Be Used....183
Releasing Parking Brake....184
Emergency Travel Operation....185
If Battery is Discharged....186
Precautions....186
Removing the Battery....186
Installing the Battery....186
Precautions for Charging Battery....187
Starting Engine With Booster Cable....188
Precautions When Connecting or Disconnecting Booster Cable....188
Connecting Booster Cable....188
Starting Engine....189
Disconnecting Booster Cable....189
Other Troubleshooting....191
Electrical System....191
Chassis....192
Engine....194
Relationship of Electronic Control System....196
Transmission Control System....202
ECSS Control System....203
Joystick Control System....203
Electronic Governor Control System....204
MAINTENANCE....205
GUIDES TO MAINTENANCE....206
Check Service Meter....206
Komatsu Genuine Replacement Parts....206
Komatsu Genuine Oils....206
Always Use Clean Washer Fluid....206
Always Use Clean Oil and Grease....206
Checking for Foreign Materials in Drained Oil and On Filters....206
Fuel Strainer....206
Welding Instructions....207
Do Not Drop Things Inside Machine....207
Dusty Work Sites....207
Avoid Mixing Oil....207
Locking Inspection Covers....207
Bleeding Air from Hydraulic Circuit....207
Precautions When Installing Hydraulic Hoses....208
Checks After Inspection and Maintenance....208
OUTLINES OF SERVICE....209
Handling Oil, Fuel, Coolant, and Performing Oil Clinic....209
Oil....209
Fuel....210
Coolant and Water for Dilution....210
Grease....211
Performing KOWA (Komatsu Oil Wear Analysis)....212
KOWA Analysis Items....212
Oil Sampling....212
Storing Oil and Fuel....213
Filters....213
Outline of Electric System....213
WEAR PARTS....214
Wear Parts List....214
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS....215
Fuel, Coolant, and Lubricant Ambient Temperature Chart....216
Recommended Brands, Other Than Komatsu Genuine Oil....217
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....218
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS....220
MAINTENANCE SCHEDULE CHART....222
SERVICE PROCEDURE....224
Initial 10 Hours Service....224
Initial 250 Hours Service....224
When Required....225
Check, Clean, Replace Air Cleaner Element....225
Clean Inside of Cooling System....228
Check Transmission Oil Level, Add Oil....232
Check Axle Oil Level, Add Oil....234
Clean Axle Case Breather....235
Clean Air Conditioner Condenser....236
Check Window Washing Fluid Level, Add Fluid....236
Clean Radiator Fins and Oil Cooler Fins....237
Check Electrical Intake Air Heater....237
Replace Bucket Teeth (if equipped)....238
Replace Bucket Tooth with Segment Edge....240
Turn, Replace Bolt-On Cutting Edge....241
Lubricate Work Equipment Control Valve Linkage....241
Check Air Conditioner....242
Replace Slow-Blow Fuse....243
Select Tires....244
Check Tire Pressure....245
Check Before Starting....246
Every 50 Hours Service....247
Drain Water, Sediment from Fuel Tank....247
Every 100 Hours Service....248
Lubricate Rear Axle Pivot Pin....248
Clean Element in Air Conditioner Fresh Air Filter....248
Check Oil Level in Hydraulic Tank, Add Oil....249
Every 250 Hours Service....250
Check Battery Electrolyte Level....250
Check Parking Brake....252
Check Alternator Belt Tension, Adjust....252
Check Air Conditioner Compressor Belt Tension, Adjust....253
Check for Loose Wheel Hub Nuts, Tighten....253
Clean Element in Air Conditioner Recirculation Filter....254
Lubricating....254
Every 500 Hours Service....257
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge....257
Replace Fuel Filter Cartridge....259
Replace Transmission Oil Filter Element....261
Lubricate Center Drive Shaft Spline....262
Check Fan Belt for Wear....262
Every 1000 Hours Service....263
Change Oil in Transmission Case, Clean Strainer....263
Clean Transmission Case Breather....264
Lubricating....264
Check Tightening Parts of Turbocharger....266
Replace Corrosion Resistor Cartridge....266
Clean Radiator Subtank Breather....267
Clean Fuel Strainer....267
Wash Fuel Tank Breather....267
Tighten ROPS Canopy....268
Every 2000 Hours Service....269
Change Oil in Hydraulic Tank, Replace Hydraulic Tank Filter Element....269
Replace Hydraulic Tank Breather Element....271
Change Axle Oil....272
Replace Element in Air Conditioner Recirculation Air Filter, Fresh Air Filter....273
Clean PPC Circuit Strainer....273
Clean Engine Breather Element....274
Check Alternator, Starting Motor....274
Check Engine Valve Clearance, Adjust....274
Check Brake Disc Wear....274
Clean and Check Turbocharger....274
Check Play of Turbocharger Rotor....274
Check Accumulator Function....275
Check Accumulator Gas Pressure....275
Check Injector....275
Every 4000 Hours Service....276
Check Water Pump....276
Check Vibration Damper....276
Check Fan Pulley and Tension Pulley....276
Check Air Conditioner Compressor, Adjust....276
Replace Injector....276
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber....277
Check for Missing Fuel Spray Prevention Caps, Hardening of Rubber....278
Every 8000 Hours Service....279
Replace High-Pressure Piping Clamps....279
Replace Fuel Spray Prevention Caps....279
SPECIFICATIONS....281
SPECIFICATIONS....282
OPTIONS, ATTACHMENTS....285
BUCKET AND TIRES....286
TIRE CHAINS....287
ELECTRONIC-CONTROLLED SUSPENSION SYSTEM....289
Operating ECSS....289
Precautions When Using ECSS Switch....289
Removal of ECSS Piping....289
Precautions When Handling Accumulator....290
AUTO-GREASING SYSTEM....291
Method of Operation....291
Starting Auto-Greasing....291
Lubrication Controller Display....292
Lubrication Controller Display Table....293
Setting the Greasing Time....294
Setting Greasing Time in Cold Areas....294
Procedure for Setting Greasing Time....295
Checking Amount of Grease....296
Replacing Grease Cartridge....296
Precautions When Handling Auto-Greasing System....297
Troubleshooting Auto-Greasing System....298
REMOTE POSITIONER....299
General Locations....299
Operating Remote Positioner....300
Adjusting Remote Positioner....300
Setting Remote Positioner Stop Position....301
Adjusting Sensor....301
JOYSTICK STEERING SYSTEM....302
Structure and Function....302
Components....304
Joystick Steering Lever....305
Kickdown Switch....306
Hold Switch....306
Steering with Joystick Lever or Steering Wheel....307
Precautions for Steering with Joystick....308
Operating the Joystick Steering System....309
Getting In and Out of Operator?s Cab....311
Adjustments....312
Adjusting Console....312
Adjusting Height of Armrest....312
Sliding the Console....312
Adjusting Air-Suspension Seat....313
CAR RADIO....315
Components....315
Power Switch/Volume....316
Tone Control Knob....316
Display....316
Clock Button/Displaying Frequency....316
AST....317
Preset Button....317
SEEK....317
Band Selector Switch....317
Tuning Switch....318
Method of Operation....318
Listening to Radio....318
Automatic Tuning....318
Manual Tuning....318
Setting Preset Buttons....319
Automatic Memory....319
Automatic Switching of Monaural/Stereo Reception....320
Adjusting Time....320
Precautions When Using....320
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM....322
Sound System Components....324
Power Switch/Volume....324
Auto-Store/Preset Scan Button....324
Bass Control Knob....324
Treble Control Knob....325
Loudness Button....325
Time/Radio Display Selector Button....325
Tape Eject Button....326
Cassette Door....326
Fast-Forward, Rewind Buttons....326
Preset Buttons....326
Metal Tape Button....327
Manual Tuning Buttons....327
Seek Tuning Buttons....327
Band Selector Button....327
Method of Operation....328
Setting Preset Buttons....328
Using Auto-Preset....328
Using Manual Preset....328
Listening to Radio....329
Listening to Cassette Tape....329
Reversing the Tape....330
Precautions When Using....330
Handling Cassette Tape....330
AIR CONDITIONER....331
Control Panel....331
Fan Switch....332
Air Conditioner Switch....332
Mode Selector Switch....332
FRESH/RECIRC Selector Switch....332
Temperature Control Switch....333
Method of Operation....334
When Not Using the Air Conditioner Regularly....335
Precautions When Using Air Conditioner....335
Inspection and Maintenance....335
Cool Box....336
BRAKE COOLING SYSTEM....337
When Required....337
Check Axle Oil Level, Add Oil....337
Clean Axle Case Breather....338
Clean Brake Cooling Oil Cooler Fins....338
Every 2000 Hours Service....339
Replace Axle Oil and Brake Cooling Oil Filter Cartridge....339
