Komatsu Wheel Loaders WA800 Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA800 Series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loaders WA800 Series 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: 7,326 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...31
GENERAL ASSEMBLY DRAWING...32
SPECIFICATIONS...33
WEIGHT TABLE ...36
LIST OF LUBRICANT AND WATER...38
10 STRUCTURE AND FUNCTION...41
POWER TRAIN...42
POWER TRAIN SYSTEM...43
ENGINE CONTROL...44
SERVO CYLINDER ...45
RADIATOR AND COOLER...49
DAMPER...50
TORQUE CONVERTER AND TRANSMISSION PIPING...51
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...53
TORQUE CONVERTER ...54
TRANSMISSION ...59
TRANSFER...69
TRANSMISSION CONTROL VALVE...70
TORQUE CONVERTER OIL COOLER...88
DRIVE SHAFT...89
CENTER SUPPORT...90
AXLE...91
FINAL DRIVE...96
AXLE MOUNT...98
CENTER HINGE PIN...100
TIRE AND WHEEL ...101
STEERING PIPING DIAGRAM...102
STEERING COLUMN...105
JOYSTICK LINKAGE...106
STEERING PUMP...108
SWITCH PUMP...112
STEERING DEMAND VALVE...124
STEERING UNIT (ORBIT-ROLL VALVE)...135
PROPORTIONAL SOLENOID VALVE...138
EPC VALVE...139
ROTARY VALVE...140
TOW-WAY RESTRICTOR VALVE...144
DIVERTER VALVE...145
BRAKE PIPING...150
BRAKE CIRCUIT DIAGRAM...152
BRAKE VALVE...156
CHARGE VALVE...167
ACCUMULATOR (FOR BRAKE)...171
SLACK ADJUSTER...172
BRAKE...175
PARKING BRAKE...176
SPRING CYLINDER...180
PARKING BRAKE SOLENOID VALVE...181
HYDRAULIC PIPING ...182
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...188
WORK EQUIPMENT LEVER LINKAGE...203
HYDRAULIC TANK...206
MAIN PISTON PUMP...209
ES VALVE...221
SERVO VALVE...223
PPC VALVE...226
PPC RELIEF VALVE...230
ACCUMULATOR (FOR PPC VALVE)...231
WORK EQUIPMENT CONTROL LEVER...232
WORK EQUIPMENT EPC VALVE...235
WORK EQUIPMENT NEUTRAL LOCK SOLENOID VALVE...238
MAIN CONTROL VALVE...240
LUBRICATION OF WORK EQUIPMENT...266
WORK EQUIPMENT LINKAGE...268
BUCKET POSITIONER AND BOOM KICK-OUT...270
OPERATION OF PROXIMITY SWITCH...272
CAB...276
ROPS CANOPY...277
AIR CONDITIONER...278
ELECTRIC CIRCUIT DIAGRAM...281
MACHINE MONITOR SYSTEM...282
MAIN MONITOR...284
MAINTENANCE MONITOR...290
MULTI MONITOR SYSTEM (IF EQUIPPED)...296
WORK EQUIPMENT CONTROL SYSTEM...318
WORK EQUIPMENT CONTROLLER ...324
ENGINE STARTING CIRCUIT...326
ENGINE STOP CIRCUIT...329
PREHEATING CIRCUIT...330
ELECTRICAL TRANSMISSION CONTROL...331
KICK-DOWN, HOLD SWITCH...334
JOYSTICK STEERING SYSTEM...335
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)...340
ELECTRIC PARKING BRAKE CONTROL...347
ENGINE CONTROL SYSTEM (FOR OPTIONAL ELECTRONIC GOVERNOR SPECIFICATION)...356
20 TESTING AND ADJUSTING...363
STANDARD VALUE TABLE FOR ENGINE...364
STANDARD VALUE TABLE FOR CHASSIS...365
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...373
TESTING AND ADJUSTING...393
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...394
MEASURING ENGINE SPEED...395
MEASURING EXHAUST GAS COLOR...397
ADJUSTING VALVE CLEARANCE...398
MEASURING COMPRESSION PRESSURE...399
MEASURING BLOW-BY PRESSURE...400
TESTING AND ADJUSTING FUEL INJECTION TIMING...401
MEASURING ENGINE OIL PRESSURE...407
MEASURING EXHAUST TEMPERATURE...408
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...409
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...410
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...411
MEASURING ACCELERATOR PEDAL OPERATING EFFORT...412
MEASURING ACCELERATOR PEDAL OPERATING ANGLE...413
ADJUSTING ACCELERATORPEDAL POTENTIOMETER (For optional electronic governor specification)...414
ADJUSTING ACCELERATORPEDAL MICROSWITCH (For optional electronic governor specification)...416
ADJUSTING FUEL CONTROL CABLE,LINKAGE,AND SERVO CYLINDER...418
ADJUSTING ENGINE STOPPING MOTOR CABLE...420
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE...422
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS...425
TESTING AND ADJUSTING STEERING OIL PRESSRUE...427
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE...428
BLEEDING AIR FROM STEERING CIRCUIT ...430
TESTING AND ADJUSTING STEERING STOP VALVE...431
TESTING AND ADJUSTING STEERING STOPPER BOLT...432
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR...433
TESTING WHEEL BRAKE PERFORMANCE ...434
TESTING WHEEL BRAKE OIL PRESSURE DROP...435
MEASURING WEAR OF WHEEL BRAKE DISC...437
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...438
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT ...440
TESTING PARKING BRAKE PERFORMANCE...441
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE...442
CHECKING AND ADJUSTING PARKING BRAKE PAD...443
TESTING AND ADJUSTING PPC PRESSURE ...445
ADJUSTING PPC VALVE LINKAGE...447
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...448
BLEEDING AIR FROM PISTON PUMP ...450
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT...451
ADJUSTING WORK EQUIPMENT LEVER LINKAGE ...452
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...454
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH...455
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH...456
TESTING PROXIMITY ACTUATION PILOT LAMP...457
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR ...458
ADJUSTING JOYSTICK LEVER POTENTIOMETER...459
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH...460
ADJUSTING WORK EQUIPMENT CONTROL LEVER...461
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER...465
ADJUSTING WORK EQUIPMENT BOOM ANGLE...471
TROUBLESHOOTING...473
POINTS TO REMEMBER WHEN TROUBLESHOOTING ...474
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...475
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...476
CHECKS BEFORE TROUBLESHOOTING ...484
TYPES AND LOCATIONS OF CONNECTORS ...485
CONNECTOR ARRANGEMENT DIAGRAM ...494
WIRING TABLE FOR CONNECTOR PIN NUMBERS...505
T-ADAPTER BOX AND T-ADAPTER TABLE...538
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM...541
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE...548
CHART OF ACTION CODES AND FAILURE CODES,AND RE-ENACTION ...550
TRANSMISSION CONTROLLER LED DISPLAY...557
METHOD OF USING JUDGEMENT TABLE...559
METHOD OF USING TROUBLESHOOTING CHARTS...560
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...562
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...565
METHOD OF USING TROUBLESHOOTING CHARTS...566
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...570
S-2 ENGINE DOES NOT START...571
(1) ENGINE DOES NOT TURN...571
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)...572
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...573
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...574
S-4 ENGINE STOPS DURING OPERATIONS...575
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...576
S-6 ENGINE LACKS OUTPUT (NO POWER)...577
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...578
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...579
S-9 OIL BECOMES CONTAMINATED QUICKLY...580
S-10 FUEL CONSUMPTION IS EXCESSIVE...581
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...582
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...583
S-13 OIL LEVEL RISES ...584
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...585
S-15 ABNORMAL NOISE IS MADE...586
S-16 VIBRATION IS EXCESSIVE...587
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)...589
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS ...590
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...592
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...600
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED...604
T-2 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED ...605
T-3 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...606
T-4 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED...607
T-5 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 1st SOLENOID) IS DISPLAYED...608
T-6 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 2nd SOLENOID) IS DISPLAYED...609
T-7 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 3rd SOLENOID) IS DISPLAYED...610
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...611
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...612
T-10 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVER SWITCH SYSTEM) IS DISPLAYED...615
T-11 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED...616
T-12 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED...619
T-13 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED...620
T-14 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...621
T-15 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM...622
T-16 SHIFT-DOWN SWITCH SIGNAL SYSTEM AND SHIFT-UP SWITCH SIGNAL SYSTEM...623
T-17 TRANSMISSION CUT-OFF SIGNAL SYSTEM...624
T-18 NEUTRALIZER SIGNAL SYSTEM...625
T-19 BUZZER SIGNAL SYSTEM...626
T-20 NETWORK SYSTEM...627
T-21 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM...628
T-22 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...629
T-23 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS...630
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...631
TROUBLE DATA DISPLAY...633
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM...636
M-1 MAIN MONITOR DOES NOT WORK...638
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP...639
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...640
M-4 ABNORMALITY IN SHIFT INDICATOR ...641
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F...641
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R...641
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N (DISPLAYS 1st-3rd)...642
d) DOES NOT DISPLAY 1ST EVEN WHEN GEAR SHIFT LEVER IS AT 1st POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)...642
e) DOES NOT DISPLAY 2nd EVEN WHEN GEAR SHIFT LEVER IS AT 2nd POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)...642
f) DOES NOT DISPLAY 3rd EVEN WHEN GEAR SHIFT LEVER IS AT 3rd POSITION(DIRECTIONAL LEVER IS AT F OR R POSITION)...643
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP...644
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...645
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP...645
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP...645
M-7 ABNORMALITY IN PARKING DISPLAY...646
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP...646
b) PARKING LAMP DISPLAY STAYS LIGHTED UP...646
M-8 ABNORMALITY IN PREHEATING SYSTEM...647
a) DOES NOT CARRY OUT PREHEATING...647
b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS...648
c) PREHEATING STAYS ON...648
d) PREHEATING TIME BECOMES SHORTER,OR THERE IS VARIATION...649
M-9 NIGHT LIGHTING DOES NOT LIGHT UP...651
M-10 ABNORMALITY IN FRONT WORKING LAMP...652
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP...652
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...652
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP...652
M-11 ABNORMALITY IN REAR WORKING LAMP...654
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...654
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...654
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP...654
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...656
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH ) IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE...656
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH )IS OFF,MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED...656
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF),CUT-OFF FUNCTION IS ALWAYS ACTUATED...656
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)...656
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON),BUT CUT-OFF FUNCTION IS NOT ACTUATED...657
M-13 ABNORMALITY IN LOW IDLING SELECTION...658
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON,THE LOW IDLING SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE...658
b) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH ) IS TURNED ON,THE MONITOR LIGHTS UP BUT THE LOW IDLING SPEED ODES NOT RISE...658
c) WHEN THE MONITOR SWITCH (LOW IDLE SELECTOR SWITCH ) IS TURNED OFF,THE MONITOR GOES OFF BUT THE LOW IDLING SPEED DOES NOT LOWER...659
M-14 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY...660
EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP...660
M-15 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY...661
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP...661
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP...661
M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...662
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N...662
b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N...662
M-17 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP))...664
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N...664
b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N...664
M-18 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED...666
a) ACTUATED CONTINUOUSLY...666
b) NOT ACTUATED...666
M-19 ABNORMALITY IN BUZZER...667
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)...667
b) BUZZER ALWAYS SOUNDS...667
M-20 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...668
M-21 ABNORMALITY IN FAILURE DISPLAY MODE...669
a) DOES NOT ENTER FAILURE DISPLAY MODE...669
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE...669
M-22 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER...670
M-23 ABNORMALITY IN AUTO-GREASING SYSTEM (OP)...671
a) CHECK POWER SUPPLY SYSTEM 1 (RELAY G1)...671
b) CHECK POWER SUPPLY SYSTEM 2 (RELAY G2)...671
c) FORCED GREASING DOES NOT START...672
d) MONITOR DOES NOT FLASH WHILE GREASE IS BEING SUPPLIED...672
e) MONITOR IS STILL FLASHING AFTER GREASING IS FINISHED, OR IT FLASHES FOR PERIOD SET WITH TIMER WHEN STARTING SWITCH IS TURNED TO ON POSITION...673
M-24 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP)...675
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...677
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM...678
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK...680
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...680
b) SOME LAMPS DO NOT LIGHT UP...680
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)...681
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS),NO LAMPS ON MAINTENANCE MONITOR GO OUT...682
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH...683
a) ENGINE OIL LEVEL DISPLAY FLASHES...683
b) ENGINE WATER LEVEL DISPLAY FLASHES...684
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH...685
a) ENGINE OIL PRESSURE DISPLAY FLASHES...685
b) BATTERY CHARGE LEVEL DISPLAY FLASHES...686
c) BRAKE OIL PRESSURE DISPLAY FLASHES...687
d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES...689
e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES...690
f) TRANSMISSION OIL FILTER DISPLAY FLASHES...691
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND...692
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS...693
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES...694
a) CHECK LAMP...694
b) CAUTION LAMP...694
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP...695
a) CHECK LAMP...695
b) CAUTION LAMP...695
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON...696
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF...697
K-12 SERVICE METER DOES NOT WORK...698
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED...698
K-14 ABNORMALITY IN GAUGE DISPLAY...699
a) ABNORMALITY FUEL GAUGE...699
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...700
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...701
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...703
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTING,ENGINE STOPPING AND PREHEATING...704
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE...706
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER...707
E-1 ENGINE DOES NOT START...708
a) STARTING MOTOR DOES NOT TURN...708
b) STARTING MOTOR TURNS (STD SPEC.)...712
E-2 ENGINE DOES NOT STOP (STD SPEC.)...714
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (STD SPEC.)...715
E-4 ABNORMALITY IN PREHEATING SYSTEM...717
a) DOES NOT CARRY OUT PREHEATING ...717
b) ALWAYS CARRIES OUT PREHEATING FOR 45 SECONDS...718
c) PREHEATING STAYS ON...718
d) PREHEATING TIME BECOMES SHORTER,OR THERE IS FLUCTUATION...719
E-5 PARKING BRAKE DOES NOT HAVE EFFECT...721
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON...721
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)...721
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...722
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...724
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)...724
E-9 KICK-DOWN SWITCH DOES NOT WORK ...726
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY...726
b) KICK-DOWN CANNOT BE CANCELED...727
E-10 BOOM KICK-OUT DOES NOT WORK...728
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION ...732
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP...735
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP...735
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF...735
E-15 ABNORMALITY IN LOW IDLING SELECTION...735
E-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...735
E-17 ABNORMALITY IN BUZZER...735
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...737
H-1 MACHINE DOES NOT MOVE...738
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)...739
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...740
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...741
H-5 STEERING DOES NOT TURN (STEERING WHEEL SPECIFICATION)...742
H-6 STEERING DOES NOT TURN (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)...743
H-7 STEERING DOES NOT TURN (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)...744
H-8 TURNING,RESPONSE OF STEERING IS POOR (STEERING WHEEL SPECIFICATION)...745
H-9 TURNING,RESPONSE OF STEERING IS POOR (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)...746
H-10 TURNING,RESPONSE OF STEERING IS POOR (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)...747
H-11 STEERING IS HEAVY (STEERING WHEEL SPECIFICATION)...748
H-12 JOYSTICK LEVER IS HEAVY (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)...748
H-13 JOYSTICK LEVER IS HEAVY (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)...749
H-14 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL SPECIFICATION)...750
H-15 STEERING WHEEL SHAKES OR JERKS (STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)...751
H-16 STEERING WHEEL SHAKES OR JERKS (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)...752
H-17 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION)...753
H-18 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION)...753
H-19 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...754
H-20 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...755
H-21 BOOM DOES NOT RISE...756
H-22 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...757
H-23 WHEN RAISING BOOM,BECOMES SLOW AT CERTAIN HEIGHT ...758
H-24 BOOM CYLINDER CANNOT HOLD DOWN BUCKET...758
H-25 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT...758
H-26 BOOM FLUCTUATES WHILE WORKING...759
H-27 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE...759
H-28 BUCKET DOES NOT TILT BACK...760
H-29 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...761
H-30 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...762
H-31 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET...762
H-32 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT...762
H-33 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE "HOLD")...763
H-34 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT...763
H-35 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY...764
TROUBLESHOOTING OF JOYSTICK STEERING CONTROL SYSTEM (J MODE)...765
JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL SYSTEM RELATED PARTS...766
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...768
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING CONTROL SYSTEM...772
J-1 FAILURE CODE [56] (SHORT CIRCUIT,DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED...774
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED...775
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED...776
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED...777
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED...778
J-6 FAILURE CODE [61] (SHORT CIRCUIT,DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED...779
J-7 FAILURE CODE [62] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED...780
J-8 FAILURE CODE [63] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED...781
J-9 ABNORMALITY IN POWER SUPPLY,POWER SUPPLY VOLTAGE...782
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT...783
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID...784
J-12 DISCONNECTION IN STEERING LEFT SOLENOID...785
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)...787
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM...788
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY...790
ELECTRIC CIRCUIT DIAGRAM FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL...794
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED...796
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED...797
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED...798
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED...799
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED...800
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED...801
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...802
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT...803
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)...804
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE...805
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)...807
CONTENTS OF ABNORMALITY IN WORK EQUIPMENT CONTROL SYSTEM AND ACTIONS OF CONTROLLER AGAINST THEM...810
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROL SYSTEM...816
[WRK-1] LOWERING OF WORK EQUIPMENT CONTROLLER SOURCE VOLTAGE...819
[WRK-2] ABNORMALITY IN SENSOR POWER SOURCE SYSTEM...820
[WRK-3] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM...822
[WRK-4] GROUNDING FAULT IN REMOTE POSITIONER RAISE POSITION SET SWITCH SYSTEM...823
[WRK-5] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE POSITION SET SWITCH...824
[WRK-6] GROUNDING FAULT IN REMOTE POSITIONER LOWER POSITION SET SWITCH SYSTEM...825
[WRK-7] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER POSITION SET SWITCH SYSTEM...826
[WRK-8] GROUNDING FAULT IN REMOTE POSITIONER RAISE/LOWER SELECTOR SWITCH SYSTEM...827
[WRK-9] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE/LOWER SELECTOR SWITCH SYSTEM...828
[WRK-10] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM ANGLE POTENTIOMETER SIGNAL SYSTEM...829
[WRK-11] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN MAIN CIRCUIT)...830
[WRK-12] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM [SHORT CIRCUIT IN MAIN CIRCUIT (WITH SOURCE POWER)]...831
[WRK-13] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN SUB CIRCUIT)...832
[WRK-14] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM [SHORT CIRCUIT IN SUB CIRCUIT (WITH SOURCE POWER)]...833
[WRK-15] ABNORMALITY IN BOOM EPC LEVER POTENTIOMETER SYSTEM (SHIFTING OF MAIN CIRCUIT AND SUB CIRCUIT FORM EACH OTHER)...834
[WRK-16] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN MAIN CIRCUIT)...835
[WRK-17] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM {SHORT CIRCUIT IN MAIN CIRCUIT (WITH SOURCE POWER)]...836
[WRK-18] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUNDING FAULT IN SUB CIRCUIT)...837
[WRK-19] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT CIRCUIT IN SUB CIRCUIT)...838
[WRK-20] ABNORMALITY IN BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHIFTING OF MAIN CIRCUIT AND SUB CIRCUIT FORM EACH OTHER)...839
[WRK-21] DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM...840
[WRK-22] GROUNDING FAULT IN ENGINE SPEED SENSOR SYSTEM...841
[WRK-23] GROUNDING FAULT IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM...842
[WRK-24] DISCONNECTION IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM...843
[WRK-25] SHORT CIRCUIT (WITH POWER SOURCE)IN REMOTE POSITIONER RAISE POSITION SET DISPLAY SYSTEM...844
[WRK-26] GROUNDING FAULT IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM...845
[WRK-27] DISCONNECTION IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM...846
[WRK-28] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER POSITION SET DISPLAY SYSTEM...847
[WRK-29] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM...848
[WRK-30] DISCONNECTION IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM...850
[WRK-31] GROUNDING FAULT IN REMOTE POSITIONER RAISE STOP DISPLAY SYSTEM...852
[WRK-32] SHORT CIRCUIT (WITH POWER SOURCE) IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM...854
[WRK-33] DISCONNECTION IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM...856
[WRK-34] GROUNDING FAULT IN REMOTE POSITIONER LOWER STOP DISPLAY SYSTEM...858
[WRK-35] DISCONNECTION IN BOOM RAISE MAGNET DETENT SYSTEM...860
[WRK-36] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE MAGNET DETENT SYSTEM...861
[WRK-37] GROUNDING FAULT IN BOOM RAISE MAGNET DETENT SYSTEM...862
[WRK-38] DISCONNECTION IN BOOM FLOAT MAGNET DETENT SYSTEM...863
[WRK-39] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM FLOAT MAGNET DETENT SYSTEM...864
[WRK-40] GROUNDING FAULT IN BOOM FLOAT MAGNET DETENT SYSTEM...865
[WRK-41] DISCONNECTION IN BUCKET TILT MAGNET DETENT SYSTEM...866
[WRK-42] SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT MAGNET DETENT SYSTEM...867
[WRK-43] GROUNDING FAULT IN BUCKET TILT MAGNET DETENT SYSTEM...868
[WRK-44] DISCONNECTION OR GROUNDING FAULT IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID A SYSTEM...869
[WRK-45] SHORT CIRCUIT (WITH POWER SOURCE) IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID A SYSTEM...870
[WRK-46] DISCONNECTION OR GROUNDING FAULT IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID B SYSTEM...871
[WRK-47] SHORT CIRCUIT (WITH POWER SOURCE) IN WORK EQUIPMENT NEUTRAL LOCK SOLENOID B SYSTEM...872
[WRK-48] DISCONNECTION IN ALARM BUZZER SYSTEM...873
[WRK-49] GROUNDING FAULT IN ALARM BUZZER SYSTEM...874
[WRK-50] SHORT CIRCUIT (WITH POWER SOURCE) IN ALARM BUZZER SYSTEM...875
[WRK-51] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE EPC SOLENOID A SYSTEM...876
[WRK-52] GROUNDING FAULT IN BOOM RAISE EPC SOLENOID A SYSTEM...877
[WRK-53] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM RAISE EPC SOLENOID B SYSTEM...878
[WRK-54] GROUNDING FAULT IN BOOM RAISE EPC SOLENOID B SYSTEM...879
[WRK-55] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOWER EPC SOLENOID A SYSTEM...880
[WRK-56] GROUNDING FAULT IN BOOM LOWER EPC SOLENOID A SYSTEM...881
[WRK-57] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOWER EPC SOLENOID B SYSTEM...882
[WRK-58] GROUNDING FAULT IN BOOM LOWER EPC SOLENOID B SYSTEM...883
[WRK-59] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT EPC SOLENOID A SYSTEM...884
[WRK-60] GROUNDING FAULT IN BUCKET TILT EPC SOLENOID A SYSTME...885
[WRK-61] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET TILT EPC SOLENOID B SYSTEM...886
[WRK-62] GROUNDING FAULT IN BUCKET TILT EPC SOLENOID B SYSTEM...887
[WRK-63] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET DUMP EPC SOLENOID A SYSTEM...888
[WRK-64] GROUNDING FAULT IN BUCKET DUMP EPC SOLENOID A SYSTEM...889
[WRK-65] DISCONNECTION OR SHORT CIRCUIT (WITH POWER SOURCE) IN BUCKET DUMP EPC SOLENOID B SYSTEM...890
[WRK-66] GROUNDING FAULT IN BUCKET DUMP EPC SOLENOID B SYSTEM...891
[WRK-67] ABNORMALITY IN WORK EQUIPMENT LEVER NEUTRAL CAUTION SYSTEM...892
[WRK-68] DISCONNECTION OR GROUNDING FAULT IN BOOM LOCK SWITCH SYSTEM...893
[WRK-69] SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM LOCK SWITCH SYSTEM...894
[WRK-70] ABNORMALITY IN BUCKET CYLINDER PROXIMITY SWITCH SYSTEM...895
[WRK-71] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN EPC LEVER ADJUSTMENT MODE INPUT SYSTEM...896
[WRK-72] DISCONNECTION,GROUNDING FAULT,OR SHORT CIRCUIT (WITH POWER SOURCE) IN BOOM ANGLE ADJUSTMENT MODE INPUT SYSTEM...897
TROUBLESHOOTING OF ELECTRONIC GOVERNOR SYSTEM (G MODE)...899
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS...900
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...902
ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS...910
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM...911
JUDGEMENT TABLE FOR ENGINE CONTROLLER...913
G-1 [90] [10] Abnormality in power source system...914
G-2 [90] [11] Abnormality in controller system...914
G-3 [90] [21] Mistaken connection of connector...915
G-4 [90] [56] Abnormality in right bank solenoid power source system...915
G-5 [90] [57] Abnormality in left bank solenoid power source system...915
G-6 [90] [58] Abnormality in back-up power source system...916
G-7 [90] [59] Abnormality in switch power source system...917
G-8 [91] [14] Abnormality in right bank governor solenoid system...918
G-9 [91] [15] Abnormality in left bank governor solenoid system...919
G-10 [91] [16] Abnormality in right bank governor cut relay system...920
G-11 [91] [17] Abnormality in left bank governor cut relay system...921
G-12 [91] [19] Abnormality in right bank governor servo system...922
G-13 [91] [1A] Abnormality in left bank governor servo system...923
G-14 [91] [1d] Abnormality in right bank pre-stroke solenoid system...924
G-15 [91] [1E] Abnormality in left bank pre-stroke solenoid system...925
G-16 [92] [12] Abnormality in right bank rack sensor system...926
G-17 [92] [13] Abnormality in left bank rack sensor system...927
G-18 [92] [18] Abnormality in rack sensor power source system...928
G-19 [93] [1b] Abnormality in engine speed sensor A system...929
G-20 [94] [1c] Abnormality in engine speed sensor B system...930
G-21 [93, 94] [1b, 1c] Abnormality in engine speed sensor A, B system...931
G-22 [95] [40] Abnormality in engine water temperature sensor system...931
G-23 [97] [31] Abnormality in accelerator sensor system...932
G-24 [98] [18] Abnormality in model selection...934
G-25 [99] [22] Engine overrun...935
G-26 Engine does not start...935
G-27 Engine does not stop...939
30 DISASSEMBLY AND ASSEMBLY...941
HOW TO READ THIS MANUAL...943
STANDARD TIGHTENING TORQUE TABLE...945
PRECAUTIONS WHEN CARRYING OUT OPERATION...949
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER...952
COATING MATERIALS LIST...955
SPECIAL TOOL LIST...958
SKETCHES OF SPECIAL TOOLS...967
STARTING MOTOR...975
REMOVAL AND INSTALLATION...975
ALTERNATOR...976
REMOVAL AND INSTALLATION...976
ENGINE OIL COOLER...977
REMOVAL AND INSTALLATION...977
FUEL INJECTION PUMP FOR LEFT BANK (WITH GOVERNOR)...978
REMOVAL AND INSTALLATION...978
FUEL INJECTION PUMP FOR RIGHT BANK (WITH GOVERNOR)...979
REMOVAL AND INSTALLATION...979
WATER PUMP...980
REMOVAL AND INSTALLATION...980
NOZZLE HOLEDR...981
REMOVAL AND INSTALLATION...981
TURBOCHARGER...982
REMOVAL AND INSTALLATION...982
ENGINE FRONT SEAL ...983
REMOVAL AND INSTALLATION...983
ENGINE REAR SEAL...985
REMOVAL AND INSTALLATION...985
CYLINDER HEAD...987
REMOVAL...987
INSTALLATION...991
RADIATOR...994
REMOVAL...994
INSTALLATION...997
ENGINE...998
REMOVAL...998
INSTALLATION...1004
DAMPER...1005
REMOVAL AND INSTALLATION...1005
DISASSEMBLY...1006
ASSEMBLY...1008
TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...1012
REMOVAL...1012
INSTALLATION...1019
TORQUE CONVERTER...1021
DISASSEMBLY...1021
ASSEMBLY...1025
TORQUE CONVERTER VALVE...1030
DISASSEMBLY AND ASSEMBLY...1030
TRANSMISSION...1031
DISASSEMBLY...1031
ASSEMBLY...1048
TRANSMISSION VALVE...1066
REMOVAL AND INSTALLATION...1066
DISASSEMBLY AND ASSEMBLY...1067
TRANSFER...1071
DISASSEMBLY...1071
ASSEMBLY...1079
PTO...1089
DISASSEMBLY...1089
ASSEMBLY...1091
CENTER SUPPORT...1094
REMOVAL...1094
INSTALLATION...1095
DISASSEMBLY...1096
ASSEMBLY...1098
DRIVE SHAFT...1101
DISASSEMBLY...1101
ASSEMBLY...1103
FRONT AXLE...1105
REMOVAL...1105
INSTALLATION...1107
REAR AXLE...1108
REMOVAL...1108
INSTALLATION...1114
DIFFERENTIAL...1115
REMOVAL...1115
INSTALLATION...1117
DISASSEMBLY...1118
ASSEMBLY...1122
FINAL DRIVE...1128
DISASSEMBLY...1128
ASSEMBLY...1131
ORBIT-ROLL...1136
REMOVAL...1136
INSTALLATION...1137
EMERGENCY STEERING PUMP...1138
REMOVAL AND INSTALLATION...1138
DIVERTER VALVE...1139
REMOVAL AND INSTALLATION...1139
DISASSEMBLY...1140
ASSEMBLY...1141
ACCUMULATOR CHARGE VALVE...1143
REMOVAL AND INSTALLATION...1143
DISASSEMBLY...1144
ASSEMBLY...1145
STEERING STOP VALVE...1147
REMOVAL AND INSTALLATION...1147
STEERING CYLINDER...1148
REMOVAL...1148
INSTALLATION...1149
STEERING VALVE...1154
REMOVAL...1154
INSTALLATION...1155
BRAKE VALVE...1156
REMOVAL AND INSTALLATION...1156
SLACK ADJUSTER...1157
REMOVAL AND INSTALLATION...1157
DISASSEMBLY...1158
ASSEMBLY...1159
BRAKE...1160
REMOVAL AND INSTALLATION...1160
DISASSEMBLY...1161
ASSEMBLY...1164
PARKING BRAKE CALIPERS...1168
REMOVAL AND INSTALLATION...1168
DISASSEMBLY...1169
ASSEMBLY...1171
PARKING BRAKE PAD...1173
REMOVAL AND INSTALLATION...1173
PARKING BRAKE SPRING CYLINDER...1174
REMOVAL AND INSTALLATION...1174
BRAKE OIL TANK...1175
REMOVAL AND INSTALLATION...1175
HYDRAULIC PUMP ...1176
REMOVAL...1176
INSTALLATION...1177
PISTON PUMP...1178
DISASSEMBLY...1178
ASSEMBLY...1184
SERVO CYLINDER...1200
REMOVAL AND INSTALLATION...1200
HYDRAULIC TANK AND FILTER CASE ASSEMBLY ...1201
REMOVAL...1201
INSTALLATION...1202
PPC VALVE...1203
REMOVAL...1203
INSTALLATION...1204
DISASSEMBLY AND ASSEMBLY...1205
WORK EQUIPMENT CONTROL VALVE...1206
REMOVAL...1206
INSTALLATION...1207
DISASSEMBLY...1208
ASSEMBLY...1210
CAB...1212
REMOVAL...1212
INSTALLATION...1214
FLOOR FRAME...1215
REMOVAL...1215
INSTALLATION...1217
CENTER HINGE PIN ...1218
REMOVAL...1218
INSTALLATION...1224
WORK EQUIPMENT ...1230
REMOVAL...1230
INSTALLATION...1235
BOOM FRONT END BUSH...1236
REPLACEMENT...1236
BUCKET CYLIMDER...1237
REMOVAL AND INSTALLATION...1237
LIFT CYLINDER...1238
REMOVAL...1238
INSTALLATION...1239
HYDRAULIC CYLINDER...1240
DISASSEMBLY...1240
ASSEMBLY...1242
AIR CONDITIONER UNIT...1244
REMOVAL...1244
INSTALLATION...1245
AIR CONDITIONER COMPRESSOR...1246
REMOVAL AND INSTALLATION...1246
RECEIVER TANK...1247
REMOVAL AND INSTALLATION...1247
AIR CONDITIONER CONDENSER...1248
REMOVAL AND INSTALLATION...1248
TRANSMISSION AND STEERING CONTROLLER...1249
REMOVAL AND INSTALLATION...1249
MAIN MONITOR...1250
REMOVAL...1250
INSTALLATION...1251
FUEL TANK...1252
REMOVAL...1252
INSTALLATION...1253
COUNTERWEIGHT...1254
REMOVAL AND INSTALLATION...1254
AJSS LEVER SWITCH ASSEMBLY...1255
REMOVAL...1255
INSTALLATION...1258
40 MAINTENANCE STANDARD...1263
ENGINE MOUNT...1264
TRANSMISSION MOUNT...1265
DAMPER...1266
TORQUE CONVERTER CHARGING,PPC AND BRAKE PUMP...1268
TORQUE CONVERTER ...1270
TORQUE CONVERTER REGULATOR VALVE...1271
TRANSMISSION...1272
TRANSFER...1275
TRANSMISSION CONTROL VALVE...1278
DRIVE SHAFT...1283
CENTER SUPPORT...1284
DIFFERENTIAL...1285
FINAL DRIVE...1288
AXLE MOUNT...1290
CENTER HINGE PIN...1292
STEERING COLUMN...1294
STEERING DEMAND VALVE...1296
DIVERTER VALVE...1298
STEERING CYLINDER MOUNT...1299
EMERGENCY STEERING PUMP...1300
BRAKE VALVE...1302
SLACK ADJUSTER...1306
BRAKE...1308
PARKING BRAKE...1310
PPC VALVE...1312
PPC RELIEF VALVE...1314
CONTROL PUMP...1315
STEERING PUMP...1316
SWITCH PUMP...1317
MAIN PISTON PUMP...1318
MAIN CONTROL VALVE...1320
HYDRAULIC CYLINDER...1324
BUCKET LINKAGE...1326
BUCKET POSITIONER AND BOOM KICK-OUT...1328
90 OTHERS...1329
ELECTRIC CIRCUIT DIAGRAM (1/16)...1331
ELECTRIC CIRCUIT DIAGRAM (2/16)...1332
ELECTRIC CIRCUIT DIAGRAM (3/16)...1333
ELECTRIC CIRCUIT DIAGRAM (4/16)...1334
ELECTRIC CIRCUIT DIAGRAM (5/16)...1335
ELECTRIC CIRCUIT DIAGRAM (6/16)...1336
ELECTRIC CIRCUIT DIAGRAM (7/16)...1337
ELECTRIC CIRCUIT DIAGRAM (8/16)...1338
ELECTRIC CIRCUIT DIAGRAM (9/16)...1339
ELECTRIC CIRCUIT DIAGRAM (10/16)...1340
ELECTRIC CIRCUIT DIAGRAM (11/16)...1341
ELECTRIC CIRCUIT DIAGRAM (12/16)...1342
ELECTRIC CIRCUIT DIAGRAM (13/16)...1343
ELECTRIC CIRCUIT DIAGRAM (14/16)...1344
ELECTRIC CIRCUIT DIAGRAM (15/16)...1345
ELECTRIC CIRCUIT DIAGRAM (16/16)...1346
ELECTRIC CIRCUIT DIAGRAM (REMOTE BOOM POSITIONER)...1347
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING SPECIFICATION)...1348
