Komatsu Wheel Loaders WA320 and WA320L Models Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA320 and WA320L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loaders WA320 and WA320L 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.
CEAM003500 - Wheel Loader WA320-3 avance plus Operation & Maintenance Manual.pdf
CEAM012202 - Wheel Loader WA320-5L Operation & Maintenance Manual.pdf
CEAM019803 - Wheel Loader WA320-6 Operation & Maintenance Manual.pdf
CEAM023302 - Wheel Loader WA320-6 Operation & Maintenance Manual.pdf
CEAM027400 - Wheel Loader WA320-7 Operation & Maintenance Manual.pdf
CEAMW19070 - Wheel Loader WA320-3 Operation & Maintenance Manual.pdf
CEBM012004 - Wheel Loader GALEO WA320-5L Shop Manual.pdf
CEBM019803 - Wheel Loader WA320-6 Shop Manual.pdf
CEBM022801 - Wheel Loader WA320-6 Shop Manual.pdf
CEBM027700 - Wheel Loader WA320-7 Shop Manual.pdf
CEBMW19071 - Wheel Loader WA320-3 Shop Manual.pdf
SEAM006101 - Wheel Loader WA320-3 Operation & Maintenance Manual.pdf
SEAM011604 - Wheel Loader WA320-3 Operation & Maintenance Manual.pdf
SEAM033202 - Wheel Loader WA320L-3 Operation & Maintenance Manual.pdf
SEAMU4190106 - Wheel Loader WA320-1 Operation & Maintenance Manual.pdf
SEBM006006 - Wheel Loader WA320-3 avance Shop Manual.pdf
SEBM017300 - Wheel Loader WA320L-3 avance Shop Manual.pdf
SEBM034604 - Wheel Loader WA320-5, WA320L-5 Shop Manual.pdf
SEBM034607 - Wheel Loader WA320-5 Shop Manual.pdf
SEBM034608 - Wheel Loader WA320-5 Shop Manual.pdf
SEBM04190107 - Wheel Loader WA300-1, WA320-1 Shop Manual.pdf
SEN06202-00 - Wheel Loader WA320-7 Shop Manual.pdf
SEN06202-01 - Wheel Loader WA320-7 Shop Manual.pdf
SEN06202-03 - Wheel Loader WA320-7 Shop Manual.pdf
SEN06597-05 - Wheel Loader WA320-8 Shop Manual.pdf
TEN00088-00 - Wheel Loader GALEO WA320L-5 Operation & Maintenance Manual.pdf
TEN00235-05 - Wheel Loader WA320-6 Operation & Maintenance Manual.pdf
TEN00456-01 - Wheel Loader WA320-6 Operation & Maintenance Manual.pdf
TEN00612-00 - Wheel Loader WA320-7 Operation & Maintenance Manual.pdf
VEAM240100 - Wheel Loader WA320-5 Operation & Maintenance Manual.pdf
VEBM450104 - Wheel Loader WA320-3 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 25,639 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM003500 - Wheel Loader WA320-3 avance plus Operation & Maintenance Manual................1
INTRODUCTION................4
1. FOREWORD................5
2. SAFETY INFORMATION................6
3. INTRODUCTION................7
3.1 INTENDED USE................7
3.2 FEATURES................7
3.3 BREAKING IN A NEW MACHINE................7
4. LOCATION OF PLATE, TABLE FOR SERIAL NUMBERS AND DISTRIBUTOR................8
4.1 MACHINE SERIAL NUMBER PLATE POSITION................8
4.2 ENGINE SERIAL NUMBER POSITION................8
4.3 TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR................8
5. TABLE OF CONTENTS................9
SAFETY................14
6. GENERAL PRECAUTIONS................15
7. PRECAUTIONS DURING OPERATION................21
7.1 BEFORE STARTING ENGINE................21
7.2 OPERATING MACHINE................22
7.3 TRANSPORTATION................31
7.4 BATTERY................32
7.5 TOWING................34
8. PRECAUTIONS FOR MAINTENANCE................35
8.1 BEFORE CARRYING OUT MAINTENANCE................35
8.2 DURING MAINTENANCE................40
8.3 TIRES................44
OPERATION................51
10. GENERAL VIEW................52
10.1 GENERAL VIEW OF MACHINE................52
10.2 GENERAL VIEW OF CONTROLS AND GAUGES................53
11. EXPLANATION OF COMPONENTS................54
11.1 MACHINE MONITORS................54
11.1.1 WARNING DISPLAYS................56
11.1.2 METER DISPLAY PORTION................60
11.2 SWITCHES................64
11.3 CONTROL LEVERS, PEDALS................71
11.4 STEERING COLUMN TILT LEVER................76
11.5 CAP WITH LOCK................77
11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................77
11.6 SAFETY BAR................79
11.7 TOWING PIN................79
11.8 GREASE PUMP................80
11.9 BACK UP ALARM................80
11.10 FUSE................81
11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT................81
11.11 SLOW-BLOW FUSE................82
11.12 STORAGE FOR THIS MANUAL................83
11.13 ELECTRIC POWER (WITH ROPS CAB)................83
12. OPERATION................84
12.1 CHECKS BEFORE STARTING................84
12.1.1 WALK AROUND CHECK................84
12.1.2 CHECK BEFORE STARTING................87
12.1.3 ADJUSTMENT BEFORE OPERATION................92
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE................95
12.2 STARTING ENGINE................97
12.2.1 COLD WEATHER STARTING................98
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE................99
12.4 MOVING MACHINE................100
12.5 CHANGING GEARS................102
12.6 CHANGING DIRECTION................102
12.7 TURNING................103
12.8 STOPPING MACHINE................104
12.9 OPERATION OF WORK EQUIPMENT................105
12.9.1 STANDARD WORK EQUIPMENT CONTROLS................105
12.9.2 MONO LEVER WORK EQUIPMENT CONTROLS................107
12.10 WORK POSSIBLE USING WHEEL LOADER................108
12.10.1 DIGGING OPERATIONS................108
12.10.2 LEVELING OPERATIONS................111
12.10.3 PUSHING OPERATION................111
12.10.4 LOAD AND CARRY OPERATIONS................111
12.10.5 LOADING OPERATIONS................112
12.11 PRECAUTIONS FOR OPERATION................113
12.11.1 PERMISSIBLE WATER DEPTH................113
12.11.2 IF WHEEL BRAKE DOES NOT WORK................113
12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES................113
12.11.4 PRECAUTIONS WHEN DRIVING MACHINE................114
12.12 ADJUSTING WORK EQUIPMENT POSTURE................115
12.12.1 ADJUSTING BOOM KICKOUT[DIRECT.QUERY(KOMATSU,4D94E_1A,|000000,)]................115
12.12.2 ADJUSTING BUCKET POSITIONER................116
12.12.3 BUCKET LEVEL INDICATOR................116
12.13 PARKING MACHINE................117
12.14 CHECKS AFTER COMPLETION OF OPERATION................118
12.15 STOPPING ENGINE................118
12.16 CHECK AFTER STOPPING ENGINE................118
12.17 LOCKING................119
12.18 HANDLING THE TIRES................120
12.18.1 PRECAUTIONS WHEN HANDLING TIRES................120
12.18.2 TIRE PRESSURE................120
13. TRANSPORTATION................122
13.1 LOADING, UNLOADING WORK................122
13.2 PRECAUTIONS FOR LOADING................122
13.3 PRECAUTIONS FOR TRANSPORTATION................123
13.4 LIFTING MACHINE................123
14. COLD WEATHER OPERATION................126
14.1 PRECAUTIONS FOR LOW TEMPERATURE................126
14.1.1 FUEL AND LUBRICANTS................126
14.1.2 COOLANT................126
14.1.3 BATTERY................126
14.2 PRECAUTIONS AFTER COMPLETION OF WORK................127
14.3 AFTER COLD WEATHER................127
15. LONG TERM STORAGE................128
15.1 BEFORE STORAGE................128
15.2 DURING STORAGE................128
15.3 AFTER STORAGE................128
16. TROUBLESHOOTING................129
16.1 WHEN MACHINE RUNS OUT OF FUEL................129
16.2 TOWING THE MACHINE................130
16.2.1 WITH THE ENGINE RUNNING................131
16.2.2 WITH THE ENGINE STOPPED................131
16.2.3 RELEASING PARKING BRAKE................132
16.2.4 EMERGENCY TRAVEL OPERATION................133
16.3 IF BATTERY IS DISCHARGED................134
16.3.1 REMOVAL AND INSTALLATION OF BATTERY................134
16.3.2 PRECAUTIONS FOR CHARGING BATTERY................135
16.3.3 STARTING ENGINE WITH BOOSTER CABLE................136
16.4 OTHER TROUBLE................138
16.4.1 ELECTRICAL SYSTEM................138
16.4.2 CHASSIS................139
16.4.3 ENGINE................142
MAINTENANCE................144
17. GUIDES TO MAINTENANCE................145
18. OUTLINES TO MAINTENANCE................148
18.1 OUTLINE OF OIL, FUEL, COOLANT................148
18.1.1 OIL................148
18.1.2 FUEL................149
18.1.3 COOLANT................149
18.1.4 GREASE................149
18.1.5 STORING OIL AND FUEL................150
18.1.6 FILTERS................150
18.2 OUTLINE OF ELECTRIC SYSTEM................151
19. WEAR PARTS LIST................152
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................153
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS................153
20.2 ENGINE OIL SPECIFICATIONS................155
20.2.1 NORMAL OPERATION................155
20.2.2 ARCTIC OPERATION................155
20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS................156
20.4 DRIVE AXLE OIL SPECIFICATIONS................156
20.5 DIESEL FUEL SPECIFICATIONS................156
20.6 COOLANT SPECIFICATIONS................156
20.6.1 GENERAL................157
20.6.2 WATER................157
20.6.3 ANTIFREEZE................158
20.6.4 SUPPLEMENTAL COOLANT ADDITIVES................159
21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS................163
21.1 INTRODUCTION OF NECESSARY TOOLS................163
21.2 TORQUE LIST................164
22. PERIODIC REPLACEMENT OF SFETY CRITICAL PARTS................165
23. MAINTENANCE SCHEDULE................169
23.1 SCHEDULED MAINTENANCE CHART................169
24. SERVICE PROCEDURE................173
24.1 INTIAL 250 HOURS SERVICE................173
24.2 WHEN REQUIRED................174
24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT................174
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL................176
24.2.3 CHECK AXLE OIL LEVEL, ADD OIL................177
24.2.4 CLEAN THE AXLE CASE BREATHER................178
24.2.5 CLEAN THE RADIATOR FINS................178
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES................179
24.2.7 REPLACE BUCKET TEETH................180
24.2.8 CHECK AIR CONDITIONER................181
24.2.9 CLEAN THE AIR CONDITIONER CONDENSER................182
24.2.10 OPERATE THE AIR CONDITONER OFF SEASON................182
24.2.11 CHECK WINDOW WASHING FLUID, ADD FLUID................182
24.2.12 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2PALCES................182
24.2.13 REPLACE SLOW BLOW FUSE................183
24.2.14 SELECTION AND INSPECTION OF TIRES................183
24.3 CHECK BEFORE STARTING................185
24.3.1 CHECK MONITOR PANEL................185
24.3.2 CHECK COOLANT LEVEL, ADD WATER................185
24.3.3 CHECK FUEL LEVEL, ADD WATER................185
24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD WATER................186
24.3.5 CHECK ELECTRIC WIRING................187
24.3.6 DRAIN WATER FROM FUEL WATER SEPARATOR................187
24.3.7 CHECK EFFECT OF PARKING BRAKE................188
24.3.8 CHECK EFFECT OF BRAKE................188
24.3.9 CHECK SOUND OF HORN AND BACKUP ALARM................188
24.3.10 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE................188
24.3.11 CHECK ENGINE EXHAUST COLOR AND SOUND................188
24.3.12 CHECK OPERATION OF GUA................188
24.3.13 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING................188
24.3.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................188
24.4 EVERY 50 HOURS SERVICE................189
24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK................189
24.5 EVERY 100 HOURS SERVICE................189
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................189
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................190
24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)................190
24.6 EVERY 250 HOURS SERVICE................191
24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILETER CARTRIDGE................191
24.6.2 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN................192
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER................193
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................193
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL................194
24.6.6 CORROSION RESISTOR................195
24.6.7 LUBRICATING................196
24.7 EVERY 500 HOURS SERVICE................197
24.7.1 REPLACE FUEL FILTER................197
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT................199
24.7.3 LUBRICATE CENTER DRIVE SHAFT SPLINE (1 PLACE)................199
24.8 EVERY 1000 HOURS SERVICE................200
24.8.1 CHANGE OIL IN TRANSMISSION, CLEAN STRAINER................200
24.8.2 CLEAN TRANSMISSION CASE BREATHER................201
24.8.3 LUBRICATE................201
24.8.4 CHECK ENGINE VALVE CLEARANCE, ADJUST................203
24.8.5 CHECK TENSION OF DRIVE BELT................206
24.8.6 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING................206
24.9 EVERY 2000 HOURS SERVICE................208
24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM................208
24.9.2 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT................212
24.9.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT................214
24.9.4 CHANGE AXLE OIL................215
24.9.5 CHECK BRAKE DISC WEAR................215
24.9.6 CHECK VIBRATION DAMPER................215
24.9.7 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULAION FILTER AND FRESH FILTER................216
24.9.8 CLEAN PPC CIRCUIT STRAINER................216
24.9.9 CHECK ACCUMULATOR GAS PRESSURE................216
SPECIFICATIONS................217
25. WA320-3MC................218
OPTIONS, ATTACHMENTS................220
26. OPTIONAL PARTS AND ATTACHMENTS................221
27. SELECTING BUCKETS AND TIRES................222
28. AIR CONDITIONING................223
28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................223
28.1.1 FAN SWITCH................223
28.1.2 AIR CONDITIONER SWITCH................223
28.1.3 MODE SELECTOR SWITCH................224
28.1.4 FRESH/RECIRC SELECTOR SWITCH................224
28.1.5 TEMPERATURE CONTROL SWITCH................224
28.2 METHOD OF OPERATION................225
28.2.1 WHEN NOT USING THE AIR CONDITIONER REGULARLY................225
28.3 COOL BOX................225
29. HANDLING ECSS................226
29.1 STRUCTURE AND FUNCTION OF ECSS................226
29.2 METHOD OF OPERATING ECSS................227
29.3 PRECAUTIONS WHEN OPERATING ECSS SWITCH................227
29.4 ACCUMULATOR PRECAUTIONS................228
30. OPTION DISPLAY................229
30.1 EMERGENCY STEERING PILOT LAMP................229
30.2 RADIO................230
30.2.1 OPERATING CONTROLS................230
30.2.2 OPERATION................231
30.2.3 SETTING THE CLOCK................233
30.2.4 REMOTE CONTROL UNIT................233
30.2.5 BATTERY REPLACEMENT................234
30.2.6 PRECAUTIONS WHEN USING................234
CEAM012202 - Wheel Loader WA320-5L Operation & Maintenance Manual................235
COVER................235
INTRODUCTION................237
FOREWORD................238
SAFETY INFORMATION................239
APPROVED AND NON-APPROVED USES................240
APPROVED FUNCTIONS................240
NON-APPROVED FUNCTIONS................240
PRODUCT IDENTIFICATION................241
MACHINE SERIAL NUMBER................241
ENGINE SERIAL NUMBER AND EMISSION LABEL................242
SERVICE METER LOCATION................242
SERIAL NUMBERS AND DEALER INFORMATION................243
MODEL: WA320-5L................243
TABLE OF CONTENTS................244
SAFETY................253
SAFETY AND WARNING DECALS................254
LOCATION OF THE SAFETY DECALS................254
DESCRIPTION OF SAFETY LABELS................255
SAFETY LABELS................255
GENERAL SAFETY RULES AND PRECAUTIONS................263
GENERAL SAFETY RULES................263
UNAUTHORIZED MODIFICATIONS................264
GENERAL SAFETY AT JOB SITE................264
WORKING ON LOOSE GROUND................264
SAFETY FEATURES................265
PERSONAL PROTECTIVE EQUIPMENT................265
FIRE AND EXPLOSION PREVENTION................266
FIRE CAUSED BY FUEL OR OIL................266
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL................266
FIRE COMING FROM ELECTRIC WIRING................267
FIRE COMING FROM HYDRAULIC LINE................267
WINDSHIELD WASHER FLUID................267
ACTION IF FIRE OCCURS................267
FIRE EXTINGUISHER AND FIRST AID KIT................267
MOUNTING AND DISMOUNTING................268
INSIDE OPERATOR’S COMPARTMENT................269
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT................269
PRECAUTIONS WHEN USING ROPS................269
EMERGENCY ESCAPE FROM OPERATOR'S CAB................269
LEAVING OPERATOR’S COMPARTMENT................270
KEEP OPERATOR'S COMPARTMENT CLEAN................270
DUST HAZARD PRECAUTIONS................271
ASBESTOS HAZARD ALERT................271
CRUSH OR PINCH POINT DANGERS................271
PRECAUTIONS BEFORE STARTING OPERATIONS................272
PRE-OPERATIONAL CHECKS................272
STARTING YOUR WORK OPERATIONS................272
WORK SITE HAZARDS................273
AVOIDING DANGEROUS SITUATIONS................273
WORKING CLEARANCES................274
RULES FOR ROAD TRAVEL................276
TRAVELING IN REVERSE................276
TRAVELING ON ICY OR SNOW-COVERED SURFACES................276
WORKING ON LOOSE OR UNSTABLE GROUND................276
TRAVEL ON SLOPES................277
PARKING THE MACHINE................278
PRECAUTIONS DURING MAINTENANCE OPERATIONS................279
WARNING TAGS................279
EQUIPMENT STORAGE................279
WORKING UNDER THE MACHINE................280
USING DROP LAMPS................280
KEEPING THE MACHINE CLEAN................281
RUNNING THE MACHINE DURING MAINTENANCE................281
RULES FOR REFUELING THE MACHINE................282
COOLING SYSTEM PRECAUTIONS................282
BATTERY PRECAUTIONS................283
STARTING THE MACHINE................283
HIGH-PRESSURE HOSES................284
SAFETY HANDLING HIGH-PRESSURE HOSES................284
PRECAUTION FOR HIGH FUEL PRESSURE................284
HIGH TEMPERATURES AREAS................284
DISPOSAL OF WASTE MATERIALS................285
INFLATING TIRES................285
ACCUMULATOR................286
CRITICAL PARTS................286
HIGH VOLTAGE................286
OPERATION................287
GENERAL VIEW................288
INSIDE VIEW OF THE CAB................289
DESCRIPTION OF ALERTS, GAUGES, AND MONITOR SYSTEM................290
STANDARD INSTRUMENT BEZEL................290
MACHINE MONITOR................291
EXPLANATION OF COMPONENTS................292
MACHINE MONITOR................292
MONITOR SYSTEM................293
TESTING ACTUATION OF MACHINE MONITOR SYSTEM................293
TYPES OF WARNING................294
EMERGENCY STOP................294
CAUTION................294
MISTAKEN OPERATION................294
INSPECTION AND MAINTENANCE................294
CENTRAL WARNING LAMP................294
CHARACTER DISPLAY PORTION................295
SERVICE METER................295
ACTION CODE DISPLAY................296
FAILURE CODE DISPLAY................297
FILTER, OIL REPLACEMENT TIME DISPLAY................298
EMERGENCY STOP ITEMS................300
BRAKE OIL PRESSURE CAUTION LAMP................300
ENGINE OIL PRESSURE CAUTION LAMP................301
BATTERY CHARGE CIRCUIT CAUTION LAMP................301
STEERING OIL PRESSURE CAUTION LAMP - RED................301
CAUTION ITEMS................302
AXLE OIL TEMPERATURE CAUTION LAMP................302
PARKING BRAKE REMINDER CAUTION LAMP................303
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP................303
FUEL LEVEL CAUTION LAMP................304
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED................304
TRAVEL SPEED LIMIT FUNCTION................304
INSPECTION AND MAINTENANCE ITEMS................305
RADIATOR COOLANT LEVEL CAUTION LAMP................305
ENGINE OIL LEVEL CAUTION LAMP................306
MAINTENANCE CAUTION LAMP................307
HST OIL FILTER CLOG CAUTION LAMP................307
AIR CLEANER CLOGGING CAUTION LAMP................307
PILOT DISPLAY PORTION................308
PARKING BRAKE PILOT LAMP................308
PREHEATING PILOT LAMP................308
EMERGENCY STEERING PILOT LAMP - GREEN................309
DIRECTIONAL LEVER POSITION PILOT LAMP................309
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION................309
TURN SIGNAL PILOT LAMP................309
HEAD LAMP HIGH BEAM PILOT LAMP................310
METER DISPLAY PORTION................311
HST OIL TEMPERATURE GAUGE................311
ENGINE COOLANT TEMPERATURE GAUGE................311
FUEL GAUGE................312
SPEEDOMETER................312
METER DISPLAY PILOT LAMP................312
OTHER FUNCTIONS OF MACHINE MONITOR................313
METHOD OF DISPLAYING ODOMETER................313
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME................313
METHOD FOR SELECTING LANGUAGE................314
METHOD OF SELECTING HST CHANGING FUNCTION................315
SWITCHES................316
STARTING SWITCH................316
SPEED RANGE SELECTOR SWITCH................317
VARIABLE SHIFT CONTROL SWITCH................317
TRACTION CONTROL SWITCH................318
E.C.S.S. SWITCH................318
LAMP SWITCH................319
TURN SIGNAL LEVER................319
DIMMER SWITCH................319
HORN BUTTON................319
HAZARD LAMP SWITCH................320
FRONT WORKING LAMP SWITCH................320
REAR WORKING LAMP SWITCH................321
MONITOR PANEL MODE SELECTOR SWITCH 1................321
MONITOR PANEL MODE SELECTOR SWITCH 2................321
FRONT WIPER SWITCH................322
REAR WIPER SWITCH................322
CIGARETTE LIGHTER................322
ROOM LAMP SWITCH................322
FAN REVERSE SWITCH................323
CONTROL LEVERS, PEDALS................324
DIRECTIONAL CONTROL LEVER................324
WORK EQUIPMENT LOCK LEVER................325
LIFT ARM CONTROL LEVER................325
BUCKET CONTROL LEVER................326
BRAKE PEDALS................327
ACCELERATOR PEDAL................327
PARKING BRAKE LEVER................328
STEERING TILT LOCK LEVER................328
SECURITY LOCKS AND SAFETY FEATURES................329
IGNITION KEY LOCKED AREAS................329
METHOD OF OPENING AND CLOSING CAP WITH LOCK................329
METHOD OF OPENING AND CLOSING COVER WITH LOCK................329
SAFETY BAR................330
TOWING PIN................330
GREASE PUMP................331
CAB DOOR INNER LOCK................331
CAB DOOR OPEN LOCK................331
CAB WINDOW OPEN LOCK CANCEL KNOB................332
FUSE................332
FUSE CAPACITY AND NAME OF CIRCUIT................332
SLOW-BLOW FUSE................333
AUXILIARY POWER................334
STORAGE BOX................334
AM/FM RADIO-CASSETTE STEREO................335
RADIO OPERATION................336
POWER SWITCH/VOLUME................336
AUTO-STORE/PRESET SCAN BUTTON................336
BASS CONTROL KNOB................336
TREBLE CONTROL KNOB................336
LOUDNESS BUTTON................337
TIME/RADIO DISPLAY SELECTOR BUTTON................337
TAPE EJECT BUTTON................337
CASSETTE DOOR................337
FAST FORWARD, REWIND BUTTONS................338
PRESET BUTTONS................338
METAL TAPE BUTTON................338
MANUAL TUNING BUTTONS................338
SEEK TUNING BUTTONS................338
BAND SELECTOR BUTTON................339
USING RADIO FEATURE................339
USING AUTO PRESET................339
USING MANUAL PRESET................339
LISTENING TO RADIO................340
LISTENING TO CASSETTE TAPE................340
REVERSING TAPE................340
PRECAUTIONS FOR RADIO OPERATION................341
AIR CONDITIONER................342
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................342
FAN SWITCH................342
AIR CONDITIONER SWITCH................342
MODE SELECTOR SWITCH................343
FRESH/RECIRC SELECTOR SWITCH................343
TEMPERATURE CONTROL SWITCH................343
METHOD OF OPERATION................344
WHEN NOT USING THE AIR CONDITIONER REGULARLY................344
COOL BOX................345
PRECAUTIONS WHEN USING THE COOLING................345
HANDLING CAB WIPER................345
PREVENTING WIPER ARM BRACKET DAMAGE................345
OPERATION................346
CHECK BEFORE STARTING ENGINE, ADJUST................346
WALK-AROUND CHECK................346
CHECK BEFORE STARTING................349
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL................349
CHECK WATER SEPARATOR................350
CHECK DUST INDICATOR................350
CHECK COOLANT LEVEL, ADD COOLANT................351
CHECK INFLATION PRESSURE OF TIRES................351
CHECK ELECTRIC WIRING................352
CHECK MONITOR PANEL................352
CHECK FUEL LEVEL, ADD FUEL................353
CHECK PARKING BRAKE................354
CHECK BRAKE PEDAL................354
ADJUSTING THE SEAT................354
ADJUST BELT LENGTH................356
ADJUST REAR VIEW MIRROR................356
OPERATIONS AND CHECKS BEFORE STARTING ENGINE................357
STARTING ENGINE................359
OPERATIONS AND CHECKS AFTER STARTING ENGINE................361
BREAKING IN THE MACHINE................361
NORMAL OPERATION................361
STOPPING ENGINE................363
MOVING THE MACHINE (DIRECTION, SPEED), STOPPING THE MACHINE................364
MOVING THE MACHINE................364
CHANGING DIRECTION................366
STOPPING THE MACHINE................367
TURNING................368
EMERGENCY STEERING................368
OPERATION OF WORK EQUIPMENT................369
LIFT ARM OPERATION................369
BUCKET OPERATION................370
WORK POSSIBLE USING WHEEL LOADER................371
DIGGING OPERATIONS................371
LOADING PILED SOIL................371
DIGGING AND LOADING ON LEVEL GROUND................372
LEVELING OPERATIONS................373
PUSHING OPERATIONS................373
LOAD AND CARRY OPERATIONS................373
LOADING OPERATIONS................374
CROSS-DRIVE LOADING................374
V-SHAPE LOADING................375
PRECAUTIONS WHEN PILING UP LOADS................375
PRECAUTIONS FOR OPERATION................375
PERMISSIBLE WATER DEPTH................375
IF WHEEL BRAKE DOES NOT WORK................375
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES................376
LOWER THE CENTER OF GRAVITY WHEN TURNING.................376
BRAKING ON DOWNHILL SLOPE................376
IF ENGINE STOPS................376
PRECAUTIONS WHEN DRIVING MACHINE................376
ADJUSTING WORK EQUIPMENT POSTURE................377
ADJUSTING BOOM KICKOUT................377
ADJUSTING BUCKET POSITIONER................378
BUCKET LEVEL INDICATOR................378
PARKING MACHINE................379
CHECK AFTER STOPPING ENGINE................380
CHECKS AFTER COMPLETION OF OPERATION................380
LOCKING................381
HANDLING THE TIRES................381
PRECAUTIONS WHEN HANDLING TIRES................381
TIRE PRESSURE................382
PRECAUTIONS FOR USING LOAD AND CARRY METHOD................382
TRANSPORTATION................383
TRANSPORTATION PROCEDURE................383
LOADING, UNLOADING WORK WITH TRAILERS................383
LOADING................383
SECURING MACHINE................384
UNLOADING................384
LIFTING MACHINE................385
LOCATION OF LIFTING POSITION MARK................386
WEIGHT TABLE................386
LIFTING PROCEDURE................387
COLD WEATHER OPERATION................388
PRECAUTIONS FOR LOW TEMPERATURE................388
FUEL AND LUBRICANTS................388
COOLANT................388
BATTERY................389
PRECAUTIONS AFTER COMPLETION OF WORK................389
AFTER COLD WEATHER................389
STEERING HYDRAULIC CIRCUIT WARM UP................390
LONG TERM STORAGE................390
BEFORE STORAGE................390
DURING STORAGE................390
AFTER STORAGE................390
TROUBLESHOOTING................391
WHEN MACHINE RUNS OUT OF FUEL................391
TOWING THE MACHINE................391
WHEN ENGINE CAN BE USED................392
WHEN ENGINE CANNOT BE USED................392
IF BATTERY IS DISCHARGED................392
REMOVAL AND INSTALLATION OF BATTERY................393
PRECAUTIONS FOR CHARGING BATTERY................393
STARTING ENGINE WITH BOOSTER CABLE................394
OTHER TROUBLE................396
ELECTRICAL SYSTEM................396
CHASSIS................397
ENGINE................399
MAINTENANCE................401
GUIDES TO MAINTENANCE................402
CHECK SERVICE METER................402
KOMATSU GENUINE REPLACEMENT PARTS................402
KOMATSU GENUINE OILS................402
ALWAYS USE CLEAN WASHER FLUID................402
ALWAYS USE CLEAN OIL AND GREASE................402
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS................402
FUEL STRAINER................402
WELDING INSTRUCTIONS................402
DO NOT DROP THINGS INSIDE MACHINE................402
DUSTY WORK SITES................403
AVOID MIXING OIL................403
LOCKING INSPECTION COVERS................403
BLEEDING AIR FROM HYDRAULIC CIRCUIT................403
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES................403
CHECKS AFTER INSPECTION AND MAINTENANCE................403
OUTLINES OF SERVICE................404
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC................404
OIL................404
FUEL................404
COOLANT................404
GREASE................405
KOWA (Komatsu Oil Wear Analysis)................405
STORING OIL AND FUEL................406
FILTERS................406
OUTLINE OF ELECTRIC SYSTEM................406
WEAR PARTS................407
WEAR PARTS LIST................407
FLUID USE ACCORDING TO AMBIENT TEMPERATURE................408
PROPER SELECTION OF FUEL, COOLANT, AND LUBRICANTS................408
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................410
TORQUE LIST................410
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................411
MAINTENANCE SCHEDULE CHART................412
SERVICE PROCEDURE................414
INITIAL 250 HOURS SERVICE................414
REPLACE HST FILTER ELEMENT................414
REPLACE HYDRAULIC FILTER ELEMENT................414
WHEN REQUIRED................414
CLEAN BELLY PANS, FAN SOLENOID................414
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT................416
CLEAN INSIDE OF COOLING SYSTEM................419
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL................422
CHECK AXLE OIL LEVEL, ADD OIL................423
CLEAN AXLE CASE BREATHER................424
CLEAN AIR CONDITIONER CONDENSER................424
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID................425
CLEAN RADIATOR COOLING FINS................425
CHECK ELECTRICAL INTAKE AIR HEATER................425
REPLACE BOLT ON CUTTING EDGE................426
REPLACE BUCKET TEETH................426
CHECK AIR CONDITIONER................427
REPLACE SLOW-BLOW FUSE................428
SELECTION AND INSPECTION OF TIRES................429
EVERY 50 HOURS SERVICE................431
DRAIN WATER, SEDIMENT FROM FUEL TANK................431
EVERY 100 HOURS SERVICE................431
LUBRICATE REAR AXLE PIVOT PIN................431
CLEAN AIR CONDITIONER FRESH AIR FILTER ELEMENT................431
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................432
EVERY 250 HOURS SERVICE................433
CHECK BATTERY ELECTROLYTE LEVEL................433
CHECK PARKING BRAKE................435
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................435
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN................436
CLEAN AIR CONDITIONER RECIRCULATION FILTER ELEMENT................436
LUBRICATING................437
EVERY 500 HOURS SERVICE................438
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE................438
REPLACE FUEL FILTER CARTRIDGE................439
CLEAN WATER SEPARATOR STRAINER................440
EVERY 1000 HOURS SERVICE................441
CHANGE OIL IN TRANSFER CASE................441
CLEAN TRANSFER CASE BREATHER................442
REPLACE HST OIL FILTER ELEMENT................443
REPLACE CORROSION RESISTOR CARTRIDGE.................444
LUBRICATING................444
CHECK MOUNTING PARTS OF TURBOCHARGER................445
CHECK PLAY OF TURBOCHARGER ROTOR................445
CHECK ALTERNATOR BELT TENSION, REPLACE................445
EVERY 2000 HOURS SERVICE................446
CHANGE HYDRAULIC OIL AND FILTER ELEMENT................446
REPLACE HYDRAULIC TANK BREATHER ELEMENT................447
CHANGE AXLE OIL................448
REPLACE AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER................448
CLEAN BRAKE CIRCUIT STRAINER................449
CHECK ALTERNATOR, STARTING MOTOR................449
CHECK ENGINE VALVE CLEARANCE, ADJUST................449
CHECK BRAKE DISC WEAR................450
CLEAN AND CHECK TURBOCHARGER................451
CHECK ACCUMULATOR GAS PRESSURE................451
CHECK VIBRATION DAMPER................451
EVERY 4000 HOURS SERVICE................452
LUBRICATING................452
CHECK WATER PUMP................452
SPECIFICATIONS................453
TECHNICAL DATA................454
STANDARD OVERALL DIMENSIONS................454
OPTIONS, ATTACHMENTS................455
SELECTING BUCKET AND TIRES................456
METHOD OF USING 3 LEVERS................457
LIFT ARM CONTROL LEVER................457
BUCKET CONTROL LEVER................458
AUXILIARY CONTROL LEVER................458
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM................459
FAN SYSTEM OPERATION................459
DIRECTION PUSH BUTTON................460
CONTROL BOX................460
CLEANING RADIATOR AND COOLER FINS................461
ROTATING THE FAN IN REVERSE................461
CEAM019803 - Wheel Loader WA320-6 Operation & Maintenance Manual................463
CEAM019803................463
INTRODUCTION................465
FOREWORD................466
SAFETY INFORMATION................467
APPROVED AND NON-APPROVED USES................468
Approved Functions................468
Non-Approved Functions................468
VISIBILITY STANDARD................469
Visibility in Immediate Area................469
12-M Radius Visibility................469
PRODUCT IDENTIFICATION................470
Machine................470
Service Meter Location................471
Directions of Machine................471
Machine Serial Number/Product Identification Number (PIN)................472
Engine Serial Number, EPA Regulations................472
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION................473
Model: WA320-6................473
TABLE OF CONTENTS................475
SAFETY................487
SAFETY AND WARNING DECALS................488
Location of the Safety Labels................488
Safety Labels................489
GENERAL SAFETY RULES AND PRECAUTIONS................495
General Safety Rules................495
Safety at Job Site................496
Safety Features................496
Clothing and Protective Equipment................496
Keep Machine Clean................497
Fire and Explosion Prevention................497
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid................497
Fire Caused by Accumulation of Flammable Material................498
Fire Caused by Electrical Wiring................498
Fire Caused by Hydraulic Piping................498
Explosion Caused by Lighting Equipment................498
Action if Fire Occurs................499
Fire Extinguisher and First Aid Kit................499
Mounting and Dismounting................500
Inside Operator’s Compartment................501
Emergency Escape from Operator’s Cab................501
Seat Belt Inspection................502
Precautions When Standing Up from Operator’s Seat................503
Leaving Operator’s Compartment................504
Parking the Machine................505
Transporting the Machine................506
Towing................507
Precautions When Using ROPS................508
Unauthorized Modification................508
Precautions for Attachments and Options................508
Precautions When Cleaning Cab Glass................509
Asbestos Hazard Alert................509
Crush or Pinch-Point Dangers................510
Precautions for Ventilation Exhaust Gas................510
PRECAUTIONS BEFORE STARTING OPERATIONS................511
Pre-Operational Checks................511
Ensure Good Visibility................511
Signs and Signals................511
Precaution for Warning Tag................512
Checks Before Starting Engine, Adjustments................512
Precautions When Starting................513
Precautions in Cold Areas................513
Precautions for Job Site................514
Work Site Hazards................514
Working on Loose or Unstable Ground................514
Prohibited Operations................515
Avoiding Dangerous Situations................515
Working Near High Voltage Cables................517
RULES FOR ROAD TRAVEL................518
Travel Precautions................518
Traveling on Slopes................519
Using the Brakes................520
Traveling in Reverse................520
Operating on Snow or Frozen Surfaces................521
PRECAUTIONS DURING INSPECTION AND MAINTENANCE................522
Warning Tags................522
Workplace Environment................522
Systems Equipped with ECSS................522
Equipment Storage................523
Working Under the Machine................523
Using Drop Lamps................524
Using Proper Tools................524
Keeping the Machine Clean................524
Precautions When Welding................524
Precautions When Using Hammer................525
Noise................525
Stopping Engine During Inspection and Maintenance................526
Running the Machine During Maintenance................528
Rules for Refueling the Machine................529
Cooling System Precautions................529
Window Washer Fluid................529
Battery Information................529
Precautions................529
Hazards................530
Using Booster Cables................531
Starting the Machine with Booster Cables................531
High-Pressure Precautions................532
Precautions for High-Pressure Oil................532
Safe Handling of High-Pressure Hoses................532
Precautions for High-Pressure Fuel................532
High-Temperature Precautions................533
High-Temperature Areas................533
High-Temperature Coolant................533
High-Temperature Oil................533
High Voltage................533
Accumulator and Gas Spring................534
Handling Tires................534
Storing Tires................535
Using Compressed Air................535
Disposal of Waste Materials................535
Critical Parts................536
Maintenance of Air Conditioner................536
OPERATION................537
GENERAL VIEW................538
General View of Machine................538
Controls and Gauges................539
Machine Monitor................540
EXPLANATION OF COMPONENTS................542
Machine Monitor................542
Types of Warnings................543
Emergency Stop................543
Caution................543
Mistaken Operation................543
Inspection and Maintenance................544
Central Warning Lamp................544
Character Display Portion................545
Service Meter................546
Engine Speed or Travel Speed................546
Action Code Display................546
Failure Code Display................548
Filter, Oil Replacement Time Display................548
Emergency Stop Items................550
Brake Oil Pressure Caution Lamp................551
Engine Oil Pressure Caution Lamp................551
Battery Charge Circuit Caution Lamp................552
Steering Oil Pressure Caution Lamp (Red) (if equipped)................552
Caution Items................553
Brake Oil Temperature Caution Lamp................554
Quick Coupler Operation Pilot Lamp (if equipped)................554
Parking Brake Reminder Caution Lamp................555
HST Oil Temperature Caution Lamp................555
Engine Coolant Temperature Caution Lamp................555
Fuel Level Caution Lamp................556
Warning/Limit Functions for Travel Speed................556
Inspection and Maintenance Items................557
Water Separator Caution Lamp................557
Radiator Coolant Level Caution Lamp................558
Engine Oil Level Caution Lamp................558
HST Oil Filter Clogging Caution Lamp................559
Air Cleaner Clogging Caution Lamp................559
Maintenance Caution Lamp................560
Pilot Display Portion................561
Parking Brake Pilot Lamp................562
Cooling Fan Reverse Rotation Pilot Lamp................562
Emergency Steering Pilot Lamp (if equipped)................562
Preheating Pilot Lamp................562
Directional Selector Pilot Lamp................563
Economy Operation Display Lamp................563
S Mode Operation Pilot Lamp................563
Shift Hold Pilot Lamp................563
Traction Control Operation Pilot Lamp................564
Travel Speed Range Selector Switch Position Pilot Lamp................564
Directional Lever Position Pilot Lamp................564
Turn Signal Pilot Lamp................565
Head Lamp High Beam Pilot Lamp................565
Meter Display Portion................566
HST (Hydrostatic Transmission) Oil Temperature Gauge................566
Engine Coolant Temperature Gauge................567
Speedometer................567
Meter Display Pilot Lamp................567
Fuel Gauge................567
OTHER FUNCTIONS OF MACHINE MONITOR................568
Overall Menu................568
Selecting Traction Level................570
Selecting HST Changing Function................571
Displaying Odometer................572
Resetting Filter, Oil Replacement Time................572
Entering Telephone Number................573
Selecting Language................574
Adjusting Monitor Brightness................575
Switching Travel Speed/Engine Speed Display................577
Switching Travel Speed/Engine Speed Display/Non-Display................578
Switches................580
Starting Switch................582
Speed Range Selector Switch................582
Variable Shift Control Switch................583
Quick Coupler Attachment Switch (if equipped)................583
Cooling Fan Auto-Reverse Rotation Switch................583
Directional Selector Actuation Switch................586
Traction Control Switch................587
Max. Traction Switch................588
Front Wiper Switch................588
Machine Monitor Mode Selector Switch 1................589
Machine Monitor Mode Selector Switch 2................589
Electronic Controlled Suspension System Switch (ECSS)................589
Horn Button................590
Lamp Switch................590
Turn Signal Lever................591
Dimmer Switch................591
Front Working Lamp Switch................591
Rear Working Lamp Switch................592
Hazard Lamp Switch................592
Rear Wiper Switch................592
FNR Switch................593
Cigarette Lighter................593
Room Lamp Switch................593
Rear Heated-Wire Glass Switch................594
Control Levers, Pedals................595
Directional Lever................595
Work Equipment Control Lever................596
Work Equipment Lock Lever................597
Accelerator Pedal................597
Brake Pedals................598
Parking Brake Lever................598
SECURITY LOCKS AND SAFETY FEATURES................599
Steering Column Tilt Lock Lever................599
Cap and Cover Lock................599
Opening the Cap (for Fuel Tank Filler Port)................600
Backup Alarm................600
Frame Lock Bar................601
Towing Pin................601
MACHINE FEATURES................602
Cab Door................602
Emergency Escape Right Door................602
Opening, Closing Cab Doors, Windows................604
Left Cab Door, Opening Lock................604
Left Cab Door, Door Handle................605
Left Cab Door, Door Open Knob................605
Cab Sliding Window Lock Release Knob................605
Cab Wiper................606
Grease Pump................606
Storage Box................606
ELECTRICAL................607
Fuses................607
Fuse Capacity and Circuits................608
Slow-Blow Fuses................609
Power Outlet................610
WORK OPERATIONS................611
Walk-Around Check................611
Precautions Before Starting Work Operations................611
Check Before Starting Engine................614
Check Machine Monitor................614
Check Coolant Level, Add Coolant................615
Check Oil Level in Engine Oil Pan, Add Oil................616
Check Water Separator, Drain Water................617
Check Air Cleaner................619
Check Fuel Level, Add Fuel................620
Check Electric Wiring................621
Check Inflation Pressure of Tires................621
Check Parking Brake................621
Check Brake Pedal................621
Check Condition of Window Washer Spray................621
Check Wiping Efficiency of Wiper................622
Check Horn................622
Check Defroster Function................622
Check Locks................622
Check Emergency Exit................622
Adjust Seat (Fabric Type)................623
Adjust Seat (Vinyl Type - If Equipped)................625
Adjust Seat Belt................627
Adjust Lever Stand................628
Adjust Mirrors................629
Final Checks Before Starting Engine................630
Starting Engine................633
Normal Starting................633
Starting Engine in Cold Weather................635
Automatic Warming-Up Operation................636
Operations and Checks After Starting Engine................637
Breaking in the Machine................637
Checks After Starting Engine................637
Normal Operation................638
Stopping Engine................640
Check After Stopping Engine................640
Moving the Machine (Directional, Speed), Stopping the Machine................641
Moving the Machine................641
Changing Direction................644
Stopping the Machine................647
Turning................649
Emergency Steering (if equipped)................650
Operation of Work Equipment................651
Lift Arm Operation................651
Bucket Operation................652
Work Possible Using Wheel Loader................653
Digging Operations................653
Loading Piled Soil or Blasted Rock................653
Digging and Loading on Level Ground................655
Leveling Operations................656
Pushing Operations................656
Load-and-Carry Operations................656
Loading Operations................657
Cross-Drive Loading................657
V-Shape Loading................657
Preparations for Loading, Gathering Rocks................658
Approaching Facing................658
Digging................659
Traveling in Reverse After Excavation................661
Approaching Dump Truck................662
Loading Dump Truck................663
Reversing Away From Dump Truck................664
Precautions................665
When Piling Up Loads................665
When Handling Blasted Rock................665
During Cutting Face Operations................669
When Switching Between Forward and Reverse................669
Turning When Tires Are Stationary................669
Permissible Water Depth................670
When Wheel Brake Does Not Work................670
When Driving Up or Down Slopes................670
When Driving the Machine................671
Adjusting Work Equipment................672
Adjusting Boom Kickout................672
Adjusting Bucket Positioner................673
Bucket Level Indicator................673
Measuring Dump Angle................674
Measuring Bucket Dump Angle................674
Measuring Coupler Dump Angle................676
Removing the Bucket................679
Installing the Bucket................680
Parking the Machine................682
Checks After Completion of Operation................684
Before Stopping Engine................684
After Stopping Engine................684
Locking the Machine................685
HANDLING TIRES................686
Precautions When Handling Tires................686
Tire Pressure................687
Precautions for Using Load-and-Carry Method................688
Precautions when Storing Tires................688
TRANSPORTATION................689
Transportation Procedure................689
Loading and Unloading Trailers................689
Loading Machine................689
Securing Machine................690
Unloading Machine................692
LIFTING MACHINE................694
Lifting Position Marks................694
Lifting Procedure................695
COLD WEATHER OPERATION................697
Precautions for Low Temperature................697
Fuel and Lubricants................697
Coolant................697
Battery................697
Precautions After Completion of Work................698
When Cold Weather Ends................698
LONG-TERM STORAGE................699
Before Storage................699
During Storage................699
After Storage................700
AUTOMATIC AIR CONDITIONER................701
Control Panel................701
Main Power Switch................702
Fan Switch................702
Air Conditioner Switch................703
Auto Switch................704
Temperature Switch................704
FRESH/RECIRC Selector Switch................704
Mode Selector Switch................705
Method of Operation................706
Cooling Operation................706
Heating Operation................706
Drying-Heating and Demisting Operation................707
When Not Using the Air Conditioner Regularly................707
Precautions When Using Air Conditioner................707
Inspection and Maintenance................708
Cool Box................708
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM................709
Sound System Components................711
Power Switch/Volume................711
Auto-Store/Preset Scan Button................711
Bass Control Knob................711
Treble Control Knob................712
Loudness Button................712
Time/Radio Display Selector Button................712
Tape Eject Button................713
Cassette Door................713
Fast-Forward, Rewind Buttons................713
Preset Buttons................713
Metal Tape Button................714
Manual Tuning Buttons................714
Seek Tuning Buttons................714
Band Selector Button................714
Method of Operation................715
Setting Preset Buttons................715
Using Auto-Preset................715
Using Manual Preset................715
Listening to Radio................716
Listening to Cassette Tape................716
Reversing the Tape................717
Precautions When Using................717
Handling Cassette Tape................717
KOMTRAX................718
Basic Precautions................718
TROUBLESHOOTING................719
When Machine Runs Out of Fuel................719
Towing the Machine................719
When Engine Can Be Used................721
When Engine Cannot Be Used................721
Emergency Travel Operation................721
If Battery is Discharged................722
Precautions................722
Removing the Battery................722
Installing the Battery................722
Precautions for Charging Battery................723
Starting Engine With Booster Cable................724
Precautions When Connecting or Disconnecting Booster Cable................724
Connecting Booster Cable................724
Starting Engine................725
Disconnecting Booster Cable................725
Other Troubleshooting................726
Electrical System................726
Chassis................727
Engine................729
MAINTENANCE................731
GUIDES TO MAINTENANCE................732
Check Service Meter................732
Komatsu Genuine Replacement Parts................732
Komatsu Genuine Oils................732
Always Use Clean Washer Fluid................732
Always Use Clean Oil and Grease................732
Checking for Foreign Materials in Drained Oil and On Filters................732
Fuel Strainer................732
Welding Instructions................733
Do Not Drop Things Inside Machine................733
Dusty Work Sites................733
Avoid Mixing Oil................733
Locking Inspection Covers................733
Bleeding Air from Hydraulic Circuit................734
Precautions When Installing Hydraulic Hoses................734
Checks After Inspection and Maintenance................734
OUTLINES OF SERVICE................735
Handling Oil, Fuel, Coolant, and Performing Oil Clinic................735
Oil................735
Fuel................736
Coolant and Water for Dilution................736
Grease................737
Performing KOWA (Komatsu Oil Wear Analysis)................738
KOWA Analysis Items................738
Oil Sampling................738
Storing Oil and Fuel................739
Filters................739
Outline of Electric System................739
WEAR PARTS................740
Wear Parts List................740
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS................741
Fuel, Coolant, and Lubricant Ambient Temperature Chart................742
Recommended Brands, Other Than Komatsu Genuine Oil................743
Biodiesel Usage................744
Biodiesel Recommendation for Komatsu Engines................744
Biodiesel Terminology................744
Certification and Standards................745
Warranty and Use of Biodiesel Fuel in Komatsu Engines................745
Requirements for Using Biodiesel Fuel in Komatsu Engines................745
Properties of Biodiesel................746
Komatsu Biodiesel Blend Specification for B5 to B20................747
Summary of Recommendations................748
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................749
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS................751
MAINTENANCE SCHEDULE CHART................753
SERVICE PROCEDURE................755
Initial 10 Hours Service................755
Initial 250 Hours Service................755
Initial 1000 Hours Service................755
When Required................756
Clean, Replace Air Cleaner Element................756
Clean Inside of Cooling System................759
Check Oil Level in Transfer Case, Add Oil................762
Check Axle Oil Level, Add Oil................764
Clean Axle Case Breather................766
Clean Air Conditioner Condenser................768
Check Window Washer Fluid Level, Add Fluid................768
Clean Radiator Fins and Cooler Fins................769
Turn, Replace Bolt-On Cutting Edge................774
Replace Bucket Teeth................775
Check Air Conditioner................778
Replace Slow-Blow Fuse................780
Check Accumulator Function................781
Select Tires................782
Check Tire Pressure................783
Clean, Replace Fuel Breather Filter................784
Check Before Starting................786
Every 50 Hours Service................787
Drain Water, Sediment from Fuel Tank................787
Every 100 Hours Service................788
Lubricate Rear Axle Pivot Pin................788
Clean Element in Air Conditioner Fresh Air Filter................789
Check Oil Level in Hydraulic Tank, Add Oil................790
Every 250 Hours Service................791
Check Battery Electrolyte Level................791
Check Parking Brake................793
Check Air Conditioner Compressor Belt Tension, Adjust................793
Check for Loose Wheel Hub Nuts, Tighten................794
Clean Element in Air Conditioner Recirculation Filter................795
Check Accumulator Function................796
Lubricating................797
Every 500 Hours Service................798
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge................798
Replace Fuel Prefilter Cartridge................800
Bleeding Air from Fuel Line................802
Every 1000 Hours Service................803
Change Oil in Transfer Case................803
Clean Transfer Case Breather................804
Replace Fuel Main Filter Cartridge................805
Replace HST Oil Filter Element................807
Lubricating................808
Check Engine Air Intake Piping Clamps for Looseness................808
Check Alternator Driving Belt Tension, Replace................808
Every 2000 Hours Service................809
Change Oil in Hydraulic Tank, Replace Hydraulic Tank Filter Element................809
Replace Hydraulic Tank Breather Element................811
Change Axle Oil................812
Replace Element in Air Conditioner Recirculation Air Filter, Fresh Air Filter................813
Clean Brake Circuit Strainer................814
Check Brake Disc Wear................815
Check PPC Accumulator Function................817
Check Alternator................818
Check Engine Valve Clearance, Adjust................818
Check Vibration Damper................818
Every 4000 Hours Service................819
Lubricating................819
Check Water Pump................819
Check Starting Motor................819
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber................820
Check for Missing Fuel Spray Prevention Caps, Hardening of Rubber................821
Every 8000 Hours Service................822
Replace High-Pressure Piping Clamps................822
Replace Fuel Spray Prevention Caps................822
SPECIFICATIONS................823
SPECIFICATIONS................824
OPTIONS, ATTACHMENTS................827
BUCKET AND TIRES................828
HYDRAULIC QUICK COUPLER................829
Removing Attachment................829
Installing Attachment................831
CEAM023302 - Wheel Loader WA320-6 Operation & Maintenance Manual................833
CEAM023302 WA320-6 S/N A35001 and UP................833
INTRODUCTION................837
FOREWORD................838
SAFETY INFORMATION................839
APPROVED AND NON-APPROVED USES................840
Approved Functions................840
Non-Approved Functions................840
VISIBILITY STANDARD................841
Visibility in Immediate Area................841
12-M Radius Visibility................841
PRODUCT IDENTIFICATION................842
Machine................842
Service Meter Location................843
Directions of Machine................843
Machine Serial Number/Product Identification Number (PIN)................844
Engine Serial Number, EPA Regulations................844
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION................845
Model: WA320-6................845
TABLE OF CONTENTS................846
SAFETY................859
SAFETY AND WARNING DECALS................860
Location of the Safety Labels................860
Safety Labels................861
GENERAL SAFETY RULES AND PRECAUTIONS................867
General Safety Rules................867
Safety at Job Site................868
Safety Features................868
Clothing and Protective Equipment................868
Keep Machine Clean................869
Fire and Explosion Prevention................869
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid................869
Fire Caused by Accumulation of Flammable Material................870
Fire Caused by Electrical Wiring................870
Fire Caused by Piping................870
Explosion Caused by Lighting Equipment................870
Action if Fire Occurs................871
Fire Extinguisher and First Aid Kit................871
Mounting and Dismounting................872
Inside Operator’s Compartment................873
Emergency Escape from Operator’s Cab................873
Precautions When Standing Up from Operator’s Seat................874
Leaving Operator’s Compartment................875
Parking the Machine................876
Transporting the Machine................877
Precautions When Using ROPS................879
Unauthorized Modification................879
Precautions for Attachments and Options................879
Precautions When Cleaning Cab Glass................880
Asbestos Hazard Alert................880
Crush or Pinch-Point Dangers................881
Precautions for Ventilation Exhaust Gas................881
PRECAUTIONS BEFORE STARTING OPERATIONS................882
Pre-Operational Checks................882
Ensure Good Visibility................882
Signs and Signals................882
Precaution for Warning Tag................883
Checks Before Starting Engine, Adjustments................883
Precautions When Starting................884
Precautions in Cold Areas................884
Seat Belt Inspection................886
Precautions for Job Site................887
Work Site Hazards................887
Working on Loose or Unstable Ground................887
Prohibited Operations................888
Avoiding Dangerous Situations................888
Working Near High Voltage Cables................890
RULES FOR ROAD TRAVEL................891
Travel Precautions................891
Traveling on Slopes................892
Using the Brakes................893
Traveling in Reverse................893
Operating on Snow or Frozen Surfaces................894
PRECAUTIONS DURING INSPECTION AND MAINTENANCE................895
Warning Tags................895
Workplace Environment................895
Systems Equipped with ECSS................895
Equipment Storage................896
Working Under the Machine................896
Using Drop Lamps................897
Using Proper Tools................897
Keeping the Machine Clean................897
Precautions When Welding................897
Precautions When Using Hammer................898
Noise................898
Stopping Engine During Inspection and Maintenance................899
Running the Machine During Maintenance................901
Rules for Refueling the Machine................902
Cooling System Precautions................902
Window Washer Fluid................902
Battery Information................902
Precautions................902
Hazards................903
Using Booster Cables................904
Starting the Machine with Booster Cables................904
High-Pressure Precautions................905
Precautions for High-Pressure Oil................905
Safe Handling of High-Pressure Hoses................905
Precautions for High-Pressure Fuel................905
High-Temperature Precautions................906
High-Temperature Areas................906
High-Temperature Coolant................906
High-Temperature Oil................906
High Voltage................906
Accumulator and Gas Spring................907
Inflating Tires................907
Storing Tires................907
Using Compressed Air................908
Disposal of Waste Materials................908
Critical Parts................908
Maintenance of Air Conditioner................908
OPERATION................909
GENERAL VIEW................910
General View of Machine................910
Controls and Gauges................912
Machine Monitor................914
EXPLANATION OF COMPONENTS................916
Machine Monitor................916
Types of Warnings................917
Emergency Stop................917
Caution................917
Mistaken Operation................917
Inspection and Maintenance................918
Central Warning Lamp................918
Character Display Portion................919
Service Meter................919
Engine Speed or Travel Speed................920
Action Code Display................920
Failure Code Display................922
Filter, Oil Replacement Time Display................922
Emergency Stop Items................924
Brake Oil Pressure Caution Lamp................925
Engine Oil Pressure Caution Lamp................925
Battery Charge Circuit Caution Lamp................926
Steering Oil Pressure Caution Lamp (Red) (if equipped)................926
Caution Items................928
Brake Oil Temperature Caution Lamp................929
Quick Coupler Operation Pilot Lamp (if equipped)................929
Parking Brake Reminder Caution Lamp................930
HST Oil Temperature Caution Lamp................930
Engine Coolant Temperature Caution Lamp................930
Fuel Level Caution Lamp................931
Warning/Limit Functions for Travel Speed................931
Inspection and Maintenance Items................932
Water Separator Caution Lamp................932
Radiator Coolant Level Caution Lamp................933
Engine Oil Level Caution Lamp................933
HST Oil Filter Clogging Caution Lamp................934
Air Cleaner Clogging Caution Lamp................934
Maintenance Caution Lamp................935
Pilot Display Portion................936
Parking Brake Pilot Lamp................936
Cooling Fan Reverse Rotation Pilot Lamp................937
Emergency Steering Pilot Lamp (if equipped)................937
Preheating Pilot Lamp................937
Directional Selector Pilot Lamp................937
Economy Operation Display Lamp................938
S Mode Operation Pilot Lamp................938
Shift Hold Pilot Lamp................938
Traction Control Operation Pilot Lamp................938
Travel Speed Range Selector Switch Position Pilot Lamp................939
Directional Lever Position Pilot Lamp................939
Turn Signal Pilot Lamp................939
Head Lamp High Beam Pilot Lamp................939
Meter Display Portion................940
HST (Hydrostatic transmission) Oil Temperature Gauge................940
Engine Coolant Temperature Gauge................941
Speedometer................941
Meter Display Pilot Lamp................941
Fuel Gauge................941
OTHER FUNCTIONS OF MACHINE MONITOR................942
Overall Menu................943
Selecting Traction Level................944
Selecting HST Changing Function................945
Displaying Odometer................946
Resetting Filter, Oil Replacement Time................946
Entering Telephone Number................947
Selecting Language................948
Adjusting Monitor Brightness................949
Switching Travel Speed/Engine Speed Display................951
Switching Travel Speed/Engine Speed Display/Non-Display................952
Switches................954
Ignition Switch................955
Speed Range Selector Switch................955
Variable Shift Control Switch................956
Quick Coupler Attachment Switch (if equipped)................956
Cooling Fan Auto-Reverse Rotation Switch................956
Directional Selector Switch Actuator Switch................959
Traction Control Switch................960
Max. Traction Switch................961
Front Wiper Switch................962
Machine Monitor Mode Selector Switch 1................962
Machine Monitor Mode Selector Switch 2................962
Electronic Controlled Suspension System Switch (ECSS)................963
Horn Button................963
Lamp Switch................964
Turn Signal Lever................964
Dimmer Switch................964
Front Working Lamp Switch................965
Rear Working Lamp Switch................965
Hazard Lamp Switch................966
Rear Wiper Switch................966
Directional Selector Switch................966
Cigarette Lighter................967
Room Lamp Switch................967
Rear Heated-Wire Glass Switch................967
Control Levers, Pedals................968
Directional Lever................968
Work Equipment Control Lever................969
Work Equipment Lock Lever................970
Accelerator Pedal................970
Brake Pedals................971
Parking Brake Lever................971
SECURITY LOCKS AND SAFETY FEATURES................972
Steering Column Tilt Lock Lever................972
Cap and Cover Lock................972
Opening and Closing Cover With Lock................972
Opening the Cap (for Fuel Tank Filler Port)................973
Backup Alarm................973
Frame Lock Bar................974
Towing Pin................974
MACHINE FEATURES................976
Cab Door................976
Emergency Escape Right Door................976
Left Cab Door, Opening Lock................978
Left Cab Door, Door Handle................979
Left Cab Door, Door Open Knob................979
Cab Sliding Window Lock Release Knob................979
Cab Wiper................980
Grease Pump................980
Storage Box................980
ELECTRICAL................981
Fuses................981
Fuse Capacity and Circuits................982
Slow-Blow Fuses................983
Power Outlet................984
WORK OPERATIONS................986
Walk-Around Check................986
Precautions Before Starting Work Operations................986
Check Before Starting Engine................990
Check Machine Monitor................990
Check Coolant Level, Add Coolant................991
Check Oil Level in Engine Oil Pan, Add Oil................992
Check Water Separator, Drain Water................993
Check Air Cleaner................995
Check Fuel Level, Add Fuel................996
Check Electric Wiring................997
Check Inflation Pressure of Tires................997
Check Parking Brake................997
Check Brake Pedal................997
Check Condition of Window Washer Spray................997
Check Wiping Efficiency of Wiper................998
Check Horn................998
Check Defroster Function................998
Check Locks................998
Check Emergency Exit................998
Seat Adjustment................1000
Adjust Seat Belt................1004
Adjust Lever Stand................1005
Adjust Mirrors................1006
Final Checks Before Starting Engine................1008
Starting Engine................1012
Normal Starting................1012
Starting Engine in Cold Weather................1014
Automatic Warming-Up Operation................1015
Operations and Checks After Starting Engine................1016
Breaking-In the Machine................1016
Checks After Starting Engine................1016
Normal Operation................1017
Stopping Engine................1019
Check After Stopping Engine................1019
Moving the Machine (Directional, Speed), Stopping the Machine................1020
Moving the Machine................1020
Changing Direction................1023
Stopping the Machine................1026
Turning................1028
Emergency Steering (if equipped)................1029
Operation of Work Equipment................1030
Lift Arm Operation................1030
Bucket Operation................1031
Work Possible Using Wheel Loader................1032
Digging Operations................1032
Loading Piled Soil or Blasted Rock................1032
Digging and Loading on Level Ground................1034
Leveling Operations................1035
Pushing Operations................1035
Load-and-Carry Operations................1035
Loading Operations................1036
Cross-Drive Loading................1036
V-Shape Loading................1036
Preparations for Loading, Gathering Rocks................1037
Approaching Facing................1037
Digging................1038
Traveling in Reverse After Excavation................1040
Approaching Dump Truck................1041
Loading Dump Truck................1042
Reversing Away From Dump Truck................1043
Precautions................1044
When Piling Up Loads................1044
When Handling Blasted Rock................1044
During Cutting Face Operations................1048
When Switching Between Forward and Reverse................1048
When Turning When Tires Are Stationary................1048
Permissible Water Depth................1049
When Wheel Brake Does Not Work................1049
When Driving Up or Down Slopes................1049
When Driving the Machine................1050
Adjusting Work Equipment................1051
Adjusting Boom Kickout................1051
Adjusting Bucket Positioner................1052
Bucket Level Indicator................1052
Measuring Dump Angle................1053
Measuring Bucket Dump Angle................1053
Measuring Coupler Dump Angle................1055
Removing the Bucket................1058
Installing the Bucket................1059
Parking the Machine................1062
Checks After Completion of Operation................1065
Before Stopping Engine................1065
After Stopping Engine................1065
Locking the Machine................1066
HANDLING TIRES................1067
Precautions When Handling Tires................1067
Tire Pressure................1068
Precautions for Using Load-and-Carry Method................1069
Precautions when Storing Tires................1069
TRANSPORTATION................1070
Transportation Procedure................1070
Loading and Unloading Trailers................1070
Loading Machine................1070
Securing Machine................1071
Unloading Machine................1073
LIFTING MACHINE................1075
Lifting Position Marks................1075
Lifting Procedure................1076
COLD WEATHER OPERATION................1078
Precautions for Low Temperature................1078
Fuel and Lubricants................1078
Coolant................1078
Battery................1078
Precautions After Completion of Work................1079
When Cold Weather Ends................1079
LONG-TERM STORAGE................1080
Before Storage................1080
During Storage................1080
After Storage................1081
MULTI-FUNCTION LEVER................1082
Kickdown Switch................1083
Hold Switch................1083
FNR Switch................1084
AUTOMATIC AIR CONDITIONER................1086
Control Panel................1086
Main Power Switch................1087
Fan Switch................1087
Air Conditioner Switch................1088
Auto Switch................1089
Temperature Switch................1089
FRESH/RECIRC Selector Switch................1089
Mode Selector Switch................1090
Method of Operation................1091
Cooling Operation................1091
Heating Operation................1091
Drying-Heating and Demisting Operation................1092
When Not Using the Air Conditioner Regularly................1092
Precautions When Using Air Conditioner................1092
Inspection and Maintenance................1093
Cool Box................1093
KOMTRAX................1094
Basic Precautions................1094
TROUBLESHOOTING................1096
When Machine Runs Out of Fuel................1096
Towing the Machine................1096
When Engine Can Be Used................1098
When Engine Cannot Be Used................1098
Emergency Travel Operation................1098
If Battery is Discharged................1100
Precautions................1100
Removing the Battery................1100
Installing the Battery................1100
Precautions for Charging Battery................1101
Starting Engine With Booster Cable................1102
Precautions When Connecting or Disconnecting Booster Cable................1102
Connecting Booster Cable................1102
Starting Engine................1103
Disconnecting Booster Cable................1103
Other Troubleshooting................1104
Electrical System................1104
Chassis................1105
Engine................1107
MAINTENANCE................1109
GUIDES TO MAINTENANCE................1110
Check Service Meter................1110
Komatsu Genuine Replacement Parts................1110
Komatsu Genuine Oils................1110
Always Use Clean Washer Fluid................1110
Always Use Clean Oil and Grease................1110
Checking for Foreign Materials in Drained Oil and On Filters................1110
Fuel Strainer................1110
Welding Instructions................1111
Do Not Drop Things Inside Machine................1111
Dusty Work Sites................1111
Avoid Mixing Oil................1111
Locking Inspection Covers................1111
Bleeding Air from Hydraulic Circuit................1112
Precautions When Installing Hydraulic Hoses................1112
Checks After Inspection and Maintenance................1112
OUTLINES OF SERVICE................1113
Handling Oil, Fuel, Coolant, and Performing Oil Clinic................1113
Oil................1113
Fuel................1114
Coolant and Water for Dilution................1114
Grease................1115
Performing KOWA (Komatsu Oil Wear Analysis)................1116
KOWA Analysis Items................1116
Oil Sampling................1116
Storing Oil and Fuel................1117
Filters................1117
Outline of Electric System................1117
WEAR PARTS................1118
Wear Parts List................1118
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS................1119
Fuel, Coolant, and Lubricant Ambient Temperature Chart................1120
Recommended Brands, Other Than Komatsu Genuine Oil................1121
Biodiesel Usage................1122
Biodiesel Recommendation for Komatsu Engines................1122
Biodiesel Terminology................1122
Certification and Standards................1123
Warranty and Use of Biodiesel Fuel in Komatsu Engines................1123
Requirements for Using Biodiesel Fuel in Komatsu Engines................1123
Properties of Biodiesel................1124
Komatsu Biodiesel Blend Specification for B5 to B20................1125
Summary of Recommendations................1126
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................1127
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS................1130
MAINTENANCE SCHEDULE CHART................1132
SERVICE PROCEDURE................1134
Initial 10 Hours Service................1134
Initial 250 Hours Service................1134
Initial 1000 Hours Service................1134
When Required................1135
Clean, Replace Air Cleaner Element................1135
Clean Inside of Cooling System................1138
Check Oil Level in Transfer Case, Add Oil................1142
Check Axle Oil Level, Add Oil................1144
Clean Axle Case Breather................1146
Clean Air Conditioner Condenser................1148
Check Window Washer Fluid Level, Add Fluid................1148
Clean Radiator Fins and Cooler Fins................1149
Turn, Replace Bolt-On Cutting Edge................1154
Replace Bucket Teeth................1155
Check Air Conditioner................1158
Replace Slow-Blow Fuse................1160
Check Accumulator Function................1161
Select Tires................1162
Check Tire Pressure................1163
Clean, Replace Fuel Breather Filter................1164
Check Before Starting................1166
Every 50 Hours Service................1167
Drain Water, Sediment from Fuel Tank................1167
Every 100 Hours Service................1168
Lubricate Rear Axle Pivot Pin................1168
Clean Element in Air Conditioner Fresh Air Filter................1169
Check Oil Level in Hydraulic Tank, Add Oil................1170
Every 250 Hours Service................1171
Check Battery Electrolyte Level................1171
Check Parking Brake................1173
Check Air Conditioner Compressor Belt Tension, Adjust................1173
Check for Loose Wheel Hub Nuts, Tighten................1174
Clean Element in Air Conditioner Recirculation Filter................1175
Check Accumulator Function................1176
Lubricating................1177
Every 500 Hours Service................1178
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge................1178
Replace Fuel Prefilter Cartridge................1180
Bleeding Air from Fuel Line................1182
Every 1000 Hours Service................1184
Change Oil in Transfer Case................1184
Clean Transfer Case Breather................1185
Replace Fuel Main Filter Cartridge................1186
Replace HST Oil Filter Element................1188
Lubricating................1189
Check Engine Air Intake Piping Clamps for Looseness................1189
Check Alternator Driving Belt Tension, Replace................1189
Every 2000 Hours Service................1190
Change Oil in Hydraulic Tank, Replace Hydraulic Tank Filter Element................1190
Replace Hydraulic Tank Breather Element................1192
Change Axle Oil................1193
Replace Element in Air Conditioner Recirculation Air Filter, Fresh Air Filter................1194
Clean Brake Circuit Strainer................1195
Check Brake Disc Wear................1196
Check PPC Accumulator Function................1198
Check Alternator................1199
Check Engine Valve Clearance, Adjust................1199
Check Vibration Damper................1199
Every 4000 Hours Service................1200
Lubricating................1200
Check Water Pump................1200
Check Starting Motor................1200
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber................1201
Check for Missing Fuel Spray Prevention Caps, Hardening of Rubber................1202
Every 8000 Hours Service................1203
Replace High-Pressure Piping Clamps................1203
Replace Fuel Spray Prevention Caps................1203
SPECIFICATIONS................1205
SPECIFICATIONS................1206
OPTIONS, ATTACHMENTS................1209
SELECTING BUCKET AND TIRES................1210
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM................1211
Sound System Components................1212
Power Switch/Volume................1212
Auto-Store/Preset Scan Button................1212
Bass Control Knob................1212
Treble Control Knob................1213
Loudness Button................1213
Time/Radio Display Selector Button................1213
Tape Eject Button................1214
Cassette Door................1214
Fast-Forward, Rewind Buttons................1214
Preset Buttons................1214
Metal Tape Button................1215
Manual Tuning Buttons................1215
Seek Tuning Buttons................1215
Band Selector Button................1215
Method of Operation................1216
Setting Preset Buttons................1216
Using Auto-Preset................1216
Using Manual Preset................1216
Listening to Radio................1217
Listening to Cassette Tape................1217
Reversing the Tape................1218
Precautions When Using................1218
Handling Cassette Tape................1218
MP3 AM/FM RADIO CD UNIT................1219
HYDRAULIC QUICK COUPLER................1220
Removing Attachment................1220
Installing Attachment................1222
METHOD OF USING 2 LEVERS................1224
Explanation of Components................1224
Bucket Control Lever................1225
Lift Arm Control Lever................1226
Max. Traction Switch................1226
CEAM027400 - Wheel Loader WA320-7 Operation & Maintenance Manual................1227
TEN00612-00-MA4.pdf................0
FOREWORD ................1231
BEFORE READING THIS MANUAL ................1232
SAFETY INFORMATION ................1233
INTRODUCTION ................1234
USE OF MACHINE ................1234
DIRECTIONS OF MACHINE ................1234
VISIBILITY FROM OPERATOR'S SEAT ................1234
PRODUCT INFORMATION ................1235
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ................1235
EPA REGULATIONS, ENGINE NUMBER PLATE ................1235
SERVICE METER LOCATION ................1236
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ................1236
CONTENTS ................1237
SAFETY ................1241
SAFETY ................1242
SAFETY LABELS ................1244
LOCATION OF SAFETY LABELS ................1244
SAFETY LABELS ................1245
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ................1252
PRECAUTIONS BEFORE STARTING OPERATION ................1252
PREPARATIONS FOR SAFE OPERATION ................1253
FIRE PREVENTION ................1255
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ................1257
DO NOT GET CAUGHT IN WORK EQUIPMENT ................1260
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ................1260
UNAUTHORIZED MODIFICATION ................1260
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ................1261
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ................1261
PRECAUTIONS FOR OPERATION ................1262
PRECAUTIONS FOR JOBSITE ................1262
STARTING ENGINE ................1265
OPERATION ................1268
TRANSPORTATION ................1274
TOWING ................1275
PRECAUTIONS FOR MAINTENANCE ................1276
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................1276
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ................1281
TIRES ................1286
OPERATION ................1287
GENERAL VIEW ................1288
GENERAL VIEW OF MACHINE ................1288
GENERAL VIEW OF CONTROLS AND GAUGES ................1290
EXPLANATION OF COMPONENTS ................1295
MACHINE MONITOR ................1295
SWITCHES ................1362
CONTROL LEVERS AND PEDALS ................1377
CAPS AND COVERS WITH LOCK ................1381
ASHTRAY ................1384
FRAME LOCK BAR ................1385
TOWING PIN ................1386
GREASE PUMP HOLDER ................1387
BATTERY DISCONNECT SWITCH ................1388
SYSTEM OPERATING LAMP ................1390
BACKUP ALARM ................1391
OPEN AND CLOSE CAB DOOR ................1392
FUSE ................1396
SLOW-BLOW FUSE ................1398
AUXILIARY ELECTRIC POWER ................1399
HANDLING RADIO ................1400
HANDLING AUTO AIR CONDITIONER ................1405
HANDLING FRONT WIPER ................1416
HANDLING REAR VIEW MONITOR ................1417
HANDLING Komatsu Diesel Particulate Filter (KDPF) ................1418
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ................1426
HANDLING MACHINES EQUIPPED WITH KOMTRAX ................1427
MACHINE OPERATIONS AND CONTROLS ................1429
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ................1429
STARTING ENGINE ................1454
CHECKS AFTER STARTING ENGINE ................1459
STOPPING ENGINE ................1462
MACHINE OPERATION ................1463
STEERING MACHINE ................1472
WORK EQUIPMENT CONTROLS AND OPERATIONS ................1474
HANDLING HYDRAULIC TYPE QUICK COUPLER ................1476
RECOMMENDED APPLICATIONS ................1481
RULES FOR OPERATION ................1487
ADJUST WORK EQUIPMENT POSTURE ................1489
PARKING MACHINE ................1496
CHECK AFTER FINISHING WORK ................1498
LOCKING ................1499
HANDLING TIRES ................1500
TRANSPORTATION ................1502
TRANSPORTATION PROCEDURE ................1502
LOADING AND UNLOADING WITH TRAILER ................1503
LIFTING MACHINE ................1507
COLD WEATHER OPERATION ................1509
COLD WEATHER OPERATION INFORMATION ................1509
AFTER DAILY WORK COMPLETION ................1510
IN COLD AREAS ................1510
AFTER COLD WEATHER SEASON ................1510
LONG-TERM STORAGE ................1511
BEFORE STORAGE ................1511
DURING STORAGE ................1511
AFTER STORAGE ................1512
STARTING MACHINE AFTER LONG-TERM STORAGE ................1512
TROUBLES AND ACTIONS ................1513
RUNNING OUT OF FUEL ................1513
TOWING MACHINE ................1514
DISCHARGED BATTERY ................1518
OTHER TROUBLE ................1522
MAINTENANCE ................1527
RULES FOR MAINTENANCE ................1528
SERVICE METER READING ................1528
KOMATSU GENUINE REPLACEMENT PARTS ................1528
KOMATSU GENUINE LUBRICANTS ................1528
ALWAYS USE CLEAN WASHER FLUID ................1528
FRESH AND CLEAN LUBRICANTS ................1528
CHECK DRAINED OIL AND USED FILTER ................1528
CAUTION FOR REFILLING OIL OR FUEL ................1528
WELDING INSTRUCTIONS ................1528
DO NOT DROP THINGS INSIDE MACHINE ................1528
PRECAUTIONS FOR KDPF ................1528
DUSTY JOBSITES ................1528
AVOID MIXING OIL ................1529
LOCKING INSPECTION COVERS ................1529
BLEEDING AIR FROM HYDRAULIC CIRCUIT ................1529
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ................1529
CHECKS AFTER INSPECTION AND MAINTENANCE ................1529
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ................1529
CLOSE ENGINE SIDE COVER SECURELY ................1529
OUTLINE OF MAINTENANCE ................1530
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ................1530
HANDLING ELECTRICAL COMPONENTS ................1534
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ................1535
TIGHTENING TORQUE LIST ................1535
MAINTENANCE SCHEDULE ................1536
MAINTENANCE SCHEDULE TABLE ................1536
MAINTENANCE PROCEDURE ................1538
EVERY 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ................1538
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ................1538
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ................1538
WHEN REQUIRED ................1539
CHECKS BEFORE STARTING ................1568
EVERY 50 HOURS MAINTENANCE ................1569
EVERY 100 HOURS MAINTENANCE ................1570
EVERY 250 HOURS MAINTENANCE ................1572
EVERY 500 HOURS MAINTENANCE ................1579
EVERY 1000 HOURS MAINTENANCE ................1584
EVERY 2000 HOURS MAINTENANCE ................1590
EVERY 4000 HOURS MAINTENANCE ................1601
EVERY 4500 HOURS MAINTENANCE ................1603
EVERY 8000 HOURS MAINTENANCE ................1604
SPECIFICATIONS ................1605
SPECIFICATIONS ................1606
ATTACHMENTS AND OPTIONS ................1609
TIRE AND BUCKET SELECTION ................1610
HANDLING FORK ................1611
EXPLANATION OF COMPONENTS ................1611
MACHINE OPERATIONS AND CONTROLS ................1613
PCS (Proportional Control Switch) ................1616
DISPLAY OF LIQUID CRYSTAL UNIT ................1617
SETTING METHOD OF PCS ................1619
REPLACEMENT PARTS ................1621
SAFETY CRITICAL PARTS ................1622
SAFETY CRITICAL PARTS LIST ................1622
CONSUMABLE PARTS ................1623
CONSUMABLE PARTS LIST ................1623
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................1624
LUBRICATION CHART ................1624
LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE AND RECOMMENDED GENUINE LUBRICANTS ................1626
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ................1628
INDEX ................1629
CEAMW19070 - Wheel Loader WA320-3 Operation & Maintenance Manual................1633
1. FORWARD................1635
2. SAFETY INFORMATION................1636
3. INTRODUCTION................1637
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................1638
5. CONTENTS................1639
SAFETY................1643
6. GENERAL PRECAUTIONS................1644
7. PRECAUTIONS DURING OPERATION................1649
7.1 BEFORE STARTING ENGINE................1649
7.2 OPERATING MACHINE................1651
7.3 TRANSPORTATION................1656
7.4 BATTERY................1657
7.5 TOWING................1658
8. PRECAUTIONS FOR MAINTENANCE................1659
8.1 BEFORE CARRYING OUT MAINTENANCE................1659
8.2 DURING MAINTENANCE................1661
8.3 TIRES................1666
9. POSITION FOR ATTACHING SAFETY LABELS................1668
OPERATION................1672
10. GENERAL VIEW................1673
10.1 GENERAL VIEW OF MACHINE................1673
10.2 GENERAL VIEW OF CONTROLS AND GAUGES................1674
11. EXPLANATION OF COMPONENTS................1675
11.1 MACHINE MONITOR................1675
11.2 SWITCHES................1685
11.3 CONTROL LEVERS, PEDALS................1691
11.4 STEERING COLUMN TILT LEVER................1695
11.5 CAP WITH LOCK................1696
11.6 SAFETY BAR................1697
11.7 TOWING PIN................1697
11.8 GREASE PUMP................1698
11.9 BACK UP ALARM................1698
11.10 FUSE................1699
11.11 SLOW-BLOW FUSE................1700
12. OPERATION................1701
12.1 CHECKS BEFORE STARTING................1701
12.2 STARTING ENGINE................1714
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE................1715
12.4 MOVING MACHINE OFF................1716
12.5 CHANGING GEAR SPEED................1718
12.6 CHANGING DIRECTION................1718
12.7 TURNING................1719
12.8 STOPPING MACHINE................1720
12.9 OPERATION OF WORK EQUIPMENT................1721
12.10 WORK POSSIBLE USING WHEEL LOADER................1722
12.11 PRECAUTIONS FOR OPERATION................1727
12.12 ADJUSTING WORK EQUIPMENT POSTURE................1729
12.13 PARKING MACHINE................1731
12.14 CHECKS AFTER COMPLETION OF OPERATION................1732
12.15 STOPPING ENGINE................1732
12.16 CHECK AFTER STOPPING ENGINE................1733
12.17 LOCKING................1733
12.18 HANDLING THE TIRES................1734
13. TRANSPORTATION................1736
13.1 LOADING, UNLOADING WORK................1736
13.2 PRECAUTIONS FOR LOADING................1737
13.3 PRECAUTIONS FOR TRANSPORTATION................1737
14. COLD WEATHER OPERATION................1738
14.1 PRECAUTIONS FOR LOW TEMPERATURE................1738
14.2 PRECAUTIONS AFTER COMPLETION OF WORK................1740
14.3 AFTER COLD WEATHER................1740
15. LONG-TERM STORAGE................1741
15.1 BEFORE STORAGE................1741
15.2 DURING STORAGE................1741
15.3 AFTER STORAGE................1741
16. TROUBLE SHOOTING................1742
16.1 WHEN MACHINE RUNS OUT OF FUEL................1742
16.2 TOWING THE MACHINE................1743
16.3 IF BATTERY IS DISCHARGED................1748
16.4 OTHER TROUBLE................1752
MAINTENANCE................1758
17. GUIDES TO MAINTENANCE................1759
18. OUTLINES OF SERVICE................1762
18.1 OUTLINE OF OIL, FUEL, COOLANT................1762
18.2 OUTLINE OF ELECTRIC SYSTEM................1765
19. WEAR PARTS LIST................1766
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................1767
20.1 ENGINE OIL SPECIFICATIONS................1769
20.2 DIESEL FUEL SPECIFICATIONS................1770
20.3 COOLANT SPECIFICATIONS................1771
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS................1777
21.1 INTRODUCTION OF NECESSARY TOOLS................1777
21.2 TORQUE LIST................1778
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................1779
23. MAINTENANCE SCHEDULE CHART................1783
23.1 MAINTENANCE SCHEDULE CHART................1783
24. SERVICE PROCEDURE................1787
24.1 INITIAL 250 HOURS SERVICE................1787
24.2 WHEN REQUIRED................1788
24.3 CHECKS BEFORE STARTING................1797
24.4 EVERY 50 HOURS SERVICE................1798
24.5 EVERY 100 HOURS SERVICE................1799
24.6 EVERY 250 HOURS SERVICE................1801
24.7 EVERY 500 HOURS SERVICE................1807
24.8 EVERY 1000 HOURS SERVICE................1811
24.9 EVERY 2000 HOURS SERVICE................1820
SPECIFICATIONS................1829
25. SPECIFICATIONS................1830
OPTIONAL ATTACHMENTS................1832
26. OPTIONAL PARTS AND ATTACHMENTS................1833
27. SELECTING BUCKETS AND TIRES................1834
28. AIR CONDITIONER................1835
28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................1835
28.2 COOL BOX COMPARTMENT................1836
29. HANDLING E.C.S.S. (ELECTRONIC CONTROL SUSPENSION SYSTEM)................1837
29.1 STRUCTURE AND FUNCTION OF E.C.S.S.................1837
29.2 METHOD OF OPERATING E.C.S.S.................1838
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH................1838
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR................1839
30. HANDLING AUTO-GREASING SYSTEM................1840
30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM................1840
30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM................1848
30.3 TROUBLE SHOOTING................1849
30.4 SPECIFICATIONS................1849
31. OPTION DISPLAY................1850
CEBM012004 - Wheel Loader GALEO WA320-5L Shop Manual................1852
COVER................1852
CONTENTS................1853
FOREWORD................1864
SAFETY................1864
SAFETY NOTICE................1864
IMPORTANT SAFETY NOTICE................1864
GENERAL PRECAUTIONS................1864
PREPARATIONS FOR WORK................1864
PRECAUTIONS DURING WORK................1864
GENERAL................1866
HOW TO READ THE SHOP MANUAL................1867
VOLUMES................1867
DISTRIBUTION AND UPDATING................1867
FILING METHOD................1867
REVISED EDITION MARK................1867
REVISIONS................1867
SYMBOLS................1867
HOISTING INSTRUCTIONS................1868
HOISTING................1868
WIRE ROPES................1868
PUSH-PULL TYPE COUPLER................1869
COATING MATERIALS................1871
STANDARD TIGHTENING TORQUE................1873
BOLTS AND NUTS STANDARD TIGHTENING TORQUE................1873
HOSE NUTS TIGHTENING TORQUE................1874
SPLIT FLANGE BOLTS TIGHTENING TORQUE................1874
FLARED NUTS TIGHTENING TORQUE................1874
O-RING BOSS PIPING JOINTS TIGHTENING TORQUE................1875
O-RING BOSS PLUGS TIGHTENING TORQUE................1875
102 ENGINE SERIES TIGHTENING TORQUE................1876
HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) TIGHTENING TORQUE................1877
ELECTRIC WIRE CODE................1878
CLASSIFICATION BY THICKNESS................1878
CLASSIFICATION BY COLOR AND CODE................1878
CONVERSION TABLES................1879
METHOD OF USING THE CONVERSION TABLE................1879
UNITS................1885
01 GENERAL................1886
GENERAL ASSEMBLY DRAWINGS................1887
SPECIFICATIONS................1888
WEIGHT TABLE................1892
LIST OF LUBRICANTS AND COOLANT................1893
10 STRUCTURE AND FUNCTION................1896
ENGINE AND DRIVE SYSTEM MOUNTING................1902
DRIVE DAMPER ASSEMBLY................1903
DRIVE DAMPER OPERATION................1903
COOLING SYSTEM ASSEMBLY................1904
REVERSING FAN SYSTEM................1905
REVERSING FAN MANIFOLD................1906
PROPORTIONAL RELIEF VALVE................1907
2-POSITION, 4-WAY SPOOL VALVE................1908
FAN CONTROLLER................1909
POWER TRAIN................1910
POWER TRAIN SYSTEM................1911
POWER TRAIN OPERATION................1912
FRONT AND REAR DRIVE LINES................1913
DRIVE LINE OPERATION................1913
HST HYDRAULIC PIPING DIAGRAM................1914
HST PUMP................1915
HST PUMP OPERATION................1916
POWER FLOW................1916
OIL FLOW................1917
PRESSURE RELIEF VALVES................1918
HIGH PRESSURE................1918
FUNCTION................1918
VALVE OPERATION................1919
LOW PRESSURE................1920
VALVE OPERATION................1920
HST CHARGE PUMP................1921
PUMP OPERATION................1922
FUNCTION................1922
SPEED RELATED VALVE (DA VALVE)................1923
FUNCTION................1923
DA VALVE OPERATION................1923
HIGH-PRESSURE CUT-OFF VALVE................1924
FUNCTION................1924
CUT-OFF VALVE OPERATION................1924
HST MOTORS................1925
HST MOTOR 1................1925
HST MOTOR 2................1926
HST OPERATING PRINCIPLE................1927
STRUCTURE................1927
MOTOR OPERATION................1927
EP SERVO VALVE................1928
FUNCTION................1928
VALVE OPERATION................1928
HA SERVO VALVE................1929
FUNCTION................1929
VALVE OPERATION................1929
FORWARD-REVERSE SHUTTLE VALVE................1930
FUNCTION................1930
SHUTTLE VALVE OPERATION................1930
TRANSFER SYSTEM................1931
INTERNAL VIEW OF TRANSFER................1932
INPUT SHAFT SPECIFICATIONS................1933
OUTPUT SHAFT SPECIFICATIONS................1935
SPECIFICATIONS................1937
CLUTCH OPERATION................1937
WHEN “ON”................1937
WHEN “OFF”................1937
LOW SPEED MODE................1938
MODE OPERATION................1938
HIGH SPEED MODE................1939
MODE OPERATION................1939
CLUTCH SOLENOID VALVE................1940
SOLENOID VALVE OPERATION................1940
AXLES................1941
FRONT AXLE................1941
REAR AXLE................1942
STANDARD DIFFERENTIALS................1943
FRONT DIFFERENTIAL................1943
SPECIFICATIONS................1944
REAR DIFFERENTIAL................1945
SPECIFICATIONS................1946
DIFFERENTIAL FUNCTION................1947
DIFFERENTIAL OPERATION................1947
TORQUE PROPORTIONING................1948
DIFFERENTIAL OPERATION................1948
LIMITED-SLIP DIFFERENTIAL................1949
FRONT DIFFERENTIAL................1949
SPECIFICATIONS................1950
LIMITED-SLIP OPERATION................1950
FINAL DRIVE................1953
SPECIFICATIONS................1953
FINAL DRIVE OUTLINE................1954
AXLE MOUNTING AND CENTER HINGE PIN................1955
AXLE MOUNTING................1955
AXLE MOUNTING OUTLINE................1956
CENTER HINGE PIN ASSEMBLY................1957
SPECIFICATIONS................1958
SPECIFICATIONS................1959
STEERING PIPING................1960
STEERING COLUMN................1961
PRIORITY VALVE................1962
PRIORITY VALVE OUTLINE................1963
ORBIT-ROLL VALVE................1965
ORBITAL-ROLL VALVE OPERATION................1966
STRUCTURE................1966
STEERING WHEEL IN NEUTRAL POSITION................1967
STEERING WHEEL TURNING LEFT................1968
STEERING WHEEL STOPPED................1969
CONNECTION BETWEEN HAND PUMP AND SLEEVE................1970
ROLE OF CENTERING SPRING................1971
CUSHION VALVE................1972
CUSHION VALVE OPERATION................1972
FUNCTION................1972
CYLINDER LAY-OUT AND STEERING CYLINDER................1973
STEERING CYLINDER................1974
EMERGENCY STEERING PIPING................1975
EMERGENCY STEERING VALVE................1976
STEERING SYSTEM DURING NORMAL OPERATION................1977
STEERING SYSTEM WHEN FAILURE OCCURS................1978
BRAKE PIPING................1979
BRAKE VALVE ASSEMBLY................1980
VALVE ASSEMBLY OUTLINE................1981
WHEN BRAKE PEDAL IS PRESSED................1981
WHEN BRAKE IS BALANCED................1982
WHEN BRAKE IS RELEASED................1983
INCHING VALVE FUNCTION................1984
INCHING VALVE OUTLINE................1984
CHARGE VALVE ASSEMBLY................1985
FUNCTION OF CHARGE VALVE................1987
VALVE OPERATION................1987
ACCUMULATOR (BRAKE SYSTEM)................1989
ACCUMULATOR FUNCTION................1989
SLACK ADJUSTER................1990
SLACK ADJUSTER FUNCTION................1991
BRAKE................1992
BRAKE OUTLINE................1993
PARKING BRAKE CONTROL................1994
BRAKE SYSTEM OUTLINE................1994
PARKING BRAKE UNIT................1995
PARKING BRAKE OUTLINE................1995
HYDRAULIC PIPING................1996
PIPING OUTLINE................1997
WORK EQUIPMENT CONTROL LINKAGE................1998
MULTI FUNCTION MONO LEVER................1999
HYDRAULIC TANK................2000
SYSTEM SPECIFICATIONS................2001
BREATHER................2001
4-GEAR PUMP UNIT................2002
PUMP OUTLINE................2002
ACCUMULATOR (PPC CIRCUIT)................2004
ACCUMULATOR OUTLINE................2004
SPECIFICATIONS................2004
LOCK VALVE................2005
LOCK VALVE OUTLINE................2005
TRAVEL DAMPER VALVE................2006
ACCUMULATOR (TRAVEL DAMPER)................2008
ACCUMULATOR FUNCTION................2008
SPECIFICATIONS................2008
HYDRAULIC PIPING FOR COOLING SYSTEM................2009
PIPING OUTLINE................2009
COOLING FAN MOTOR................2010
FAN MOTOR SPECIFICATIONS................2011
MOTOR FUNCTION................2011
PRINCIPLE OF OPERATION................2011
WORK EQUIPMENT CONTROL VALVE................2013
2-SPOOL VALVE................2013
3-SPOOL VALVE................2016
3-RELIEF VALVE................2019
VALVE FUNCTION................2019
VALVE OPERATION................2019
4-RELIEF VALVE................2020
VALVE FUNCTION................2020
VALVE OPERATION................2020
SUCTION VALVE................2021
VALVE FUNCTION................2021
VALVE OPERATION................2021
CUT-OFF VALVE................2022
VALVE FUNCTION................2023
WORK EQUIPMENT CONTROL VALVE OPERATION................2025
WORK EQUIPMENT PPC VALVE................2031
2-LEVER TYPE................2031
PPC VALVE OPERATION................2033
WHEN BUCKET IS IN NEUTRAL................2033
FINE CONTROL MODE (NEUTRAL ¤ FINE)................2034
(FINE ¤ NEUTRAL)................2034
LEVER IS MOVED TO END OF STRTOKE................2035
LEVER IS IN “FLOAT”................2035
MONO-LEVER TYPE................2036
MONO-LEVER OPERATION................2038
IN NEUTRAL POSITION................2038
FINE CONTROL MODE (NEUTRAL ¤ FINE)................2039
(FINE ¤ NEUTRAL)................2039
LEVER IS MOVED TO END OF STROKE................2040
LEVER IS IN “FLOAT”................2040
ATTACHMENT PPC VALVE................2041
PPC VALVE OPERATION................2042
IN NEUTRAL POSITION................2042
AT FULL STROKE................2044
WORK EQUIPMENT LINKAGE................2045
BUCKET................2047
BUCKET POSITIONER AND BOOM KICK-OUT................2048
POSITIONER SYSTEM OUTLINE................2049
BUCKET POSITIONER................2049
BOOM KICK-OUT................2049
PROXIMITY SWITCH OPERATION................2049
FUNCTION OF PROXIMITY SWITCH................2052
FUNCTION OF PROXIMITY SWITCH................2055
WORK EQUIPMENT CYLINDER................2056
LIFT CYLINDER................2056
BUCKET CYLINDER................2056
AIR CONDITIONER SYSTEM................2057
AIR CONDITIONER PIPING................2057
MACHINE MONITORING SYSTEM................2058
SYSTEM OUTLINE AND CIRCUIT DIAGRAMS................2058
MACHINE MONITOR (Starting And Lighting)................2060
POWER SUPPLY NETWORK................2061
MACHINE MONITOR (STANDARD)................2068
MACHINE MONITOR (OPTIONAL LOAD METER)................2069
ITEMS DISPLAYED ON MONITOR................2070
MONITOR MODE FUNCTIONS................2075
ELECTRICAL SYSTEM FAILURE HISTORY................2075
MACHINE SYSTEM FAILURE HISTORY................2075
REAL-TIME MONITOR................2076
SPEED METER SPECIFICATIONS................2078
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRICAL SYSTEM................2080
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM................2083
REAL-TIME MONITOR FUNCTION................2085
SPEED METER SPECIFICATION................2085
LOAD METER SPECIFICATION................2088
TUNING FUNCTION................2095
LOAD METER SPECIFICATIONS................2095
MAINTENANCE FUNCTION................2097
HOW TO INPUT INTERVAL................2099
FUNCTION OF SELECTING OPTIONAL DEVICE................2101
SPEED METER................2101
SELECTION OF TIRE................2102
LOAD METER................2103
SETTING MACHINE SERIAL NUMBER................2105
LOAD METER FUNCTION................2106
INPUT/OUTPUT SIGNAL................2114
SPEED METER SPECIFICATIONS................2114
LOAD METER SPECIFICATIONS................2116
ELECTRICAL SYSTEM (HST CONTROLLER)................2121
CONTROL FUNCTION................2122
HST CONTROLLER................2125
FORWARD-REVERSE SELECTOR SWITCH (IF EQUIPPED)................2127
SYSTEM OUTLINE................2127
FUNCTION................2127
ENGINE START CIRCUIT................2129
CIRCUIT OPERATION................2129
FUNCTION................2130
ENGINE STOP CIRCUIT................2131
CIRCUIT OPERATION................2131
AUTOMATIC PREHEAT SYSTEM CIRCUIT................2132
SYSTEM OUTLINE................2132
PREHEAT OPERATION................2132
PARKING BRAKE CIRCUIT................2133
PARKING BRAKE OPERATION................2134
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM................2136
SYSTEM FUNCTION................2136
SENSORS................2137
ENGINE SPEED SENSOR................2137
SYSTEM FUNCTION................2137
TRAVEL SPEED SENSOR................2137
SYSTEM FUNCTION................2137
ENGINE OIL PRESSURE SENSOR................2138
SYSTEM FUNCTION................2138
FUEL LEVEL SENSOR................2138
SYSTEM FUNCTION................2138
ENGINE COOLANT AND HST OIL TEMPERATURE SENSOR................2139
SYSTEM FUNCTION................2139
PREHEATING COOLANT TEMPERATURE SENSOR................2139
SYSTEM FUNCTION................2139
AXLE OIL TEMPERATURE SENSOR................2140
SYSTEM FUNCTION................2140
HST OIL PRESSURE SENSOR (LOAD METER)................2140
SYSTEM FUNCTION................2140
EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)................2141
SYSTEM FUNCTION................2141
HST FILTER CLOG SENSOR................2141
SYSTEM FUNCTION................2141
COOLANT LEVEL SENSOR................2142
SYSTEM FUNCTION................2142
ENGINE OIL LEVEL SENSOR................2143
SYSTEM FUNCTION................2143
AIR CLEANER CLOG SENSOR................2143
SYSTEM FUNCTION................2143
LIFT ARM ANGLE SENSOR (IF EQUIPPED)................2144
SYSTEM FUNCTION................2144
20 TESTING, ADJUSTING AND TROUBLESHOOTING................2146
STANDARD VALUE TABLE................2148
ENGINE................2148
CHASSIS................2149
SPECIAL TOOLS................2154
ENGINE COMPONENTS................2157
MEASURING EXHAUST SMOKE................2157
MEASURING EXHAUST TEMPERATURE................2157
ADJUSTING VALVE CLEARANCE................2157
MEASURING COMPRESSION PRESSURE................2157
MEASURING CRANCASE PRESSURE................2157
MEASURING ENGINE OIL PRESSURE................2157
MEASURING BOOST PRESSURE................2157
MEASURING FUEL PRESSURE................2157
ADJUSTING ENGINE SPEED SENSOR................2157
BLEEDING AIR FROM FUEL SYSTEM................2157
MEASURING ENGINE SPEED................2158
MEASURING LOW AND HIGH IDLE................2158
MEASURING HST STALL SPEED................2159
MEASURING HYDRAULIC STALL................2159
MEASURING FULL STALL SPEED................2159
ACCELERATOR PEDAL................2160
TESTING PEDAL FORCE................2160
OPERATING ANGLE OF PEDAL................2161
ADJUSTING ENGINE STOP SOLENOID................2162
ADJUSTING ENGINE SPEED SENSOR................2163
REFRIGERENT COMPRESSOR BELT................2164
DIRECTIONAL LEVER................2165
HST OIL PRESSURE................2166
MEASURING................2166
ADJUSTING................2169
CLUTCH CONTROL PRESSURE................2171
STEERING WHEEL................2172
MEASURING STEERING WHEEL END PLAY................2172
MEASURING OPERATING FORCE ON STEERING WHEEL................2172
MEASURING OPERATING TIME FOR STEERING WHEEL................2173
STEERING OIL PRESSURE................2174
MEASURING MAIN RELIEF PRESSURE................2174
ADJUSTING MAIN RELIEF PRESSURE................2174
BLEEDING AIR FROM STEERING CIRCUIT................2175
HYDRAULIC FAN................2176
MEASURING FAN SPEED................2176
MEASURING OIL PRESSURE................2176
REVERSING FAN CONTROLLER, IF EQUIPPED................2177
LED INDICATORS................2177
MEASURING BRAKE PEDAL................2178
BRAKE PEDAL LINKAGE................2179
MEASURING BRAKE PERFORMANCE................2180
ACCUMULATOR CHARGE PRESSURE................2181
BRAKE OIL PRESSURE................2182
MEASURING WEAR OF BRAKE DISC................2184
BLEEDING AIR FROM BRAKE CIRCUIT................2185
PARKING BRAKE PERFORMANCE................2186
PARKING BRAKE LINKAGE................2187
WORK EQUIPMENT CONTROL LEVER................2189
WORK EQUIPMENT PRESSURE................2190
WORK EQUIPMENT PPC OIL PRESSURE................2192
TESTING AND ADJUSTING................2192
BLEEDING AIR................2194
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................2195
BUCKET POSITIONER................2196
BOOM KICK-OUT................2197
PROXIMITY SWITCH ACTUATION DISPLAY LAMP................2198
PROCEDURE FOR CHECKING DIODE................2200
SPECIAL FUNCTIONS OF MACHINE MONITOR................2201
FLOW OF MODES AND FUNCTIONS................2202
REAL-TIME MONITORING ITEMS................2226
POINTS TO REMEMBER WHEN TROUBLESHOOTING................2235
SEQUENCE OF EVENTS IN TROUBLESHOOTING................2237
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................2238
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT................2238
HANDLING CONTROL BOX................2243
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS................2244
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT................2245
CHECKS BEFORE TROUBLESHOOTING................2247
USING TROUBLESHOOTING CHARTS................2248
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING................2249
TABLE FOR CONNECTOR PIN NUMBERS................2252
T-ADAPTER TABLE................2276
CONNECTOR TYPES AND MOUNTING LOCATIONS................2279
CONNECTOR LAYOUT DRAWING................2285
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)................2290
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................2291
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL................2291
USER CODE MEMORY RETENTION FUNCTION................2291
ERROR CODE AND POSSIBLE CAUSE TABLE................2292
FUSE SYSTEM CHECK................2294
FUSE PANNEL CONNECTION TABLE................2294
INFORMATION CONTAINED IN TESTING PROCEDURES................2295
CODE KEY TABLE................2296
ERROR CODE: [989F00]................2297
TRANSMISSION PROTECTION ALERT (00)................2297
ERROR CODE: [DDD7KX]................2299
SPEEDOMETER SIGNAL OUT OF RANGE................2299
ERROR CODE: [DHH1KX]................2301
HST OIL PRESSURE SIGNAL OUT OF RANGE................2301
ERROR CODE: [DLE2LC]................2303
ENGINE SPEED SENSOR OUT OF RANGE................2303
ERROR CODE: [DLT3KA]................2305
ON SPEEDOMETER SIGNAL................2305
ERROR CODE: [DW26KZ]................2307
MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED................2307
ERROR CODE: [DX19KZ]................2311
MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED................2311
ERROR CODE: [DX20KZ]................2315
CLUTCH SOLENOID SYSTEM OPEN OR SHORTED................2315
TROUBLESHOOTING CODE: [HST-1]................2319
DEFECTIVE HST POWER CONTROLLER SOURCE................2319
TROUBLESHOOTING CODE: [HST-2]................2323
TRAVEL SPEED RANGES DO NOT CHANGE................2323
TROUBLESHOOTING CODE: [HST-3]................2327
TRACTION CONTROL INNOPERABLE................2327
TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE)................2330
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................2333
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL................2333
USER CODE MEMORY RETENTION FUNCTION................2333
ERROR CODE AND POSSIBLE CAUSE TABLE................2334
FUSE SYSTEM CHECK................2336
FUSE PANNEL CONNECTION TABLE................2336
FUSE SYSTEM CHECK................2337
FUSE PANNEL CONNECTION TABLE................2337
INFORMATION CONTAINED IN TESTING PROCEDURES................2338
CODE KEY TABLE................2339
ERROR CODE: [15B0NX]................2340
HST OIL FILTER SHOWING CLOGGED CONDITION................2340
ERROR CODE: [2G42ZG]................2342
LOW ACCUMULATOR OIL PRESSURE INDICATED................2342
ERROR CODE: [989F00]................2344
TRANSMISSION PROTECTION CAUTION INDICATED................2344
ERROR CODE: [989FN1]................2345
HST OVERSPEED CONDITION................2345
ERROR CODE: [AA1ANX]................2346
CLOGGED AIR CLEANER INDICATED (STANDARD)................2346
CLOGGED AIR CLEANER INDICATED (LOAD METER)................2348
ERROR CODE: [AB00L6]................2350
DEFECTIVE BATTERY CHARGING CIRCUIT................2350
ERROR CODE: [AB00MA]................2352
DEFECTIVE BATTERY CHARGING CIRCUIT................2352
ERROR CODE: [B@BAZG]................2354
ABNORMAL ENGINE OIL PRESSURE INDICATED................2354
ERROR CODE: [B@BAZK]................2356
ABNORMAL ENGINE OIL LEVEL INDICATION................2356
ERROR CODE: [B@BCNS]................2358
ENGINE COOLANT INDICATING OVERHEAT CONDITION................2358
ERROR CODE: [B@BCZK]................2360
ABNORMAL COOLANT LEVEL INDICATION................2360
ERROR CODE: [B@C7NS]................2362
BRAKE COOLING OIL INDICATING OVERHEATING CONDITION................2362
ERROR CODE: [B@CRNS]................2364
HST OIL SHOWING OVERHEATING CONDITION................2364
ERROR CODE: [D5ZHL6]................2366
IGNITION SWITCH “C” (IGN) INPUT FAILURE INDICATED................2366
ERROR CODE: [DAF3KK]................2370
WITH IGNITION SWITCH ON, POWER SUPPLY FOR MEMORY IS OFF................2370
ERROR CODE: [DAF5KP]................2372
DEFECTIVE 5-V POWER SUPPLY OUTPUT (KP)................2372
ERROR CODE: [DAF6KP]................2374
DEFECTIVE 24-V POWER SUPPLY OUTPUT (KP)................2374
ERROR CODE: [DAF0KT]................2376
CONTROLLER INTERNAL FAILURE)................2376
ERROR CODE: [DAJ0KR]................2378
HST CONTROLLER COMMUNICATION FAILURE................2378
ERROR CODE [D182KZ]................2382
THE PREHEATER RELAY COIL IS OPEN OR SHORTED................2382
ERROR CODE [D1B0KB]................2384
HST SAFETY (TRANSMISSION CUT-OFF) RELAY OPEN OR SHORTED (KB)................2384
ERROR CODE: [DD1CLD]................2386
DEFECTIVE SUBTOTAL SWITCH................2386
ERROR CODE: [DD15LD]................2388
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET................2388
ERROR CODE: [DD16LD]................2390
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET................2390
ERROR CODE: [DD17LD]................2392
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET................2392
ERROR CODE: [DD18LD]................2394
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET................2394
ERROR CODE: [DDK3KB]................2396
IMPROPER INPUT FOR MULTIPLE SHIFT (FNR) LEVER (STANDARD)................2396
IMPROPER INPUT FOR MULTIPLE SHIFT (FNR) LEVER (LOAD METER)................2398
ERROR CODE: [DDS5L6]................2400
DECREASED STEERING OIL PRESSURE................2400
ERROR CODE: [DDY0LD]................2402
DEFECTIVE CANCEL SWITCH................2402
ERROR CODE: [DGE2KX]................2404
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE................2404
ERROR CODE: [DGE3L6]................2406
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE................2406
ERROR CODE: [DGH1KX]................2408
HST OIL SHOWING OVERHEATING CONDITION................2408
ERROR CODE: [DGR4KA]................2410
AXLE OIL INDICATING SHORT CIRCUIT................2410
ERROR CODE: [DGR4KX]................2412
BRAKE COOLING OIL INDICATING OPEN CIRCUIT................2412
ERROR CODE: [DHE4L6]................2414
ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM................2414
ERROR CODE: [DHPCKX]................2416
POSSIBLE DEFECTIVE BOTTOM PRESSURE SENSOR................2416
ERROR CODE: [DHPDKX]................2418
POSSIBLE DEFECTIVE ROD PRESSURE SENSOR................2418
ERROR CODE: [DKA0KX]................2420
POSSIBLE DEFECTIVE BOOM ANGLE SENSOR................2420
ERROR CODE: [DV00KB]................2422
POSSIBLE SHORT OR OPEN IN ALARM BUZZER................2422
TROUBLESHOOTING CODE: [MON-1]................2424
PARKING BRAKE INDICATOR LAMP DOES NOT WORK................2424
TROUBLESHOOTING CODE: [MON-2]................2428
BRAKE OIL PRESSURE NOT INDICATING CORRECTLY................2428
TROUBLESHOOTING CODE: [MON-3]................2430
ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY................2430
TROUBLESHOOTING CODE: [MON-4]................2432
HST OIL TEMPERATURE NOT INDICATING CORRECTLY................2432
TROUBLESHOOTING CODE: [MON-5]................2434
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY................2434
TROUBLESHOOTING CODE: [MON-6]................2436
ABNORMAL COOLANT LEVEL INDICATION................2436
TROUBLESHOOTING CODE: [MON-7]................2438
STEERING OIL PRESSURE NOT READING CORRECTLY................2438
TROUBLESHOOTING CODE: [MON-8]................2440
EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY................2440
TROUBLESHOOTING CODE: [MON-9]................2442
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY................2442
TROUBLESHOOTING CODE: [MON-10]................2444
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY................2444
TROUBLESHOOTING CODE: [MON-11]................2446
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY................2446
TROUBLESHOOTING CODE: [MON-12]................2448
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY................2448
TROUBLESHOOTING CODE: [MON-13]................2450
ALARM BUZZER DOES NOT STOP OR REMAINS ON................2450
TROUBLESHOOTING CODE: [MON-14]................2452
ABNORMAL ENGINE OIL LEVEL INDICATION................2452
TROUBLESHOOTING CODE: [MON-15]................2454
CLOGGED AIR CLEANER INDICATED (STANDARD)................2454
CLOGGED AIR CLEANER INDICATED (LOAD METER)................2456
TROUBLESHOOTING CODE: [MON-16]................2458
DEFECTIVE CANCEL SWITCH................2458
TROUBLESHOOTING CODE: [MON-17]................2460
DEFECTIVE SUBTOTAL SWITCH................2460
TROUBLESHOOTING CODE: [MON-18]................2462
POSSIBLE DEFECTIVE BOTTOM PRESSURE SENSOR................2462
TROUBLESHOOTING CODE: [MON-19]................2464
POSSIBLE DEFECTIVE ROD PRESSURE SENSOR................2464
TROUBLESHOOTING CODE: [MON-20]................2466
FRONT WINDSHIELD WIPER DOES NOT WORK................2466
REAR WINDSHIELD WIPER DOES NOT WORK................2468
TROUBLESHOOTING CODE: [MON-21]................2470
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION................2470
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................2474
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................2475
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL................2475
USER CODE MEMORY RETENTION FUNCTION................2475
FUSE SYSTEM CHECK................2476
FUSE PANEL CONNECTION TABLE................2476
INFORMATION CONTAINED IN TESTING PROCEDURES................2477
CODE: (E-1)................2479
ENGINE WILL NOT CRANK................2479
CODE: (E-2)................2483
THE ENGINE DOES NOT SHUT DOWN................2483
CODE: (E-3)................2486
COLD START PREHEATER DOES NOT WORK PROPERLY................2486
CODE: (E-4)................2490
PARKING BRAKE DOES NOT FUNCTION PROPERLY................2490
EMERGENCY BRAKE SYSTEM DOES NOT FUNCTION................2494
CODE: (E-5)................2495
BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY................2495
CODE: (E-6)................2498
BUCKET LEVER FUNCTION NOT WORKING PROPERLY................2498
CODE: (E-7)................2501
FLOAT HOLD FUNCTION NOT WORKING PROPERLY................2501
CODE: (E-8)................2504
FRONT WINDSHIELD WIPER DOES NOT WORK................2504
REAR WINDSHIELD WIPER DOES NOT WORK................2508
CODE: (E-9)................2510
THE WINDOW WASHER DOES NOT WORK................2510
CODE: (E-10)................2512
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION................2512
HEADLAMPS (LO BEAM) DO NOT FUNCTION................2517
HEADLAMPS (HI BEAM) DO NOT FUNCTION................2521
CLEARANCE LAMPS DO NOT FUNCTION................2525
TURN SIGNALS DO NOT FUNCTION................2529
WORK LAMPS DO NOT FUNCTION................2533
CODE: (E-11)................2537
HORN DOES NOT SOUND................2537
CODE: (E-12)................2539
AIR CONDITIONER SYSTEM DOES NOT WORK................2539
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED................2542
AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED................2546
CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS................2550
CANNOT SWITCH VENT FUNCTIONS................2552
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)................2554
METHOD OF USING TROUBLESHOOTING CHART................2556
FAILURE CODE AND CAUSE TABLE................2559
CODE: (H-1)................2561
THE MACHINE DOES NOT START................2561
CODE: (H-2)................2562
THE TRAVEL SPEED IS SLOW................2562
CODE: (H-3)................2563
THE THRUST FORCE IS WEAK................2563
CODE: (H-4)................2564
ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY................2564
CODE: (H-5)................2565
THE GEARS DO NOT CHANGE SPEED RANGE................2565
CODE: (H-6)................2566
THE STEERING WHEEL DOES NOT TURN................2566
CODE: (H-7)................2567
STEERING WHEEL MOVEMENT IS HEAVY................2567
CODE: (H-8)................2568
STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT................2568
CODE: (H-10)................2569
BRAKES DO NOT WORK OR WORKS POORLY................2569
CODE: (H-11)................2570
BRAKES IS NOT RELEASING OR DRAGGED................2570
CODE: (H-11)................2571
THE PARKING BRAKE INNOPERABLE................2571
CODE: (H-12)................2572
THE LIFT ARM DOES NOT RISE OR LOWER................2572
CODE: (H-13)................2573
LIFT ARM MOVES SLOW OR RISING FORCE IS POOR................2573
CODE: (H-14)................2574
WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS................2574
CODE: (H-15)................2574
THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES)................2574
CODE: (H-16)................2574
HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN................2574
CODE: (H-17)................2574
THE LIFT ARM WOBBLES DURING OPERATION................2574
CODE: (H-18)................2575
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY................2575
CODE: (H-19)................2576
THE BUCKET DOES NOT TILT BACK................2576
CODE: (H-20)................2577
BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT................2577
CODE: (H-21)................2578
THE BUCKET OPERATES SLOWLY IN TILTING-BACK................2578
CODE: (H-22)................2578
BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET................2578
CODE: (H-23)................2578
HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN................2578
CODE: (H-24)................2578
THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)................2578
CODE: (H-25)................2579
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY................2579
CODE: (H-26)................2579
CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY................2579
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................2580
METHOD OF USING TROUBLESHOOTING CHARTS................2581
(S-1) ENGINE STARTING PERFORMANCE IS POOR................2585
(S-2) ENGINE HAS STARTING PROBLEMS................2587
ENGINE DOES NOT CRANK................2587
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK................2588
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START................2589
(S-3) ENGINE DOES NOT RUN SMOOTHLY................2590
(S-4) ENGINE STOPS DURING OPERATIONS................2591
(S-5) ENGINE SPEED HUNTS................2592
(S-6) ENGINE LACKS POWER................2593
(S-7) EXHAUST SMOKE IS BLACK................2594
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE................2595
(S-9) OIL BECOMES CONTAMINATED QUICKLY................2596
(S-10) FUEL CONSUMPTION IS EXCESSIVE................2597
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR................2598
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP................2599
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)................2600
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)................2601
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG................2602
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING................2603
30 DISASSEMBLY AND ASSEMBLY................2604
HOW TO USE THIS MANUAL................2607
REMOVAL AND INSTALLATION OF COMPONANTS................2607
SPECIAL TOOLS................2607
REMOVAL................2607
INSTALLATION................2607
OVERHAUL OF COMPONANTS................2608
SPECIAL TOOLS................2608
DISASSEMBLY................2608
ASSEMBLY................2608
PRECAUTIONS WHEN CARRYING OUT AN OPERATION................2609
SPECIAL TOOL LIST................2611
SKETCH OF SPECIAL TOOLS................2614
CONNECTOR REPAIR PROCEDURES................2619
CONTACT TERMINAL REMOVAL (HD30 TYPE)................2619
STRIPING INSULATION................2620
CRIMPING CONTACT TERMINAL (HD30 TYPE)................2621
INSERTION OF CONTACT TERMINAL (HD30 TYPE)................2622
CONTACT TERMINAL REMOVAL (DT TYPE)................2623
STRIPING INSULATION................2624
CRIMPING CONTACT TERMINAL (DT TYPE)................2625
INSERTION OF CONTACT TERMINAL (DT TYPE)................2626
ENGINE ASSEMBLY................2627
REMOVAL PROCEDURES................2627
ENGINE INSTALLATION................2634
RADIATOR, AFTERCOOLER AND OIL COOLER................2636
RADIATOR REMOVAL PROCEDURES................2636
RADIATOR INSTALLATION PROCEDURES................2637
AFTERCOOLER REMOVAL PROCEDURES................2637
AFTERCOOLER INSTALLATION PROCEDURES................2639
OIL COOLER REMOVAL PROCEDURES................2639
OIL COOLER INSTALLATION PROCEDURES................2641
COOLING FAN AND FAN MOTOR ASSEMBLY................2642
REMOVAL PROCEDURES................2642
INSTALLATION PROCEDURES................2643
FUEL TANK ASSEMBLY................2644
REMOVAL PROCEDURES................2644
INSTALLATION PROCEDURES................2646
TRANSFER ASSEMBLY................2647
REMOVAL PROCEDURES................2647
INSTALLATION PROCEDURES................2649
SPECIAL TOOLS................2650
DISASSEMBLY PROCEDURES................2650
ASSEMBLY PROCEDURES................2661
PARKING BRAKE ASSEMBLY................2675
REMOVAL PROCEDURES................2675
INSTALLATION PROCEDURES................2676
SPECIAL TOOLS................2677
DISASSEMBLY PROCEDURES................2677
ASSEMBLY PROCEDURES................2679
FRONT AXLE ASSEMBLY................2683
REMOVAL PROCEDURES................2683
INSTALLATION PROCEDURES................2685
REAR AXLE ASSEMBLY................2686
REMOVAL PROCEDURES................2686
INSTALLATION PROCEDURES................2688
FRONT AND REAR AXLE HOUSING................2690
SPECIAL TOOLS................2690
DISASSEMBLY PROCEDURES................2690
ASSEMBLY PROCEDURES................2696
DIFFERENTIAL CARRIER................2704
SPECIAL TOOLS................2704
DISSEMBLY PROCEDURES................2704
Disassembly Of Standard Differential Carrier................2710
Disassembly Of Anti-slip Differential................2712
ASSEMBLY PROCEDURES................2717
ASSEMBLY OF ANTI-SLIP DIFFERENTIAL................2717
ASSEMBLY OF STANDARD DIFFERENTIAL CARRIER................2721
HST AND 4-GEAR PUMP ASSEMBLY................2732
REMOVAL PROCEDURES................2732
INSTALLATION PROCEDURES................2734
HST MOTOR 1 ASSEMBLY................2735
REMOVAL PROCEDURES................2735
INSTALLATION PROCEDURES................2736
HST MOTOR 2 ASSEMBLY................2737
REMOVAL PROCEDURES................2737
INSTALLATION PROCEDURES................2738
WORK EQUIPMENT CONTROL VALVE................2739
REMOVAL PROCEDURES................2739
INSTALLATION PROCEDURES................2740
TRAVEL DAMPER VALVE................2741
REMOVAL PROCEDURES................2741
INSTALLATION PROCEDURES................2742
HYDRAULIC TANK................2743
REMOVAL PROCEDURES................2743
INSTALLATION PROCEDURES................2745
WORK EQUIPMENT................2746
REMOVAL PROCEDURES................2746
INSTALLATION PROCEDURES................2749
BUCKET LINK PIN................2749
BUCKET HINGE PIN................2750
BUCKET CYLINDER PIN (ON ROD SIDE)................2750
BOOM CYLINDER PIN (ON ROD SIDE)................2751
BOOM PIN (ON FRAME SIDE)................2751
BUCKET LINK PIN................2752
BELL CRANK CENTER PIN................2752
HST PUMP................2754
SPECIAL TOOLS LIST................2754
DISASSEMBLY PROCEDURES................2754
ASSEMBLY PROCEDURES................2767
HST MOTOR................2786
SPECIAL TOOLS LIST................2786
DISASSEMBLY PROCEDURES................2786
ASSEMBLY PROCEDURES................2797
HYDRAULIC CYLINDER................2806
SPECIAL TOOLS................2806
DISASSEMBLY PROCEDURES................2807
ASSEMBLY PROCEDURES................2809
OPERATOR'S CAB ASSEMBLY................2813
SPECIAL TOOLS................2813
REMOVAL PROCEDURES................2813
INSTALLATION PROCEDURES................2818
OPERATOR'S CAB GLASS................2819
SPECIAL TOOLS................2819
REMOVAL PROCEDURES................2819
INSTALLATION PROCEDURES................2820
COATING MATERIALS................2829
CENTER HINGE PIN................2830
SPECIAL TOOLS................2830
REMOVAL PROCEDURES................2830
INSTALLATION PROCEDURES................2837
REAR COUNTERWEIGHT................2843
REMOVAL PROCEDURES................2843
INSTALLATION PROCEDURES................2844
AIR CONDITIONER UNIT................2845
SPECIAL TOOLS................2845
REMOVAL PROCEDURES................2845
LOAD METER SPECIFICATION................2846
INSTALLATION PROCEDURES................2848
REFRIGERENT COMPRESSOR ASSEMBLY................2849
SPECIAL TOOLS................2849
REMOVAL PROCEDURES................2849
INSTALLATION PROCEDURES................2850
MONITOR PANEL................2851
REMOVAL PROCEDURES................2851
INSTALLATION PROCEDURES................2855
90 OTHERS................2856
HYDRAULIC CIRCUIT DIAGRAM................2857
ELECTRICAL CIRCUIT DIAGRAM................2858
STANDARD FLOOR HARNESS................2858
LIGHT SWITCH AND FRONT WIPER................2858
MONITOR CONTROLLER................2859
TO CAB HARNESS................2860
TO REAR AND BULKHEAD HARNESS................2861
TO HST HARNESS................2862
TO SHORT CONNECTOR................2863
TO HST CONTROLLER................2864
AIR CONDITIONER RELAY HARNESS................2865
JOINT CONNECTOR................2866
FLOOR HARNESS FOR LOAD METER................2867
LIGHT SWITCH AND FRONT WIPER................2867
MONITOR CONTROLLER................2868
TO CAB HARNESS................2869
TO REAR AND BULKHEAD HARNESS................2870
TO HST HARNESS................2871
TO KOMTRAX................2872
HST CONTROLLER................2873
AIR CONDITIONER RELAY HARNESS................2874
JOINT CONNECTOR................2875
HST AND BULK HEAD HARNESS................2876
GRILL HARNESS................2877
ENGINE AND POWER SUPPLY HARNESS................2878
CAB HARNESS................2879
EMERGENCY STEERING AND MULTI-FUNCTION HARNESS................2880
LOAD METER AND PRINTER HARNESS................2881
FRONT HARNESS................2882
REVERSE FAN WIRING DIAGRAM................2883
CEBM019803 - Wheel Loader WA320-6 Shop Manual................2885
CEBM019803 - WA320-6 sn A34001 - A34999................2885
CONTENTS................2886
REVISED PAGES................2887
SAFETY................2899
Safety Notice................2899
IMPORTANT SAFETY NOTICE................2899
General Precautions................2899
Preparations for Work................2900
Precautions During Work................2900
Seat Belt Inspection................2901
GENERAL................2902
HOW TO READ THE SHOP MANUAL................2903
Volumes................2903
Distribution and Updating................2903
Filing Method................2903
Revised Edition Mark................2903
Revisions................2903
Symbols................2903
HOISTING INSTRUCTIONS................2904
Hoisting................2904
Making Signs/Hand Signals................2904
Precautions................2904
Precautions for Sling Work................2904
Precautions for Using Mobile Crane................2905
Precautions for Using Overhead Hoist Crane................2905
Selecting Wire Ropes................2906
AIR CONDITIONER CIRCUITS................2907
Precautions for Handling Hoses and Tubes................2907
Disconnecting Hoses and Tubes................2907
Connecting Hoses and Tubes................2907
MAINTENANCE STANDARD TERMS................2908
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT................2910
Handling Electric Equipment................2910
Handling Wiring Harnesses and Connectors................2910
Main Failures Occurring in Wiring Harness................2910
Removing, Installing, and Drying Connectors and Wiring Harnesses................2911
Handling Controller................2915
Troubleshooting Electric Circuits................2915
Handling Hydraulic Equipment................2916
Handling Connectors Used for Engines................2917
Slide Lock Type................2917
Pull Lock Type................2918
Push Lock Type................2918
Turn-housing Type (Round Green Connector)................2920
PRECAUTIONS FOR OPERATIONS................2921
Precautions When Carrying Out Removal Work................2921
Precautions When Carrying Out Installation Work................2922
Precautions When Completing the Operation................2923
PUSH-PULL COUPLER................2924
Type 1................2924
Disconnection................2924
Connection................2924
Type 2................2925
Disconnection................2925
Connection................2925
Type 3................2926
Disconnection................2926
Connection................2926
COATING MATERIALS................2927
STANDARD TIGHTENING TORQUE................2929
Standard Tightening Tables................2929
For Bolts and Nuts................2929
For Split Flange Bolts................2930
For O-Ring Boss Piping Joints................2930
For O-Ring Boss Plugs................2931
For Hoses (Taper-Seal Type and Face-Seal Type)................2931
For Face Seal Joints................2932
For 102, 107, and 114 Engine Series (Bolts and Nuts)................2932
For 102, 107, and 114 Engine Series (Eye Joints)................2933
For 102, 107, and 114 Engine Series (Taper Screws)................2933
CONVERSION TABLES................2934
Method of Using the Conversion Table................2934
01 GENERAL................2941
SPECIFICATIONS................2942
Dimension Drawing................2942
Specification Tables................2944
WEIGHT TABLE................2950
FUEL, COOLANT, AND LUBRICANTS................2952
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD................2955
ENGINE AND COOLING SYSTEM................2959
Engine and Transfer Mount................2959
Damper................2960
Cooling System................2962
Cooling System Hydraulic Piping Diagram................2963
Cooling Fan Motor................2964
Hydraulic Motor................2968
Suction Safety Valve................2969
Reversible Valve................2971
Flow Control Valve (Continuously Variable Type)................2972
POWER TRAIN SYSTEM................2973
Drive Line Components................2973
Power Train System Diagram................2974
Drive Shaft................2976
HST Hydraulic Piping Diagram................2977
HST Pump................2978
Operation................2980
High-Pressure Relief Valve................2981
Low-pressure Relief Valve................2983
HST Charge Pump................2984
Speed-Related Valve (DA Valve)................2986
High-Pressure Cutoff Valve................2987
HST Motor................2988
HST Motor 1................2988
HST Motor 2................2990
EP Servo Valve................2992
HA Servo Valve................2993
Directional Shuttle Valve................2994
Transfer................2996
Input Shaft................3000
Output Shaft................3004
Outline................3008
Operation of Clutch................3009
Power Transmitting Route................3010
Clutch Solenoid Valve................3012
DRIVE AXLE SYSTEM................3014
Front and Rear Axles................3014
Front Axle................3014
Rear Axle................3016
Differential................3018
Front Differential................3018
Rear Differential................3022
Torque Proportioning Differential................3026
Limited Slip Differential (if equipped)................3028
Final Drive................3032
Front Final Drive................3032
Rear Final Drive................3034
STEERING SYSTEM................3037
Steering Piping Diagram................3037
Steering Column................3038
Priority Valve................3039
Orbitrol Valve................3043
Operation................3046
Connection of Hand Pump and Sleeve................3050
Cushion Valve................3052
Steering Cylinder................3054
Emergency Steering Piping Diagram (if equipped)................3056
Emergency Steering Valve (if equipped)................3058
Steering Relief Valve (if equipped)................3062
BRAKE SYSTEM................3064
Brake Piping Diagram................3064
Charge Valve................3066
Brake Valve................3070
Braking Operation................3072
Inching Valve................3075
Accumulator (for Brake)................3076
Slack Adjuster................3078
Brakes................3080
Front Brake................3080
Rear Brake................3082
Parking Brake System................3085
Brake Control................3085
Parking Brake................3086
UNDERCARRIAGE AND FRAME................3088
Axle Mounting and Center Hinge Pin................3088
Tires................3093
Radial Tire................3093
Bias Tire................3094
HYDRAULIC SYSTEM................3096
Work Equipment Hydraulic Piping Diagram................3096
Work Equipment Control Lever Linkage................3098
Multi-Function Mono-Lever Type................3098
2-Lever Type (if equipped)................3099
Hydraulic Tank................3100
Breather................3101
4-Gear Pump................3102
Work Equipment Control Valve................3104
2-Spool Type................3104
3-Spool Type................3108
Relief Valve................3112
Safety-Suction Valve................3113
Suction Valve................3114
Operation of Work Equipment Control Valve................3115
Cutoff Valve................3122
PPC Valve................3125
Work Equipment PPC Valve: Mono Lever Type................3125
Work Equipment PPC Valve: 2-Lever Type (if equipped)................3131
Attachment PPC Valve................3138
Lock Valve (for PPC Circuit)................3140
Accumulator (for PPC Circuit)................3141
ECSS Valve................3142
Accumulator (for ECSS)................3145
Work Equipment................3146
Work Equipment Linkage................3146
Bucket................3148
Bucket Positioner and Boom Kickout................3150
Operation of Proximity Switch................3152
Work Equipment Cylinders................3158
Lift Cylinder................3158
Bucket Cylinder................3158
CAB ENVIRONMENT................3159
Cab................3159
Air Conditioner................3160
Air Conditioner Piping Diagram................3160
Refrigerant Circuit Diagram................3162
Air Conditioner Unit................3163
Blower and Intake Unit................3166
Compressor................3168
Condenser................3169
Receiver................3170
Air Conditioner Panel................3172
ELECTRICAL SYSTEM................3176
Machine Monitor System................3176
System Circuit Diagram................3178
Machine Monitor................3180
Items Displayed on Monitor................3181
Machine Monitor Operation Switches................3190
Setting Machine Monitor................3191
Troubleshooting Function................3192
Character Display Function................3192
Operator Mode Functions................3193
Service Mode Functions................3196
Input and Output Signals................3201
Electrical System (HST Controller System)................3209
Input and Output Signals Diagram................3209
HST Controller Gearshifting Control Function................3210
HST Controller Protection Function................3216
Cooling Fan Control Function................3219
System Circuit Diagram................3224
HST Controller................3226
ECSS System................3228
ELECTRONIC TRANSMISSION CONTROL................3230
KOMTRAX Terminal System................3230
KOMTRAX Terminal................3232
Engine Starting Circuit................3234
Engine Stopping Circuit................3236
Preheating Circuit................3237
Engine Output Lowering Function................3238
Automatic Warm-up Function................3238
Parking Brake Circuit................3239
Max. Traction Switch (if equipped)................3241
Multi-Function Knob................3242
Modification of Multi-Function Lever................3243
Sensors................3246
Speed Sensor................3246
HST Oil Temperature Sensor................3248
Brake Oil Temperature Sensor................3248
HST Oil Pressure Sensor................3249
HST Oil Filter Clogging Sensor................3249
Coolant Level Sensor................3250
Fuel Level Sensor................3251
Accelerator Pedal Sensor................3252
Air Cleaner Clogging Sensor................3254
Water-in-Fuel Sensor................3255
Boom Kick-Out Proximity Switch................3256
Bucket Positioner Proximity Switch................3256
20 STANDARD VALUE TABLES................3257
STANDARD VALUE TABLES................3259
Standard Value Table for Engine................3259
Standard Value Table for Chassis................3260
MACHINE POSTURE................3265
30 TESTING AND ADJUSTING................3267
TOOLS................3271
Tools for Testing, Adjusting, and Troubleshooting................3271
ENGINE COMPONENTS................3277
Engine Speed................3277
Measure Engine Speed (Low and High Idle)................3277
Measure HST Stall Speed................3277
Measure Hydraulic Stall Speed................3278
Measure HST Stall and Hydraulic Stall (Full Stall) Speed................3278
Exhaust Gas Color................3279
Using Handy Smoke Checker A1................3279
Using Smoke Meter A2................3279
Adjusting Valve Clearance................3281
Measuring Engine Compression................3283
Measuring Blow-by Pressure................3286
Measuring Engine Oil Pressure................3288
Intake Air (Boost) Pressure................3289
Measuring with Monitoring Function................3289
Measuring with Measuring Tool................3290
FUEL SYSTEM................3291
Handling Fuel System Equipment................3291
Releasing Residual Pressure in Fuel System................3291
Measuring Fuel Pressure................3292
Measuring Pressure in Fuel Low-pressure Circuit................3292
Measuring Pressure in Fuel Return Circuit................3293
Measuring Fuel Negative-Pressure Circuit Pressure................3294
Fuel Delivery, Return, and Leak Rate................3295
Measuring Supply Pump Delivery................3295
Measuring Return Rate from Supply Pump................3297
Measuring Leakage from Pressure Limiter................3298
Measuring Return Rate from Injector................3299
Bleeding Air from Fuel Circuit................3300
Testing Leakage in Fuel System................3301
Handling Reduced Cylinder Mode Operation................3302
Handling No-Injection Cranking Operation................3302
Handling Controller Voltage Circuit................3302
EXHAUST SYSTEM AND PIPING................3303
Checking Muffler and Muffler Stack for Looseness and Damage................3303
Checking Muffler Function................3303
Checking Installed Condition of Cylinder Head and Manifolds................3303
Checking Engine Piping for Damage and Looseness................3303
BELTS................3304
Air Conditioner Compressor Belt................3304
Testing the Tension................3304
Adjusting the Tension................3304
Replacing Alternator Belt................3305
ACCELERATOR PEDAL................3306
Testing Operating Effort................3306
Testing Operating Angle................3307
DIRECTIONAL LEVER................3308
Checking Operating Effort................3308
Checking Travel................3308
POWER TRAIN OIL PRESSURES................3309
HST Oil Pressure................3309
Testing High-Pressure Cutoff Oil Pressure................3309
Testing Low-Pressure Relief Pressure................3310
Testing Servo Piston Control Pressure (DA Pressure)................3311
Testing Servo Piston Actuating Pressure................3312
Adjusting High-Pressure Cutoff Valve................3312
Adjusting Low-Pressure Relief Valve................3313
Adjusting DA Pressure................3314
Testing Clutch Control Pressure................3315
STEERING SYSTEM................3317
Steering Wheel................3317
Measuring Play................3317
Measuring Operating Effort................3318
Measuring Operating Time................3318
Steering Oil Pressure................3319
Measuring Main Relief Pressure................3319
Adjusting Main Relief Pressure................3320
Bleeding Air from Steering Circuit................3321
HYDRAULIC DRIVE FAN................3322
Measuring Fan Speed................3322
Measuring Fan Drive Oil Pressure................3323
WHEEL BRAKE SYSTEM................3324
Measuring Pressing Angle of Brake Pedal................3324
Brake Pedal Linkage................3325
Testing................3325
Adjusting................3325
Measuring Brake Performance................3326
Accumulator Charge................3327
Measuring................3327
Adjusting................3328
Measuring Brake Oil Pressure................3329
Testing Wear of Wheel Brake Disc................3332
Bleeding Air from Brake Circuit................3333
Releasing Residual Pressure in Brake Accumulator Circuit................3334
PARKING BRAKE SYSTEM................3335
Testing Parking Brake Performance................3335
Parking Brake Control Cable................3336
Testing................3336
Adjusting................3336
WORK EQUIPMENT SYSTEM................3337
Work Equipment Control Lever................3337
Measuring Operating Effort................3337
Measuring Travel................3337
Work Equipment Hydraulic Pressure................3338
Measuring................3338
Adjusting................3338
PPC Oil Pressure................3340
Measuring PPC Valve Basic Pressure................3340
Measuring PPC Valve Output Pressure................3341
Bleeding Air from Hydraulic Circuit................3342
Bleeding Air from Work Equipment PPC Circuit................3342
Bleeding Air from Cylinders................3342
Releasing Residual Pressure in Hydraulic Circuit................3343
Between Each Hydraulic Cylinder and Control Valve................3343
In Brake Accumulator Circuit................3343
In PPC Accumulator Circuit................3343
Work Equipment Positioners................3344
Bucket Positioner................3344
Boom Kickout Switch................3345
Proximity Switch Operation Pilot Lamp................3346
ELECTRICAL SYSTEM TROUBLESHOOTING................3347
Procedure for Testing Diodes................3347
When Using Digital Type Circuit Tester................3347
When Using Analog Type Circuit Tester................3348
Preparation for Troubleshooting Electric System................3349
Machine Monitor................3349
HST Controller................3350
KOMTRAX Terminal................3351
Sensors................3352
Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)................3352
Supply Pump IMV Solenoid (FUEL REGULATOR)................3352
Common Rail Pressure Sensor (FUEL RAIL PRESS)................3353
Engine Coolant Temperature Sensor (COOLANT TEMP)................3353
KOMTRAX TERMINAL SYSTEM................3354
Terminal Installed at Plant Before Shipment................3354
Terminal Retrofitted Machine After Shipment................3354
Starting Operation................3354
Application for the Start of Use................3357
Komtrax Terminal Lamps................3358
Contents of 7-Segment and Dot Displays for CPU................3360
MACHINE MONITOR SYSTEM................3361
Adjusting Machine Monitor................3361
Adjusting for Replaced, Reassembled, or Added Sensor/Controller................3362
Adjustment for User’s Needs................3363
Special Functions of Machine Monitor (EMMS)................3364
Normal and Special Functions of Machine Monitor................3365
Functions and Flow of Service Mode................3366
Operator Mode................3369
Service Meter Display Function (1)................3369
Traction Level Selection Function (2)................3369
HST Function Selection Function (3)................3369
Odometer Display Function (4)................3370
Maintenance Monitoring Function (5)................3370
Telephone Number Input Function (6)................3370
Language Selection Function (7)................3370
Monitor Brightness Adjustment Function (8)................3371
Travel Speed/Engine Speed Display Selecting Function (9)................3371
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)................3372
Action Code Display Function (11)................3372
Failure Code Display Function (12)................3373
Service Mode................3374
Switching to Service Mode and Screen Display (1)................3374
Electrical System Fault History Display Function (ELECTRIC FAULT) (2)................3376
Mechanical System Fault History Display Function (MACHINE FAULT) (3)................3378
Real-Time Monitoring Function (REAL-TIME MONITOR) (4)................3379
Real-Time Monitoring Code Tables................3382
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)................3396
No-Injection Cranking Function (6)................3397
Adjustment Function (TUNING) (7)................3398
Maintenance Monitoring Function (8)................3402
Operating Information Display Function (9)................3408
Optional Device Selecting Function (10)................3411
Machine Serial Number Input Function (11)................3415
Model Select Function (MACHINE WA***) (12)................3415
Initialize Function (13)................3416
Setting Procedure for Service Meter and Odometer................3417
PM-CLINIC INSPECTION TABLE................3421
40 TROUBLESHOOTING................3425
POINTS TO REMEMBER WHEN TROUBLESHOOTING................3435
SEQUENCE OF EVENTS IN TROUBLESHOOTING................3437
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................3438
Precautions when Handling Electrical Equipment................3438
Handling Electronic Control Unit................3443
Points to Remember When Troubleshooting Electrical Circuits................3444
Handling Hydraulic Equipment................3445
ELECTRIC WIRE CODE................3447
How to Read Electric Wire Code................3447
Type, Symbol, and Material................3447
Dimensions................3448
Color Codes Table................3449
Types of Circuits and Color Codes................3450
Classification by Thickness................3450
Classification by Color and Code................3451
CHECKS BEFORE TROUBLESHOOTING................3452
Categories and Method of Using Troubleshooting Charts................3453
Troubleshooting Individual Electrical Circuits................3454
Chart Use................3456
Chart Tips................3456
Troubleshooting Individual Hydraulic Circuits................3457
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................3459
X-Type Connectors................3459
SWP-Type Connectors................3461
M-Type Connectors................3463
S-Type Connectors................3465
MIC-Type Connectors................3467
AMP040-Type Connectors................3469
AMP070-Type Connectors................3471
Miscellaneous Types of Connectors................3473
HD30 Series Connectors................3477
DT Series Connectors................3482
DTM Series Connectors................3484
DTHD Series Connectors................3484
DTP Series Connectors................3485
DRC26 Series Connectors................3486
DRC12, 16 Connectors................3488
AMP Connectors for Pump Controller (CH700)................3489
BOSCH Connectors for Engine................3491
SUMITOMO Connectors for Engine................3492
CANNON Connectors for Engine................3493
AMP Connectors for Engine................3494
FRAMATOME Connectors for Engine................3495
PACKARD Connectors for Engine................3497
OT Series Connectors for Engine................3498
T-BRANCH BOX and T-BRANCH ADAPTER TABLE................3499
MODE CHART................3504
INFORMATION CONTAINED IN TESTING PROCEDURES................3507
TROUBLESHOOTING BY FAILURE CODE................3509
Failure Code Table................3509
FUSE BOX AND SLOW-BLOW FUSES................3515
Connection Table of Fuse Box and Slow-Blow Fuses................3515
Fuse Box: FS1................3515
Fuse Box: FS2................3516
Slow-Blow Fuses................3517
FAILURE CODES................3518
2G40ZG................3520
Brake: Oil Pressure Reduction................3520
6091NX................3522
HST Filter: Clogging................3522
989FN1................3523
Travel Speed: Overrun Alarm................3523
AA1ANX................3524
Air Cleaner: Clogging................3524
AB00L6................3526
Alternator R System: Hot Short................3526
AB00MA................3528
Alternator R System: Ground Fault/Disconnection/Low Charge Voltage................3528
B@BAZG................3530
Engine: Oil Pressure Reduction................3530
B@BAZK................3531
Engine Oil: Low Level................3531
B@BCNS................3532
Engine: Overheat................3532
B@BCZK................3534
Engine: Low Coolant Level................3534
B@C6NS................3536
Front Brake: High Oil Temperature................3536
B@CRNS................3537
HST: High Oil Temperature................3537
CA111................3538
Abnormality in Engine Controller................3538
CA115................3539
Engine Ne or Bkup Speed Sensor Error................3539
CA122................3540
Charge Pressure Sensor High Error................3540
CA123................3542
Charge Pressure Sensor Low Error................3542
CA131................3544
Throttle Sensor High Error................3544
CA132................3546
Throttle Sensor Low Error................3546
CA144................3548
Coolant Sensor High Error................3548
CA145................3550
Coolant Sensor Low error................3550
CA153................3552
Charge Temperature Sensor High Error................3552
CA154................3554
Charge Temperature Sensor Low Error................3554
CA155................3556
Lowering of Speed by Abnormally High Charge Temperature................3556
CA187................3558
Sensor Power Supply 2 Low Error................3558
CA221................3560
Atmospheric Pressure Sensor High Error................3560
CA222................3562
Atmospheric Sensor Low Error................3562
CA227................3564
Sensor Power Supply 2 High Error................3564
CA234................3566
Engine Overspeed................3566
CA238................3567
Ne Speed Sensor Power Supply Error................3567
CA271................3568
IMV (IMA) Short Circuit................3568
CA272................3570
IMV (IMA) Disconnection................3570
CA322................3572
Injector #1 Open/Short Error................3572
CA323................3574
Injector #5 Open/Short Error................3574
CA324................3576
Injector #3 Open/Short Error................3576
CA325................3578
Injector #6 Open/Short Error................3578
CA331................3580
Injector #2 Open/Short Error................3580
CA332................3582
Injector #4 Open/Short Error................3582
CA342................3584
Calibration Code Inconsistency................3584
CA351................3586
Injectors Drive Circuit Error................3586
CA352................3588
Sensor Power Supply 1 Low Error................3588
CA386................3590
Sensor Power Supply 1 High Error................3590
CA428................3592
Abnormally High Level in Water Sensor................3592
CA429................3594
Abnormally Low Level in Water Sensor................3594
CA431................3596
Idle Validation Switch Error................3596
CA432................3600
Idle Validation Action Error................3600
CA435................3604
Engine Oil Pressure Switch Error................3604
CA441................3606
Battery Voltage Low Error................3606
CA442................3610
Battery Voltage High Error................3610
CA449................3612
Common Rail Pressure High Error 2................3612
CA451................3614
Common Rail Pressure Sensor High Error................3614
CA452................3616
Common Rail Pressure Sensor Low Error................3616
CA488................3618
Lowering of Torque by Abnormally High Charge Temperature................3618
CA553................3619
Common Rail Pressure High Error 1................3619
CA559................3620
Supply Pump Pressure Very Low Error................3620
CA689................3622
Engine Ne Speed Sensor Error................3622
CA731................3624
Engine Bkup Speed Sensor Phase Error................3624
CA757................3625
All Continuous Data Lost Error................3625
CA778................3628
Engine Bkup Speed Sensor Error................3628
CA1633................3630
KOMNET Datalink Timeout Error................3630
CA2185................3634
Throttle Sensor Supply Voltage High Error................3634
CA2186................3636
Throttle Sensor Power Supply Low Error................3636
CA2249................3638
Supply Pump Pressure Very Low Error 2................3638
CA2311................3640
Abnormality in IMV (IMA) Solenoid................3640
CA2555................3642
Intake Heater Relay Disconnection Error................3642
CA2556................3644
Intake Heater Relay Short Circuit Error................3644
D160KY................3646
Backup Alarm/Lamp Relay 1 Circuit: Hot Short................3646
D192KY................3648
ECSS Solenoid Relay: Hot Short................3648
D1B0KA................3650
HST Safety Relay: Disconnection................3650
D1B0KB................3652
HST Safety Relay: Ground Fault................3652
D1B0KY................3654
HST Safety Relay: Hot Short................3654
D5ZHL6................3656
IGN C System: Ground Fault/Disconnection................3656
DAF3KK................3658
UNSW Power Supply: Ground Fault/Disconnection................3658
DAFRKR................3660
Machine Monitor CAN-NET Signal: Disconnection................3660
DAJ0KK................3662
HST Controller Power Supply: Low Voltage................3662
DAJ0KT................3664
HST Controller Memory (EEPROM): Abnormality................3664
DAJ1L4................3666
HST Controller Main Power Line: Disconnection/Ground Fault................3666
DAJ1L6................3668
HST Controller Main Power Line: Hot Short................3668
DAJ2KK................3670
Controller Solenoid Power Supply: Low Voltage................3670
DAJ2L3................3672
HST Controller Load Power Supply Holding Line: Hot Short in Wiring Harness................3672
DAJ2L4................3674
HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault................3674
DAJ5KX................3676
Sensor 5V Power Supply: Out-of-Output Range................3676
DAJ9KQ................3678
HST Controller Model Selection: Disagreement of Model Selection Signals................3678
DAJRKR................3680
HST Controller CAN-NET Signal: Disconnection................3680
DAJRMA................3685
HST Controller: Disagreement in Option Selection................3685
DB2RKR................3686
Engine Controller CAN-NET: Disconnection in Signal Line................3686
DD1NL4................3692
Fan Automatic Reverse Switch Signal: Abnormality................3692
DD1NLD................3694
Fan Reverse Switch Signal: Abnormality................3694
DDB6KA................3696
Parking Brake Reminder Signal: Disconnection/Short Circuit................3696
DDB6KB................3698
Parking Brake Indicator Signal: Ground Fault................3698
DDB6KZ................3700
Parking Brake Switch or Parking Brake Reminder Switch: Trouble................3700
DDB6L0................3702
Parking Brake Reminder Signal: Ground Fault................3702
DDB6L4................3704
Parking Brake Indicator Signal: Disconnection/Hot Short................3704
DDD7KX................3706
Travel Speed Control Dial Signal: Disconnection/Ground Fault................3706
DDD7KY................3708
Travel Speed Control Dial Signal: Hot Short................3708
DDE5MA................3710
Emergency Steering Operation Switch: Disconnection................3710
DDK3KA................3712
Directional Selector Switch: Disconnection/Hot Short................3712
DDK3KB................3714
Directional Selector Switch: Ground Fault................3714
DDK6KA................3716
FNR Lever: Disconnection/Ground Fault................3716
DDK6KY................3720
FNR Lever: Hot Short................3720
DDS5L6................3722
Steering: Low Oil Pressure (Operation of Emergency Steering)................3722
DF10KA................3724
Travel Speed Range Selector Switch: Disconnection/Ground Fault................3724
DF10KB................3728
Travel Speed Range Selector Switch: Hot Short................3728
DGH1KX................3730
HST Oil Temperature Sensor: Ground Fault................3730
DGR2KB................3732
Brake Oil Temperature Sensor: Ground Fault................3732
DGR2KZ................3734
Brake Oil Temperature Sensor: Disconnection/Hot Short................3734
DHH1KX................3736
HST Oil Pressure Sensor: Disconnection/Ground Fault................3736
DHH1KY................3738
HST Oil Pressure Sensor: Hot Short................3738
DHTCL6................3740
HST Filter Clogging Sensor: Functional Defect................3740
DJF1KA................3742
Fuel Level Sensor: Disconnection/Hot Short................3742
DLT3KX................3744
Travel Speed Sensor B: Abnormality................3744
DLT4KX................3748
Travel Speed Sensor A: Abnormality................3748
DLT4LC................3750
Travel Speed Sensor A & B: Abnormality................3750
DV00KY................3752
Alarm Buzzer: Hot Short................3752
DW26KA................3754
Motor 2 Solenoid: Disconnection/Ground Fault................3754
DW26KY................3756
Motor 2 Solenoid: Hot Short................3756
DW7BKY................3758
Fan Reverse Solenoid Circuit: Hot Short................3758
DW7BKZ................3760
Fan Reverse Solenoid Circuit: Disconnection/Ground Fault................3760
DX16KA................3762
Fan EPC Solenoid: Disconnection................3762
DX16KB................3764
Fan EPC Solenoid: Ground Fault................3764
DX16KY................3766
Fan EPC Solenoid: Hot Short................3766
DX19KA................3768
Motor 1 Solenoid: Disconnection................3768
DX19KB................3770
Motor 1 Solenoid: Ground Fault................3770
DX19KY................3772
Motor 1 Solenoid: Hot Short................3772
DX20KA................3774
Clutch EPC Solenoid: Disconnection................3774
DX20KB................3776
Clutch EPC Solenoid: Ground Fault................3776
DX20KY................3778
Clutch EPC Solenoid: Hot Short................3778
DXH7KB................3780
Reverse Solenoid: Ground Fault................3780
DXH7KZ................3782
Reverse Solenoid: Disconnection/Hot Short................3782
DXH8KB................3784
Forward Solenoid: Ground Fault................3784
DXH8KZ................3786
Forward Solenoid: Disconnection/Hot Short................3786
J141N1................3788
Steering Pump: Overrun Alarm................3788
M100N1................3789
HST Pump: Overrun Alarm................3789
M400N1................3790
Motor 1: Overrun Alarm................3790
TROUBLESHOOTING: E-MODE................3792
Troubleshooting Electrical System................3792
Information in Troubleshooting Table................3792
E-1................3794
Engine Does Not Start................3794
E-2................3802
Preheater Does Not Operate Manually................3802
E-3................3806
Travel Speed is Low or High................3806
E-4................3812
ECSS Does Not Operate................3812
E-5................3815
ECSS Keeps Operating................3815
E-6................3818
Defective Boom Kickout Function and Cancellation................3818
E-7................3822
Defective Bucket Positioner Function and Cancellation................3822
E-8................3826
Defective Lift Arm FLOATING Holding Function and Cancellation................3826
E-9................3830
Travel Direction Selection System Does Not Function................3830
E-10................3834
Fan Does Not Reverse................3834
E-11................3838
Fan Keeps Rotating in Reverse................3838
E-12................3840
Wiper Does Not Operate................3840
E-13................3844
Windshield Washer Does Not Operate................3844
E-14................3847
Headlamp, Clearance Lamp, and Tail Lamp Do Not Light Up or Go Off................3847
E-15................3855
Working Lamp Does Not Light Up or Go Off................3855
E-16................3860
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off................3860
E-17................3866
Brake Lamp Does Not Light or It Keeps Lighting Up................3866
E-18................3868
Backup Lamp Does Not Light or It Keeps Lighting Up................3868
E-19................3871
Backup Alarm Does Not Sound or It Keeps Sounding................3871
E-20................3874
Horn Does Not Sound or It Keeps Sounding................3874
E-21................3876
Alarm Buzzer Does Not Sound or It Keeps Sounding................3876
E-22................3878
Air Conditioner Does Not Operate or Stop................3878
E-23................3881
The KOMTRAX System Does Not Work Properly................3881
Lamp Display Section of KOMTRAX Terminal................3883
TROUBLESHOOTING: H-MODE................3884
Troubleshooting Hydraulic and Mechanical Systems................3884
Method of Using Troubleshooting Chart................3884
Table of Failure Codes and Causes................3886
H-1................3888
Machine Does Not Start................3888
H-2................3889
Travel Speed Is Slow................3889
H-3................3890
Traction Force Is Weak................3890
H-4................3891
Engine Stalls When Traveling or Engine Speed Drops Excessively................3891
H-5................3892
Shift Range is Not Shifted................3892
H-6................3893
Steering Wheel Does Not Turn................3893
H-7................3894
Steering Wheel is Heavy................3894
H-8................3895
Steering Wheel Shakes or Jerks................3895
H-9................3896
Machine Deviates Naturally to One Side When Traveling................3896
H-10................3897
Brake Does Not Work or Does Not Work Well................3897
H-11................3898
Brake Is Not Released or Is Dragged................3898
H-12................3899
Lift Arm Does Not Rise or Lower................3899
H-13................3900
Lift Arm Moves Slowly or Lift Arm Rising Force Is Insufficient................3900
H-14................3901
When Rising, Lift Arm Starts to Move Slowly at a Specific Height................3901
H-15................3901
Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Rises in the Air)................3901
H-16................3901
Hydraulic Drifts of the Lift Arm Occur Often................3901
H-17................3902
Lift Arm Wobbles During Operation................3902
H-18................3902
When Control Lever Is Switched from HOLD to RAISE, Lift Arm Falls Temporarily................3902
H-19................3903
Bucket Does Not Tilt Back................3903
H-20................3904
Bucket Moves Slowly or Tilting-Back Force Is Insufficient................3904
H-21................3905
Bucket Starts to Operate Slowly in the Midst of Tilting Back................3905
H-22................3905
Bucket Cylinder Cannot Hold Down the Bucket................3905
H-23................3905
Hydraulic Drifts of the Bucket Occur Often................3905
H-24................3906
Bucket Wobbles During Travel with Load................3906
H-25................3906
When Control Lever Is Switched from HOLD to TILT, the Bucket Falls Temporarily................3906
H-26................3907
Control Levers of Lift Arm and Bucket Do Not Move Smoothly and Are Heavy................3907
H-27................3908
ECSS Does Not Operate and Machine Pitches and Bounces................3908
H-28................3909
Fan Revolution Is Abnormal................3909
50 DISASSEMBLY AND ASSEMBLY................3911
HOW TO READ THIS MANUAL................3915
Removal and Installation of Assemblies................3915
Disassembly and Assembly of Assemblies................3917
COATING MATERIALS LIST................3919
SPECIAL TOOLS LIST................3923
SKETCHES OF SPECIAL TOOLS................3927
CONNECTOR REPAIR PROCEDURES................3934
Stripping Insulation................3934
Wire Inspection................3934
Contact Terminal Removal (HD30 Type)................3935
Crimping Contact Terminal (HD30 Type)................3936
Insertion Of Contact Terminal (HD30 Type)................3937
Contact Terminal Removal (DT Type)................3938
Crimping Contact Terminal (DT Type)................3939
Insertion Of Contact Terminal (DT Type)................3940
ENGINE AND COOLING SYSTEM................3941
Fuel Supply Pump Assembly................3941
Removal................3941
Installation................3943
Fuel Injector Assembly................3944
Removal................3944
Installation................3949
Cylinder Head Assembly................3953
Removal................3953
Installation................3962
Engine Hood Assembly................3968
Removal................3968
Installation................3971
Radiator................3972
Removal................3972
Installation................3975
Air Aftercooler................3976
Removal................3976
Installation................3977
Hydraulic Oil Cooler Assembly................3978
Removal................3978
Installation................3980
Engine Assembly................3981
Removal................3981
Installation................3987
Engine Front Oil Seal Assembly................3989
Removal................3989
Installation................3991
Engine Rear Oil Seal Assembly................3992
Removal................3992
Installation................3994
Cooling Fan and Fan Motor Assembly................3997
Removal................3997
Installation................4000
Fuel Tank Assembly................4001
Removal................4001
Installation................4003
POWER TRAIN................4004
Transfer Case Assembly................4004
Removal................4004
Installation................4007
Transfer Assembly................4009
Disassembly................4010
Assembly................4021
Parking Brake Assembly................4034
Removal................4034
Installation................4035
Disassembly................4036
Assembly................4039
Front Axle Assembly................4043
Removal................4043
Installation................4045
Rear Axle Assembly................4046
Removal................4046
Installation................4049
Axle Housing Assembly................4050
Disassembly................4051
Assembly................4057
Differential Assembly................4066
Disassembly................4067
Assembly................4079
UNDERCARRIAGE AND FRAME................4097
Center Hinge Pin................4097
Removal................4097
Installation................4104
Counterweight................4110
Removal................4110
Installation................4111
HYDRAULIC SYSTEM................4112
HST Pump and 4-Gear Pump Assembly................4112
Removal................4112
Installation................4115
HST Pump Assembly................4117
Disassembly................4117
Assembly................4130
HST Motor 1 Assembly................4150
Removal................4150
Installation................4151
HST Motor 2 Assembly................4152
Removal................4152
Installation................4153
HST Motor Assembly................4154
Disassembly................4154
Assembly................4166
Work Equipment Control Valve Assembly................4176
Removal................4176
Installation................4178
Hydraulic Tank Assembly................4179
Removal................4179
Installation................4181
Hydraulic Cylinder Assembly................4182
Disassembly................4183
Assembly................4186
WORK EQUIPMENT................4190
Work Equipment Assembly................4190
Removal................4190
Installation................4194
CAB AND ITS ATTACHMENTS................4199
Operator’s Cab and Floor Frame Assembly................4199
Removal................4199
Installation................4204
Operator’s Cab Glass (Stuck Glass)................4206
Removal................4206
Installation................4207
Operator’s Seat Assembly................4215
Disassembly................4216
Assembly................4223
Air Conditioner Unit................4228
Removal................4228
Installation................4233
ELECTRICAL SYSTEM................4234
Monitor Panel................4234
Removal................4234
Installation................4236
Engine Controller Assembly................4237
Removal................4237
Installation................4238
HST Controller Assembly................4239
Removal................4239
Installation................4239
KOMTRAX Terminal Assembly................4240
Removal................4240
Installation................4241
WASTE HANDLER GUARDS................4242
Hydraulic Tank Guard................4242
Removal................4242
Installation................4244
Rear Light Guards................4245
Removal................4245
Installation................4245
Front Light Guards................4246
Removal................4246
Installation................4246
Front Step................4247
Removal................4247
Installation................4247
Axle Seal Guards................4248
Removal................4248
Installation................4248
Boom Cylinder Hose Guards................4249
Removal................4249
Installation................4249
Front Frame Underguard................4250
Removal................4250
Installation................4250
Fuel Tank Guard................4251
Removal................4251
Installation................4252
Rear Frame Underguard................4253
Removal................4253
Installation................4253
WASTE HANDLER SCREENS................4255
Lower Engine Baffle................4255
Removal................4255
Installation................4255
Hood Screen................4256
Removal................4256
Installation................4256
Exhaust Cover................4257
Removal................4257
Installation................4257
90 DIAGRAMS AND SCHEMATICS................4259
AUTOMATIC GREASING CIRCUIT DIAGRAM................4261
HYDRAULIC SYSTEM................4263
HYDRAULIC CIRCUIT DIAGRAM................4263
ELECTRICAL SYSTEM................4264
ELECTRICAL CIRCUIT DIAGRAM (1/9)................4264
ELECTRICAL CIRCUIT DIAGRAM (2/9)................4265
ELECTRICAL CIRCUIT DIAGRAM (3/9)................4266
ELECTRICAL CIRCUIT DIAGRAM (4/9)................4267
ELECTRICAL CIRCUIT DIAGRAM (5/9)................4268
ELECTRICAL CIRCUIT DIAGRAM (6/9)................4269
ELECTRICAL CIRCUIT DIAGRAM (7/9)................4270
ELECTRICAL CIRCUIT DIAGRAM (8/9)................4271
ELECTRICAL CIRCUIT DIAGRAM (9/9)................4272
ELECTRICAL CIRCUIT DIAGRAM (1/3)................4273
ELECTRICAL CIRCUIT DIAGRAM (2/3)................4274
ELECTRICAL CIRCUIT DIAGRAM (3/3)................4275
CEBM022801 - Wheel Loader WA320-6 Shop Manual................4277
CEBM022801 - WA320-6 snA35001 and up................4277
CONTENTS................4278
REVISED PAGES................4279
SAFETY................4291
Safety Notice................4291
IMPORTANT SAFETY NOTICE................4291
General Precautions................4291
Preparations for Work................4292
Precautions During Work................4292
Seat Belt Inspection................4293
GENERAL................4294
HOW TO READ THE SHOP MANUAL................4295
Volumes................4295
Distribution and Updating................4295
Filing Method................4295
Revised Edition Mark................4295
Revisions................4295
Symbols................4295
HOISTING INSTRUCTIONS................4296
Hoisting................4296
Making Signs/Hand Signals................4296
Precautions................4296
Precautions for Sling Work................4296
Precautions for Using Mobile Crane................4297
Precautions for Using Overhead Hoist Crane................4297
Selecting Wire Ropes................4298
AIR CONDITIONER CIRCUITS................4299
Precautions for Handling Hoses and Tubes................4299
Disconnecting Hoses and Tubes................4299
Connecting Hoses and Tubes................4299
MAINTENANCE STANDARD TERMS................4300
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT................4302
Handling Electric Equipment................4302
Handling Wiring Harnesses and Connectors................4302
Main Failures Occurring in Wiring Harness................4302
Removing, Installing, and Drying Connectors and Wiring Harnesses................4303
Handling Controller................4307
Troubleshooting Electric Circuits................4307
Handling Hydraulic Equipment................4308
Handling Connectors Used for Engines................4309
Slide Lock Type................4309
Pull Lock Type................4310
Push Lock Type................4310
Turn-housing Type (Round Green Connector)................4312
PRECAUTIONS FOR OPERATIONS................4313
Precautions when Carrying Out Removal Work................4313
Precautions when Carrying Out Installation Work................4314
Precautions when Completing the Operation................4315
PUSH-PULL COUPLER................4316
Type 1................4316
Disconnection................4316
Connection................4316
Type 2................4317
Disconnection................4317
Connection................4317
Type 3................4318
Disconnection................4318
Connection................4318
COATING MATERIALS................4319
STANDARD TIGHTENING TORQUE................4321
Standard Tightening Tables................4321
For Bolts and Nuts................4321
For Split Flange Bolts................4322
For O-Ring Boss Piping Joints................4322
For O-Ring Boss Plugs................4323
For Hoses (Taper-Seal Type and Face-Seal Type)................4323
For Face Seal Joints................4324
For 102, 107, and 114 Engine Series (Bolts and Nuts)................4324
For 102, 107, and 114 Engine Series (Eye Joints)................4325
For 102, 107, and 114 Engine Series (Taper Screws)................4325
CONVERSION TABLES................4326
Method of Using the Conversion Table................4326
01 GENERAL................4333
SPECIFICATIONS................4334
Dimension Drawing................4334
Specification Tables................4336
WEIGHT TABLE................4342
FUEL, COOLANT, AND LUBRICANTS................4344
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD................4347
ENGINE AND COOLING SYSTEM................4351
Engine and Transfer Mount................4351
Damper................4352
Cooling System................4354
Cooling System Hydraulic Piping Diagram................4355
Cooling Fan Motor................4356
Hydraulic Motor................4360
Suction Safety Valve................4361
Reversible Valve................4363
Flow Control Valve (continuously-variable type)................4364
POWER TRAIN SYSTEM................4365
Drive Line Components................4365
Power Train System Diagram................4366
Drive Shaft................4368
HST Hydraulic Piping Diagram................4369
HST Pump................4370
Operation................4372
High-Pressure Relief Valve................4373
Low-pressure Relief Valve................4375
HST Charge Pump................4376
Speed-Related Valve (DA Valve)................4378
High-Pressure Cutoff Valve................4379
HST Motor................4380
HST Motor 1................4380
HST Motor 2................4382
EP Servo Valve................4384
HA Servo Valve................4385
Directional Shuttle Valve................4386
Transfer................4388
Input Shaft................4392
Output Shaft................4396
Outline................4400
Operation of Clutch................4401
Power Transmitting Route................4402
Clutch Solenoid Valve................4404
DRIVE AXLE SYSTEM................4406
Front and Rear Axles................4406
Front Axle................4406
Rear Axle................4408
Differential................4410
Front Differential................4410
Rear Differential................4414
Torque Proportioning Differential................4418
Limited Slip Differential (if equipped)................4420
Final Drive................4424
Front Final Drive................4424
Rear Final Drive................4426
STEERING SYSTEM................4429
Steering Piping Diagram................4429
Steering Column................4430
Priority Valve................4431
Orbitrol Valve................4435
Operation................4438
Connection of Hand Pump and Sleeve................4442
Cushion Valve................4444
Steering Cylinder................4446
Emergency Steering Piping Diagram (if equipped)................4448
Emergency Steering Valve (if equipped)................4450
Steering Relief Valve (if equipped)................4454
BRAKE SYSTEM................4456
Brake Piping Diagram................4456
Charge Valve................4458
Brake Valve................4462
Braking Operation................4464
Inching Valve................4467
Accumulator (for Brake)................4468
Slack Adjuster................4470
Brakes................4472
Front Brake................4472
Rear Brake................4474
Parking Brake System................4477
Brake Control................4477
Parking Brake................4478
UNDERCARRIAGE AND FRAME................4480
Axle Mounting and Center Hinge Pin................4480
Tires................4485
Radial Tire................4485
Bias Tire................4486
HYDRAULIC SYSTEM................4488
Work Equipment Hydraulic Piping Diagram................4488
Work Equipment Control Lever Linkage................4490
Multi-Function Mono-Lever Type................4490
2-Lever Type (if equipped)................4491
Hydraulic Tank................4492
Breather................4493
4-Gear Pump................4494
Work Equipment Control Valve................4496
2-Spool Type................4496
3-Spool Type................4500
Relief Valve................4504
Safety-Suction Valve................4505
Suction Valve................4506
Operation of Work Equipment Control Valve................4507
Cutoff Valve................4514
PPC Valve................4517
Work Equipment PPC Valve: Mono Lever Type................4517
Work Equipment PPC Valve: 2-Lever Type (if equipped)................4523
Attachment PPC Valve................4530
Lock Valve (for PPC Circuit)................4532
Accumulator (for PPC Circuit)................4533
ECSS Valve................4534
Accumulator (for ECSS)................4537
Work Equipment................4538
Work Equipment Linkage................4538
Bucket................4540
Bucket Positioner and Boom Kickout................4542
Operation of Proximity Switch................4544
Work Equipment Cylinders................4550
Lift Cylinder................4550
Bucket Cylinder................4550
CAB ENVIRONMENT................4551
Cab................4551
Air Conditioner................4552
Air Conditioner Piping Diagram................4552
Refrigerant Circuit Diagram................4554
Air Conditioner Unit................4555
Blower and Intake Unit................4558
Compressor................4560
Condenser................4561
Receiver................4562
Air Conditioner Panel................4564
ELECTRICAL SYSTEM................4568
Machine Monitor System................4568
System Circuit Diagram................4570
Machine Monitor................4572
Items Displayed on Monitor................4573
Machine Monitor Operation Switches................4582
Setting Machine Monitor................4583
Troubleshooting Function................4584
Character Display Function................4584
Operator Mode Functions................4585
Service Mode Functions................4588
Input and Output Signals................4593
Electrical System (HST Controller System)................4601
Input and Output Signals Diagram................4601
HST Controller Gearshifting Control Function................4602
HST Controller Protection Function................4608
Cooling Fan Control Function................4611
System Circuit Diagram................4616
HST Controller................4619
ECSS System................4621
ELECTRONIC TRANSMISSION CONTROL................4623
KOMTRAX Terminal System................4623
KOMTRAX Terminal................4625
Engine Starting Circuit................4627
Engine Stopping Circuit................4629
Preheating Circuit................4630
Engine Output Lowering Function................4631
Automatic Warm-up Function................4631
Parking Brake Circuit................4632
Max. Traction Switch (if equipped)................4634
Multi-Function Knob................4635
Modification of Multi-Function Lever................4636
Sensors................4639
Speed Sensor................4639
HST Oil Temperature Sensor................4641
Brake Oil Temperature Sensor................4641
HST Oil Pressure Sensor................4642
HST Oil Filter Clogging Sensor................4642
Coolant Level Sensor................4643
Fuel Level Sensor................4644
Accelerator Pedal Sensor................4645
Air Cleaner Clogging Sensor................4647
Water-in-Fuel Sensor................4648
Boom Kick-Out Proximity Switch................4649
Bucket Positioner Proximity Switch................4649
20 STANDARD VALUE TABLES................4651
STANDARD VALUE TABLES................4653
Standard Value Table for Engine................4653
Standard Value Table for Chassis................4654
MACHINE POSTURE................4659
30 TESTING AND ADJUSTING................4661
TOOLS................4665
Tools for Testing, Adjusting, and Troubleshooting................4665
ENGINE COMPONENTS................4671
Engine Speed................4671
Measure Engine Speed (Low and High Idle)................4671
Measure HST Stall Speed................4671
Measure Hydraulic Stall Speed................4672
Measure HST Stall and Hydraulic Stall (Full Stall) Speed................4672
Exhaust Gas Color................4673
Using Handy Smoke Checker A1................4673
Using Smoke Meter A2................4673
Adjusting Valve Clearance................4675
Measuring Engine Compression................4677
Measuring Blow-by Pressure................4680
Measuring Engine Oil Pressure................4682
Intake Air (Boost) Pressure................4683
Measuring with Monitoring Function................4683
Measuring with Measuring Tool................4684
FUEL SYSTEM................4685
Handling Fuel System Equipment................4685
Releasing Residual Pressure in Fuel System................4685
Measuring Fuel Pressure................4686
Measuring Pressure in Fuel Low-pressure Circuit................4686
Measuring Pressure in Fuel Return Circuit................4687
Measuring Fuel Negative-Pressure Circuit Pressure................4688
Fuel Delivery, Return, and Leak Rate................4689
Measuring Supply Pump Delivery................4689
Measuring Return Rate from Supply Pump................4691
Measuring Leakage from Pressure Limiter................4692
Measuring Return Rate from Injector................4693
Bleeding Air from Fuel Circuit................4694
Testing Leakage in Fuel System................4695
Handling Reduced Cylinder Mode Operation................4696
Handling No-Injection Cranking Operation................4696
Handling Controller Voltage Circuit................4696
EXHAUST SYSTEM AND PIPING................4697
Checking Muffler and Muffler Stack for Looseness and Damage................4697
Checking Muffler Function................4697
Checking Installed Condition of Cylinder Head and Manifolds................4697
Checking Engine Piping for Damage and Looseness................4697
BELTS................4698
Air Conditioner Compressor Belt................4698
Testing the Tension................4698
Adjusting the Tension................4698
Replacing Alternator Belt................4699
ACCELERATOR PEDAL................4700
Testing Operating Effort................4700
Testing Operating Angle................4701
DIRECTIONAL LEVER................4702
Checking Operating Effort................4702
Checking Travel................4702
POWER TRAIN OIL PRESSURES................4703
HST Oil Pressure................4703
Testing High-Pressure Cutoff Oil Pressure................4703
Testing Low-Pressure Relief Pressure................4704
Testing Servo Piston Control Pressure (DA Pressure)................4705
Testing Servo Piston Actuating Pressure................4706
Adjusting High-Pressure Cutoff Valve................4706
Adjusting Low-Pressure Relief Valve................4707
Adjusting DA Pressure................4708
Testing Clutch Control Pressure................4709
STEERING SYSTEM................4711
Steering Wheel................4711
Measuring Play................4711
Measuring Operating Effort................4712
Measuring Operating Time................4712
Steering Oil Pressure................4713
Measuring Main Relief Pressure................4713
Adjusting Main Relief Pressure................4715
Bleeding Air from Steering Circuit................4716
HYDRAULIC DRIVE FAN................4717
Measuring Fan Speed................4717
Measuring Fan Drive Oil Pressure................4718
WHEEL BRAKE SYSTEM................4719
Measuring Pressing Angle of Brake Pedal................4719
Brake Pedal Linkage................4720
Testing................4720
Adjusting................4720
Measuring Brake Performance................4721
Accumulator Charge................4722
Measuring................4722
Adjusting................4723
Measuring Brake Oil Pressure................4724
Testing Wear of Wheel Brake Disc................4727
Bleeding Air from Brake Circuit................4728
Releasing Residual Pressure in Brake Accumulator Circuit................4729
PARKING BRAKE SYSTEM................4730
Testing Parking Brake Performance................4730
Parking Brake Control Cable................4731
Testing................4731
Adjusting................4731
WORK EQUIPMENT SYSTEM................4732
Work Equipment Control Lever................4732
Measuring Operating Effort................4732
Measuring Travel................4732
Work Equipment Hydraulic Pressure................4733
Measuring................4733
Adjusting................4733
PPC Oil Pressure................4735
Measuring PPC Valve Basic Pressure................4735
Measuring PPC Valve Output Pressure................4736
Bleeding Air from Hydraulic Circuit................4737
Bleeding Air from Work Equipment PPC Circuit................4737
Bleeding Air from Cylinders................4737
Releasing Residual Pressure in Hydraulic Circuit................4738
Between Each Hydraulic Cylinder and Control Valve................4738
In Brake Accumulator Circuit................4738
In PPC Accumulator Circuit................4738
Work Equipment Positioners................4739
Bucket Positioner................4739
Boom Kickout Switch................4740
Proximity Switch Operation Pilot Lamp................4741
ELECTRICAL SYSTEM TROUBLESHOOTING................4742
Procedure for Testing Diodes................4742
When Using Digital Type Circuit Tester................4742
When Using Analog Type Circuit Tester................4743
Preparation for Troubleshooting Electric System................4744
Machine Monitor................4744
HST Controller................4745
KOMTRAX Terminal................4746
Sensors................4747
Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)................4747
Supply Pump IMV Solenoid (FUEL REGULATOR)................4747
Common Rail Pressure Sensor (FUEL RAIL PRESS)................4748
Engine Coolant Temperature Sensor (COOLANT TEMP)................4748
KOMTRAX TERMINAL SYSTEM................4749
Terminal Installed at Plant Before Shipment................4749
Terminal Retrofitted Machine After Shipment................4749
Starting Operation................4749
Application for the Start of Use................4752
Komtrax Terminal Lamps................4753
Contents of 7-Segment and Dot Displays for CPU................4755
MACHINE MONITOR SYSTEM................4756
Adjusting Machine Monitor................4756
Adjusting for Replaced, Reassembled, or Added Sensor/Controller................4757
Adjustment for User’s Needs................4758
Special Functions of Machine Monitor (EMMS)................4759
Normal and Special Functions of Machine Monitor................4760
Functions and Flow of Service Mode................4761
Operator Mode................4764
Service Meter Display Function (1)................4764
Traction Level Selection Function (2)................4764
HST Function Selection Function (3)................4764
Odometer Display Function (4)................4765
Maintenance Monitoring Function (5)................4765
Telephone Number Input Function (6)................4765
Language Selection Function (7)................4765
Monitor Brightness Adjustment Function (8)................4766
Travel Speed/Engine Speed Display Selecting Function (9)................4766
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)................4767
Action Code Display Function (11)................4767
Failure Code Display Function (12)................4768
Service Mode................4769
Switching to Service Mode and Screen Display (1)................4769
Electrical System Fault History Display Function (ELECTRIC FAULT) (2)................4771
Mechanical System Fault History Display Function (MACHINE FAULT) (3)................4773
Real-Time Monitoring Function (REAL-TIME MONITOR) (4)................4774
Real-Time Monitoring Code Tables................4777
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)................4791
No-Injection Cranking Function (6)................4792
Adjustment Function (TUNING) (7)................4793
Maintenance Monitoring Function (8)................4797
Operating Information Display Function (9)................4803
Optional Device Selecting Function (10)................4806
Machine Serial Number Input Function (11)................4810
Model Select Function (MACHINE WA***) (12)................4810
Initialize Function (13)................4811
Setting Procedure for Service Meter and Odometer................4812
PM-CLINIC INSPECTION TABLE................4816
40 TROUBLESHOOTING................4821
POINTS TO REMEMBER WHEN TROUBLESHOOTING................4831
SEQUENCE OF EVENTS IN TROUBLESHOOTING................4833
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................4834
Precautions when Handling Electrical Equipment................4834
Handling Electronic Control Unit................4839
Points to Remember when Troubleshooting Electrical Circuits................4840
Handling Hydraulic Equipment................4841
ELECTRIC WIRE CODE................4843
How to Read Electric Wire Code................4843
Type, Symbol, and Material................4843
Dimensions................4844
Color Codes Table................4845
Types of Circuits and Color Codes................4846
Classification by Thickness................4846
Classification by Color and Code................4847
CHECKS BEFORE TROUBLESHOOTING................4848
Categories and Method of Using Troubleshooting Charts................4849
Troubleshooting Individual Electrical Circuits................4850
Chart Use................4852
Chart Tips................4852
Troubleshooting Individual Hydraulic Circuits................4853
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................4855
X-Type Connectors................4855
SWP-Type Connectors................4857
M-Type Connectors................4859
S-Type Connectors................4861
MIC-Type Connectors................4863
AMP040-Type Connectors................4865
AMP070-Type Connectors................4867
Miscellaneous Types of Connectors................4869
HD30 Series Connectors................4873
DT Series Connectors................4878
DTM Series Connectors................4880
DTHD Series Connectors................4880
DTP Series Connectors................4881
DRC26 Series Connectors................4882
DRC12, 16 Connectors................4884
AMP Connectors for Pump Controller (CH700)................4885
BOSCH Connectors for Engine................4887
SUMITOMO Connectors for Engine................4888
CANNON Connectors for Engine................4889
AMP Connectors for Engine................4890
FRAMATOME Connectors for Engine................4891
PACKARD Connectors for Engine................4893
OT Series Connectors for Engine................4894
T-BRANCH BOX and T-BRANCH ADAPTER TABLE................4895
MODE CHART................4900
INFORMATION CONTAINED IN TESTING PROCEDURES................4903
TROUBLESHOOTING BY FAILURE CODE................4905
Failure Code Table................4905
FUSE BOX AND SLOW-BLOW FUSES................4911
Connection Table of Fuse Box and Slow-Blow Fuses................4911
Fuse Box: FS1................4911
Fuse Box: FS2................4912
Slow-Blow Fuses................4913
FAILURE CODES................4914
2G40ZG................4916
Brake: Oil Pressure Reduction................4916
6091NX................4918
HST Filter: Clogging................4918
989FN1................4919
Travel Speed: Overrun Alarm................4919
AA1ANX................4920
Air Cleaner: Clogging................4920
AB00L6................4922
Alternator R System: Hot Short................4922
AB00MA................4924
Alternator R System: Ground Fault/Disconnection/Low Charge Voltage................4924
B@BAZG................4926
Engine: Oil Pressure Reduction................4926
B@BAZK................4927
Engine Oil: Low Level................4927
B@BCNS................4928
Engine: Overheat................4928
B@BCZK................4930
Engine: Low Coolant Level................4930
B@C6NS................4932
Front Brake: High Oil Temperature................4932
B@CRNS................4933
HST: High Oil Temperature................4933
CA111................4934
Abnormality in Engine Controller................4934
CA115................4935
Engine Ne or Bkup Speed Sensor Error................4935
CA122................4936
Charge Pressure Sensor High Error................4936
CA123................4938
Charge Pressure Sensor Low Error................4938
CA131................4940
Throttle Sensor High Error................4940
CA132................4942
Throttle Sensor Low Error................4942
CA144................4944
Coolant Sensor High Error................4944
CA145................4946
Coolant Sensor Low Error................4946
CA153................4948
Charge Temperature Sensor High Error................4948
CA154................4950
Charge Temperature Sensor Low Error................4950
CA155................4952
Lowering of Speed by Abnormally High Charge Temperature................4952
CA187................4954
Sensor Power Supply 2 Low Error................4954
CA221................4956
Atmospheric Pressure Sensor High Error................4956
CA222................4958
Atmospheric Sensor Low Error................4958
CA227................4960
Sensor Power Supply 2 High Error................4960
CA234................4962
Engine Overspeed................4962
CA238................4963
Ne Speed Sensor Power Supply Error................4963
CA271................4964
IMV (IMA) Short Circuit................4964
CA272................4966
IMV (IMA) Disconnection................4966
CA322................4968
Injector #1 Open/Short Error................4968
CA323................4970
Injector #5 Open/Short Error................4970
CA324................4972
Injector #3 Open/Short Error................4972
CA325................4974
Injector #6 Open/Short Error................4974
CA331................4976
Injector #2 Open/Short Error................4976
CA332................4978
Injector #4 Open/Short Error................4978
CA342................4980
Calibration Code Inconsistency................4980
CA351................4982
Injectors Drive Circuit Error................4982
CA352................4984
Sensor Power Supply 1 Low Error................4984
CA386................4986
Sensor Power Supply 1 High Error................4986
CA428................4988
Abnormally High Level in Water Sensor................4988
CA429................4990
Abnormally Low Level in Water Sensor................4990
CA431................4992
Idle Validation Switch Error................4992
CA432................4996
Idle Validation Action Error................4996
CA435................5000
Engine Oil Pressure Switch Error................5000
CA441................5002
Battery Voltage Low Error................5002
CA442................5006
Battery Voltage High Error................5006
CA449................5008
Common Rail Pressure High Error 2................5008
CA451................5010
Common Rail Pressure Sensor High Error................5010
CA452................5012
Common Rail Pressure Sensor Low Error................5012
CA488................5014
Lowering of Torque by Abnormally High Charge Temperature................5014
CA553................5015
Common Rail Pressure High Error 1................5015
CA559................5016
Supply Pump Pressure Very Low Error................5016
CA689................5018
Engine Ne Speed Sensor Error................5018
CA731................5020
Engine Bkup Speed Sensor Phase Error................5020
CA757................5021
All Continuous Data Lost Error................5021
CA778................5024
Engine Bkup Speed Sensor Error................5024
CA1633................5026
KOMNET Datalink Timeout Error................5026
CA2185................5030
Throttle Sensor Supply Voltage High Error................5030
CA2186................5032
Throttle Sensor Power Supply Low Error................5032
CA2249................5034
Supply Pump Pressure Very Low Error 2................5034
CA2311................5036
Abnormality in IMV (IMA) Solenoid................5036
CA2555................5038
Intake Heater Relay Disconnection Error................5038
CA2556................5040
Intake Heater Relay Short Circuit Error................5040
D160KY................5042
Backup Alarm/Lamp Relay 1 Circuit: Hot Short................5042
D192KY................5044
ECSS Solenoid Relay: Hot Short................5044
D1B0KA................5046
HST Safety Relay: Disconnection................5046
D1B0KB................5048
HST Safety Relay: Ground Fault................5048
D1B0KY................5050
HST Safety Relay: Hot Short................5050
D5ZHL6................5052
IGN C System: Ground Fault/Disconnection................5052
DAF3KK................5054
UNSW Power Supply: Ground Fault/Disconnection................5054
DAFRKR................5056
Machine Monitor CAN-NET Signal: Disconnection................5056
DAJ0KK................5058
HST Controller Power Supply: Low Voltage................5058
DAJ0KT................5060
HST Controller Memory (EEPROM): Abnormality................5060
DAJ1L4................5062
HST Controller Main Power Line: Disconnection/Ground Fault................5062
DAJ1L6................5064
HST Controller Main Power Line: Hot Short................5064
DAJ2KK................5066
Controller Solenoid Power Supply: Low Voltage................5066
DAJ2L3................5068
HST Controller Load Power Supply Holding Line: Hot Short in Wiring Harness................5068
DAJ2L4................5070
HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault................5070
DAJ5KX................5072
Sensor 5V Power Supply: Out-of-Output Range................5072
DAJ9KQ................5074
HST Controller Model Selection: Disagreement of Model Selection Signals................5074
DAJRKR................5076
HST Controller CAN-NET Signal: Disconnection................5076
DAJRMA................5081
HST Controller: Disagreement in Option Selection................5081
DB2RKR................5082
Engine Controller CAN-NET: Disconnection in Signal Line................5082
DD1NL4................5088
Fan Automatic Reverse Switch Signal: Abnormality................5088
DD1NLD................5090
Fan Reverse Switch Signal: Abnormality................5090
DDB6KA................5092
Parking Brake Reminder Signal: Disconnection/Short Circuit................5092
DDB6KB................5094
Parking Brake Indicator Signal: Ground Fault................5094
DDB6KZ................5096
Parking Brake Switch or Parking Brake Reminder Switch: Trouble................5096
DDB6L0................5098
Parking Brake Reminder Signal: Ground Fault................5098
DDB6L4................5100
Parking Brake Indicator Signal: Disconnection/Hot Short................5100
DDD7KX................5102
Travel Speed Control Dial Signal: Disconnection/Ground Fault................5102
DDD7KY................5104
Travel Speed Control Dial Signal: Hot Short................5104
DDE5MA................5106
Emergency Steering Operation Switch: Disconnection................5106
DDK3KA................5108
Directional Selector Switch: Disconnection/Hot Short................5108
DDK3KB................5110
Directional Selector Switch: Ground Fault................5110
DDK6KA................5112
FNR Lever: Disconnection/Ground Fault................5112
DDK6KY................5116
FNR Lever: Hot Short................5116
DDS5L6................5118
Steering: Low Oil Pressure (Operation of Emergency Steering)................5118
DF10KA................5120
Travel Speed Range Selector Switch: Disconnection/Ground Fault................5120
DF10KB................5124
Travel Speed Range Selector Switch: Hot Short................5124
DGH1KX................5126
HST Oil Temperature Sensor: Ground Fault................5126
DGR2KB................5128
Brake Oil Temperature Sensor: Ground Fault................5128
DGR2KZ................5130
Brake Oil Temperature Sensor: Disconnection/Hot Short................5130
DHH1KX................5132
HST Oil Pressure Sensor: Disconnection/Ground Fault................5132
DHH1KY................5134
HST Oil Pressure Sensor: Hot Short................5134
DHTCL6................5136
HST Filter Clogging Sensor: Functional Defect................5136
DJF1KA................5138
Fuel Level Sensor: Disconnection/Hot Short................5138
DLT3KX................5140
Travel Speed Sensor B: Abnormality................5140
DLT4KX................5144
Travel Speed Sensor A: Abnormality................5144
DLT4LC................5146
Travel Speed Sensor A & B: Abnormality................5146
DV00KY................5148
Alarm Buzzer: Hot Short................5148
DW26KA................5150
Motor 2 Solenoid: Disconnection/Ground Fault................5150
DW26KY................5152
Motor 2 Solenoid: Hot Short................5152
DW7BKY................5154
Fan Reverse Solenoid Circuit: Hot Short................5154
DW7BKZ................5156
Fan Reverse Solenoid Circuit: Disconnection/Ground Fault................5156
DX16KA................5158
Fan EPC Solenoid: Disconnection................5158
DX16KB................5160
Fan EPC Solenoid: Ground Fault................5160
DX16KY................5162
Fan EPC Solenoid: Hot Short................5162
DX19KA................5164
Motor 1 Solenoid: Disconnection................5164
DX19KB................5166
Motor 1 Solenoid: Ground Fault................5166
DX19KY................5168
Motor 1 Solenoid: Hot Short................5168
DX20KA................5170
Clutch EPC Solenoid: Disconnection................5170
DX20KB................5172
Clutch EPC Solenoid: Ground Fault................5172
DX20KY................5174
Clutch EPC Solenoid: Hot Short................5174
DXH7KB................5176
Reverse Solenoid: Ground Fault................5176
DXH7KZ................5178
Reverse Solenoid: Disconnection/Hot Short................5178
DXH8KB................5180
Forward Solenoid: Ground Fault................5180
DXH8KZ................5182
Forward Solenoid: Disconnection/Hot Short................5182
J141N1................5184
Steering Pump: Overrun Alarm................5184
M100N1................5185
HST Pump: Overrun Alarm................5185
M400N1................5186
Motor 1: Overrun Alarm................5186
TROUBLESHOOTING: E-MODE................5188
Troubleshooting Electrical System................5188
Information in Troubleshooting Table................5188
E-1................5190
Engine Does Not Start................5190
E-2................5198
Preheater Does Not Operate Manually................5198
E-3................5202
Travel Speed is Low or High................5202
E-4................5208
ECSS Does Not Operate................5208
E-5................5211
ECSS Keeps Operating................5211
E-6................5214
Defective Boom Kickout Function and Cancellation................5214
E-7................5218
Defective Bucket Positioner Function and Cancellation................5218
E-8................5222
Defective Lift Arm FLOATING Holding Function and Cancellation................5222
E-9................5226
Travel Direction Selection System Does Not Function................5226
E-10................5230
Fan Does Not Reverse................5230
E-11................5234
Fan Keeps Rotating in Reverse................5234
E-12................5236
Wiper Does Not Operate................5236
E-13................5240
Windshield Washer Does Not Operate................5240
E-14................5243
Headlamp, Clearance Lamp, and Tail Lamp Do Not Light Up or Go Off................5243
E-15................5251
Working Lamp Does Not Light Up or Go Off................5251
E-16................5256
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off................5256
E-17................5262
Brake Lamp Does Not Light or It Keeps Lighting Up................5262
E-18................5264
Backup Lamp Does Not Light or It Keeps Lighting Up................5264
E-19................5267
Backup Alarm Does Not Sound or It Keeps Sounding................5267
E-20................5270
Horn Does Not Sound or It Keeps Sounding................5270
E-21................5272
Alarm Buzzer Does Not Sound or It Keeps Sounding................5272
E-22................5274
Air Conditioner Does Not Operate or Stop................5274
E-23................5277
The KOMTRAX System Does Not Work Properly................5277
Lamp Display Section of KOMTRAX Terminal................5279
TROUBLESHOOTING: H-MODE................5280
Table of Failure Codes and Causes................5282
Troubleshooting Hydraulic and Mechanical Systems................5280
Method of Using Troubleshooting Chart................5280
H-1................5284
Machine Does Not Start................5284
H-2................5285
Travel Speed Is Slow................5285
H-3................5286
Traction Force Is Weak................5286
H-4................5287
Engine Stalls When Traveling or Engine Speed Drops Excessively................5287
H-5................5288
Shift Range is Not Shifted................5288
H-6................5289
Steering Wheel Does Not Turn................5289
H-7................5290
Steering Wheel Is Heavy................5290
H-8................5291
Steering Wheel Shakes or Jerks................5291
H-9................5292
Machine Deviates Naturally to One Side When Traveling................5292
H-10................5293
Brake Does Not Work or Does Not Work Well................5293
H-11................5294
Brake Is Not Released or Is Dragged................5294
H-12................5295
Lift Arm Does Not Rise or Lower................5295
H-13................5296
Lift Arm Moves Slowly or Lift Arm Rising Force Is Insufficient................5296
H-14................5297
When Rising, Lift Arm Starts to Move Slowly at a Specific Height................5297
H-15................5297
Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Rises in the Air)................5297
H-16................5297
Hydraulic Drifts of the Lift Arm Occur Often................5297
H-17................5298
Lift Arm Wobbles During Operation................5298
H-18................5298
When Control Lever Is Switched from HOLD to RAISE, Lift Arm Falls Temporarily................5298
H-19................5299
Bucket Does Not Tilt Back................5299
H-20................5300
Bucket Moves Slowly or Tilting-Back Force Is Insufficient................5300
H-21................5301
Bucket Starts to Operate Slowly in the Midst of Tilting Back................5301
H-22................5301
Bucket Cylinder Cannot Hold Down the Bucket................5301
H-23................5301
Hydraulic Drifts of the Bucket Occur Often................5301
H-24................5302
Bucket Wobbles During Travel with Load................5302
H-25................5302
When Control Lever Is Switched from HOLD to TILT, the Bucket Falls Temporarily................5302
H-26................5303
Control Levers of Lift Arm and Bucket Do Not Move Smoothly and Are Heavy................5303
H-27................5304
ECSS Does Not Operate and Machine Pitches and Bounces................5304
H-28................5305
Fan Revolution Is Abnormal................5305
50 DISASSEMBLY AND ASSEMBLY................5307
HOW TO READ THIS MANUAL................5311
Removal and Installation of Assemblies................5311
Disassembly and Assembly of Assemblies................5313
COATING MATERIALS LIST................5315
SPECIAL TOOLS LIST................5319
SKETCHES OF SPECIAL TOOLS................5323
CONNECTOR REPAIR PROCEDURES................5330
Stripping Insulation................5330
Wire Inspection................5330
Contact Terminal Removal (HD30 Type)................5331
Crimping Contact Terminal (HD30 Type)................5332
Insertion Of Contact Terminal (HD30 Type)................5333
Contact Terminal Removal (DT Type)................5334
Crimping Contact Terminal (DT Type)................5335
Insertion Of Contact Terminal (DT Type)................5336
ENGINE AND COOLING SYSTEM................5337
Fuel Supply Pump Assembly................5337
Removal................5337
Installation................5339
Fuel Injector Assembly................5340
Removal................5340
Installation................5345
Cylinder Head Assembly................5349
Removal................5349
Installation................5358
Engine Hood Assembly................5364
Removal................5364
Installation................5367
Radiator................5368
Removal................5368
Installation................5371
Air Aftercooler................5372
Removal................5372
Installation................5373
Hydraulic Oil Cooler Assembly................5374
Removal................5374
Installation................5376
Engine Assembly................5377
Removal................5377
Installation................5383
Engine Front Oil Seal Assembly................5385
Removal................5385
Installation................5387
Engine Rear Oil Seal Assembly................5388
Removal................5388
Installation................5390
Cooling Fan and Fan Motor Assembly................5393
Removal................5393
Installation................5396
Fuel Tank Assembly................5397
Removal................5397
Installation................5399
POWER TRAIN................5400
Transfer................5400
Removal................5400
Installation................5403
Transfer Assembly................5405
Disassembly................5406
Assembly................5417
Parking Brake Assembly................5430
Removal................5430
Installation................5431
Disassembly................5432
Assembly................5435
Front Axle Assembly................5439
Removal................5439
Installation................5441
Rear Axle Assembly................5442
Removal................5442
Installation................5445
Axle Housing Assembly................5446
Disassembly................5447
Assembly................5453
Differential Assembly................5462
Disassembly................5463
Assembly................5475
UNDERCARRIAGE AND FRAME................5493
Center Hinge Pin................5493
Removal................5493
Installation................5500
Counterweight................5506
Removal................5506
Installation................5507
HYDRAULIC SYSTEM................5508
HST Pump and 4-Gear Pump Assembly................5508
Removal................5508
Installation................5511
HST Pump Assembly................5513
Disassembly................5513
Assembly................5526
HST Motor 1 Assembly................5546
Removal................5546
Installation................5547
HST Motor 2 Assembly................5548
Removal................5548
Installation................5549
HST Motor Assembly................5550
Disassembly................5550
Assembly................5562
Work Equipment Control Valve Assembly................5572
Removal................5572
Installation................5574
Hydraulic Tank Assembly................5575
Removal................5575
Installation................5577
Hydraulic Cylinder Assembly................5578
Disassembly................5579
Assembly................5582
WORK EQUIPMENT................5586
Work Equipment Assembly................5586
Removal................5586
Installation................5590
CAB AND ITS ATTACHMENTS................5595
Operator’s Cab and Floor Frame Assembly................5595
Removal................5595
Installation................5600
Operator’s Cab Glass (Stuck Glass)................5602
Removal................5602
Installation................5603
Operator’s Seat Assembly................5611
Disassembly................5612
Assembly................5619
Air Conditioner Unit................5624
Removal................5624
Installation................5629
ELECTRICAL SYSTEM................5630
Monitor Panel................5630
Removal................5630
Installation................5632
Engine Controller Assembly................5633
Removal................5633
Installation................5634
HST Controller Assembly................5635
Removal................5635
Installation................5635
KOMTRAX Terminal Assembly................5636
Removal................5636
Installation................5637
WASTE HANDLER GUARDS................5638
Hydraulic Tank Guard................5638
Removal................5638
Installation................5640
Rear Light Guards................5641
Removal................5641
Installation................5641
Front Light Guards................5642
Removal................5642
Installation................5642
Front Step................5643
Removal................5643
Installation................5643
Axle Seal Guards................5644
Removal................5644
Installation................5644
Boom Cylinder Hose Guards................5645
Removal................5645
Installation................5645
Front Frame Underguard................5646
Removal................5646
Installation................5646
Fuel Tank Guard................5647
Removal................5647
Installation................5648
Rear Frame Underguard................5649
Removal................5649
Installation................5649
WASTE HANDLER SCREENS................5651
Lower Engine Baffle................5651
Removal................5651
Installation................5651
Hood Screen................5652
Removal................5652
Installation................5652
Exhaust Cover................5653
Removal................5653
Installation................5653
90 DIAGRAMS AND SCHEMATICS................5655
AUTOMATIC GREASING CIRCUIT DIAGRAM................5657
HYDRAULIC CIRCUIT DIAGRAM................5659
ELECTRICAL CIRCUIT DIAGRAM (1/9)................5660
ELECTRICAL CIRCUIT DIAGRAM (2/9)................5661
ELECTRICAL CIRCUIT DIAGRAM (3/9)................5662
ELECTRICAL CIRCUIT DIAGRAM (4/9)................5663
ELECTRICAL CIRCUIT DIAGRAM (5/9)................5664
ELECTRICAL CIRCUIT DIAGRAM (6/9)................5665
ELECTRICAL CIRCUIT DIAGRAM (7/9)................5666
ELECTRICAL CIRCUIT DIAGRAM (8/9)................5667
ELECTRICAL CIRCUIT DIAGRAM (9/9)................5668
ELECTRICAL CIRCUIT DIAGRAM (1/3)................5669
ELECTRICAL CIRCUIT DIAGRAM (2/3)................5670
ELECTRICAL CIRCUIT DIAGRAM (3/3)................5671
CONNECTOR LIST AND STEREOGRAM................5672
CEBM027700 - Wheel Loader WA320-7 Shop Manual................5673
00 Index and foreword ................5675
Index ................5676
Foreword, safety and general information ................5691
Important safety notice ................5691
How to read the shop manual ................5698
Explanation of terms for maintenance standard ................5700
Handling equipment of fuel system devices ................5702
Handling of intake system parts ................5703
Handling of hydraulic equipment ................5704
Method of disconnecting and connecting of push-pull type coupler ................5706
Handling of electrical equipment ................5709
How to read electric wire code ................5717
Precautions when performing operation ................5720
Practical use of KOMTRAX ................5725
Standard tightening torque table ................5726
List of abbreviation ................5732
Conversion table ................5737
01 Specification ................5743
Table of contents ................5744
Specifications ................5745
Specification drawing ................5745
Specifications ................5747
Weight table ................5752
Table of fuel, coolant, and lubricants ................5754
10 Structure and function ................5755
Table of contents ................5756
Engine and cooling system ................5758
Engine related parts ................5758
KVGT ................5760
EGR system piping drawing ................5767
EGR system circuit diagram ................5769
EGR valve ................5771
EGR cooler ................5773
KCCV layout drawing ................5774
KCCV ventilator ................5776
KDPF ................5778
Cooling system ................5782
Cooling fan motor ................5784
Power train ................5794
Power train system ................5794
Layout of power train parts ................5796
Damper ................5797
HST pump ................5798
HST motor1 ................5811
HST motor2 ................5813
Transfer ................5818
Clutch solenoid valve ................5825
Drive shaft ................5827
Axle ................5828
Differential ................5830
Torque proportional differential ................5834
Limited slip differential ................5836
Final drive ................5841
Steering system ................5843
Layout of steering devices ................5843
Steering column ................5844
Priority valve ................5845
Cushion valve ................5849
Emergency steering valve ................5850
Orbitrol valve ................5853
Brake system ................5859
Layout of brake parts ................5859
Brake accumulator charge valve ................5861
Brake valve ................5866
Brake accumulator ................5870
Slack adjuster ................5871
Brake ................5873
Parking brake control ................5876
Parking brake ................5877
Parking brake solenoid valve ................5878
Undercarriage and frame ................5880
Axle mount ................5880
Center hinge pin ................5882
Tire ................5883
Hydraulic system ................5885
Hydraulic component layout ................5885
Work equipment control ................5887
Hydraulic tank ................5888
Double type gear pump ................5891
Steering and work equipment pump ................5892
Control valve ................5904
CLSS ................5914
Hydraulic circuit diagram and names of valves ................5918
Self-pressure reducing valve ................5931
Work equipment PPC valve ................5936
Work equipment lock solenoid valve ................5944
PPC circuit accumulator ................5945
ECSS accumulator ................5946
Work equipment ................5947
Work equipment linkage ................5947
Bucket ................5948
Cab and its attachments ................5949
ROPS cab ................5949
Cab mount ................5951
Electrical system ................5952
Engine control system ................5952
Preheating system ................5955
Engine output limit function ................5957
Automatic warm-up function ................5958
Parking brake control system ................5959
System operating lamp function ................5963
Battery disconnect switch function ................5964
HST controller system ................5966
Machine monitor system ................6006
Rearview monitor system ................6027
KOMTRAX system ................6030
System component parts ................6033
Sensor ................6056
20 Standard value tables ................6077
Table of contents ................6078
Standard service value table ................6079
Standard value table for engine ................6079
Standard value table for machine ................6081
Standard value table for electrical system ................6093
30 Testing and adjusting ................6103
Table of contents ................6104
General information on testing and adjusting ................6106
Tools for testing and adjusting ................6106
Sketch of tools for testing and adjusting ................6112
Engine and cooling system ................6113
Testing engine speed ................6113
Testing boost pressure ................6114
Testing exhaust gas temperature ................6116
Testing exhaust gas color ................6117
Testing and adjusting valve clearance ................6119
Testing compression pressure ................6122
Testing blowby pressure ................6126
Testing engine oil pressure ................6127
Testing EGR valve and KVGT driving oil pressure ................6128
Testing fuel pressure ................6129
Testing fuel discharge, return and leakage ................6134
Bleeding air from fuel system ................6139
Testing fuel circuit for leakage ................6141
Handling cylinder cutout mode operation ................6142
Handling no-injection cranking operation ................6143
Testing of KDPF and muffler stack for looseness and damage ................6144
Testing of installed condition of cylinder heads and manifolds ................6145
Testing engine piping for damage and looseness ................6146
Testing and adjusting air conditioner compressor belt tension ................6147
Replacing alternator belt ................6148
Power train ................6149
Testing oil leakage from axle final drive ................6149
Testing drive shaft for looseness, backlash, and damage ................6150
Testing accelerator pedal ................6151
Testing and adjusting HST oil pressure ................6152
Testing transfer clutch control pressure ................6155
Steering system ................6156
Testing directional lever ................6156
Testing steering wheel ................6157
Testing work equipment control lever ................6159
Testing and adjusting steering circuit oil pressure ................6161
Bleeding air from steering cylinder circuit ................6163
Brake system ................6164
Testing brake pedal ................6164
Testing braking performance ................6165
Testing and adjusting of accumulator charge pressure ................6166
Testing wheel brake oil pressure ................6168
Testing lowering of wheel brake pressure ................6169
Testing wear of wheel brake disc ................6171
Bleeding air from wheel brake circuit ................6172
Releasing remaining pressure in brake accumulator circuit ................6173
Testing parking brake performance ................6174
Testing wear of parking brake disc ................6175
Testing parking brake release pressure ................6176
Method of releasing parking brake manually ................6177
Hydraulic system ................6178
Testing fan speed ................6178
Testing fan circuit oil pressure ................6179
Bleeding air from hydraulic fan circuit ................6181
Testing and adjusting work equipment PPC oil pressure ................6182
Testing and adjusting work equipment oil pressure ................6184
Bleeding air from work equipment circuit ................6188
Releasing remaining pressure from work equipment circuit ................6189
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ................6191
Work equipment ................6195
Testing and adjusting bucket positioner and bucket proximity switch ................6195
Testing and adjusting boom position detection lever ................6197
Electrical system ................6198
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................6198
Special functions of machine monitor ................6199
Angle adjustment of rear view camera ................6277
Handling voltage circuit of engine controller ................6278
Handling battery disconnect switch ................6279
Testing diodes ................6280
Pm clinic ................6281
Pm Clinic service ................6281
Check sheet ................6282
40 Troubleshooting ................6287
Table of contents ................6288
General information on troubleshooting ................6297
Troubleshooting points ................6297
Sequence of events in troubleshooting ................6299
Checks before troubleshooting ................6301
Inspection procedure before troubleshooting ................6303
Preparation for troubleshooting of electrical system ................6320
Classification and procedures for troubleshooting ................6326
Symptom and troubleshooting numbers ................6329
Information in troubleshooting table ................6332
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ................6334
Connector list and layout ................6337
Connector contact identification ................6351
T-branch box and T-branch adapter table ................6389
Fuse location table ................6394
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................6397
Precautions when performing troubleshooting of machine monitor ................6400
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ................6402
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................6407
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ................6408
Failure codes table ................6409
Troubleshooting by failure code (Display of code) ................6421
Failure code [2F00MA] Failure of Parking Brake Circuit ................6421
Failure code [2F00MB] Malfunction of Parking Brake ................6424
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ................6426
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................6428
Failure code [6091NX] HST Oil Filter Clogging ................6430
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ................6432
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. ................6434
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ................6436
Failure code [879AKA] A/C Inner Sensor Open Circuit ................6438
Failure code [879AKB] A/C Inner Sensor Short Circuit ................6439
Failure code [879BKA] A/C Outer Sensor Open Circuit ................6440
Failure code [879BKB] A/C Outer Sensor Short Circuit ................6441
Failure code [879CKA] Ventilating Sensor Open Circuit ................6442
Failure code [879CKB] Ventilating Sensor Short Circuit ................6443
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................6444
Failure code [879EMC] Ventilation Damper Abnormality ................6445
Failure code [879FMC] Air Mix Damper Abnormality ................6446
Failure code [989L00] Engine Controller Lock Caution 1 ................6447
Failure code [989M00] Engine Controller Lock Caution 2 ................6448
Failure code [989N00] Engine Controller Lock Caution 3 ................6449
Failure code [A1U0N3] HC Desorb Request 1 ................6450
Failure code [A1U0N4] HC Desorb Request 2 ................6452
Failure code [AA10NX] Air Cleaner Clogging ................6454
Failure code [B@BAZG] Eng Oil Press Low ................6456
Failure code [B@BAZK] Engine Oil Level Low ................6457
Failure code [B@BCNS] Eng Water Overheat ................6459
Failure code [B@BCZK] Eng Water Level Low ................6460
Failure code [B@CRNS] HST Oil Temp. Overheat ................6462
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................6463
Failure code [CA122] Chg Air Press Sensor High Error ................6464
Failure code [CA123] Chg Air Press Sensor Low Error ................6466
Failure code [CA131] Throttle Sensor High Error ................6468
Failure code [CA132] Throttle Sensor Low Error ................6470
Failure code [CA144] Coolant Temp Sens High Error ................6472
Failure code [CA145] Coolant Temp Sens Low Error ................6474
Failure code [CA153] Chg Air Temp Sensor High Error ................6476
Failure code [CA154] Chg Air Temp Sensor Low Error ................6478
Failure code [CA187] Sensor 2 Supply Volt Low Error ................6480
Failure code [CA221] Ambient Press Sensor High Error ................6482
Failure code [CA222] Ambient Press Sensor Low Error ................6484
Failure code [CA227] Sensor 2 Supply Volt High Error ................6486
Failure code [CA234] Eng Overspeed ................6487
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................6488
Failure code [CA239] Ne Speed Sens Supply Volt High Error ................6489
Failure code [CA271] IMV/PCV1 Short Error ................6490
Failure code [CA272] IMV/PCV1 Open Error ................6492
Failure code [CA295] Ambient Press Sens In Range Error ................6494
Failure code [CA322] Inj #1(L#1) Open/Short Error ................6495
Failure code [CA323] Inj #5(L#5) Open/Short Error ................6497
Failure code [CA324] Inj #3(L#3) Open/Short Error ................6499
Failure code [CA325] Inj #6(L#6) Open/Short Error ................6501
Failure code [CA331] Inj #2(L#2) Open/Short Error ................6503
Failure code [CA332] Inj #4(L#4) Open/Short Error ................6505
Failure code [CA343] ECM Critical Internal Failure ................6507
Failure code [CA351] Injectors Drive Circuit Error ................6508
Failure code [CA352] Sensor 1 Supply Volt Low Error ................6509
Failure code [CA356] Mass Air Flow Sensor High Error ................6511
Failure code [CA357] Mass Air Flow Sensor Low Error ................6513
Failure code [CA386] Sensor 1 Supply Volt High Error ................6515
Failure code [CA428] Water in Fuel Sensor High Error ................6516
Failure code [CA429] Water in Fuel Sensor Low Error ................6518
Failure code [CA431] Idle Validation Sw Error ................6520
Failure code [CA432] Idle Validation Process Error ................6523
Failure code [CA435] Eng Oil Press Sw Error ................6526
Failure code [CA441] Battery Voltage Low Error ................6527
Failure code [CA442] Battery Voltage High Error ................6529
Failure code [CA449] Rail Press Very High Error ................6530
Failure code [CA451] Rail Press Sensor High Error ................6531
Failure code [CA452] Rail Press Sensor Low Error ................6533
Failure code [CA488] Chg Air Temp High Torque Derate ................6535
Failure code [CA515] Rail Press Sens Sup Volt High Error ................6536
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................6538
Failure code [CA553] Rail Press High Error ................6540
Failure code [CA555] Crankcase Press High Error 1 ................6541
Failure code [CA556] Crankcase Press High Error 2 ................6542
Failure code [CA559] Rail Press Low Error ................6543
Failure code [CA595] Turbo Speed High Error 2 ................6545
Failure code [CA687] Turbo Speed Low Error ................6546
Failure code [CA689] Eng Ne Speed Sensor Error ................6548
Failure code [CA691] Intake Air Temp Sens High Error ................6550
Failure code [CA692] Intake Air Temp Sens Low Error ................6552
Failure code [CA697] ECM Internal Temp Sensor High Error ................6554
Failure code [CA698] ECM Int Temp Sensor Low Error ................6555
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................6556
Failure code [CA778] Eng Bkup Speed Sensor Error ................6558
Failure code [CA1117] Persistent Data Lost Error ................6563
Failure code [CA1664] KDOC Malfunction ................6564
Failure code [CA1691] Regeneration Ineffective ................6567
Failure code [CA1695] Sensor 5 Supply Volt High Error ................6570
Failure code [CA1696] Sensor 5 Supply Volt Low Error ................6571
Failure code [CA1843] Crankcase Press Sens High Error ................6573
Failure code [CA1844] Crankcase Press Sens Low Error ................6575
Failure code [CA1879] KDPF Delta P Sensor High Error ................6577
Failure code [CA1881] KDPF Delta P Sensor Low Error ................6579
Failure code [CA1883] KDPF Delta P Sens In Range Error ................6581
Failure code [CA1921] KDPF Soot Load High Error 1 ................6585
Failure code [CA1922] KDPF Soot Load High Error 2 ................6588
Failure code [CA1942] Crankcase Press Sens In Range Error ................6593
Failure code [CA1993] KDPF Delta Pressure Low Error ................6594
Failure code [CA2185] Throt Sensor Sup Volt High Error ................6597
Failure code [CA2186] Throt Sensor Sup Volt Low Error ................6599
Failure code [CA2249] Rail Press Very Low Error ................6601
Failure code [CA2271] EGR Valve Pos Sens High Error ................6602
Failure code [CA2272] EGR Valve Pos Sens Low Error ................6604
Failure code [CA2288] Turbo Speed High Error 1 ................6607
Failure code [CA2311] IMV Solenoid Error ................6608
Failure code [CA2349] EGR Valve Solenoid Open Error ................6609
Failure code [CA2353] EGR Valve Solenoid Short Error ................6611
Failure code [CA2357] EGR Valve Servo Error ................6613
Failure code [CA2373] Exhaust Manifold Press Sens High error ................6614
Failure code [CA2374] Exhaust Manifold Press Sens Low error ................6616
Failure code [CA2375] EGR Orifice Temp Sens High Error ................6618
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................6620
Failure code [CA2381] KVGT Pos Sens High Error ................6622
Failure code [CA2382] KVGT Pos Sens Low Error ................6624
Failure code [CA2383] KVGT Solenoid Open Error ................6627
Failure code [CA2386] KVGT Solenoid Short Error ................6629
Failure code [CA2387] KVGT Servo Error ................6631
Failure code [CA2554] Exh Manifold Press Sens In Range Error ................6632
Failure code [CA2555] Grid Htr Relay Volt Low Error ................6633
Failure code [CA2556] Grid Htr Relay Volt High Error ................6635
Failure code [CA2637] KDOC Face Plugging ................6637
Failure code [CA2639] Manual Stationary Regeneration Request ................6639
Failure code [CA2961] EGR Orifice Temp High Error 1 ................6642
Failure code [CA2973] Chg Air Press Sensor In Range Error ................6643
Failure code [CA3133] KDPF Outlet Press Sens High Error ................6644
Failure code [CA3134] KDPF Outlet Press Sens Low Error ................6646
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ................6648
Failure code [CA3251] KDOC Inlet Temp High Error ................6652
Failure code [CA3253] KDOC Temp Error - Non Regeneration ................6655
Failure code [CA3254] KDOC Outlet Temp High Error 1 ................6658
Failure code [CA3255] KDPF Temp Error - Non Regeneration ................6661
Failure code [CA3256] KDPF Outlet Temp High Error 1 ................6664
Failure code [CA3311] KDOC Outlet Temp High Error 2 ................6667
Failure code [CA3312] KDPF Outlet Temp High Error 2 ................6670
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................6673
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................6676
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................6679
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................6683
Failure code [CA3317] KDOC Outlet Temp Sens High Error ................6686
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ................6689
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................6693
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ................6696
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ................6699
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ................6703
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ................6705
Failure code [CA3741] Rail Press Valve Trip Error ................6707
Failure code [D110L4] Disconnection of Battery Relay Signal ................6708
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................6710
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ................6712
Failure code [D191KA] Disconnection of Neutral Output Relay ................6714
Failure code [D191KB] Ground Fault of Neutral Output Relay ................6716
Failure code [D191KY] Hot Short of Neutral Output Relay ................6718
Failure code [D192KA] Disconnection of ECSS Solenoid ................6720
Failure code [D192KB] Ground Fault of ECSS Solenoid ................6722
Failure code [D192KY] Hot Short of ECSS Solenoid ................6723
Failure code [D19JKZ] Personal Code Relay Abnormality ................6724
Failure code [D1B0KA] Disconnection of HST Safety Relay ................6726
Failure code [D1B0KB] Ground Fault of HST Safety Relay ................6728
Failure code [D1B0KY] Hot Short of HST Safety Relay ................6730
Failure code [D1B0MC] Malfunction of HST Safety Relay ................6732
Failure code [D1E6KA] Disconnection of Parking Brake Relay ................6733
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................6735
Failure code [D1E6KY] Hot Short of Parking Brake Relay ................6737
Failure code [D5ZHKA] Failure of Key SW C Signal ................6739
Failure code [D5ZHKB] Key SW C Signal Short Circuit ................6741
Failure code [D5ZHL6] Disconnection of Key SW C ................6743
Failure code [D811MC] KOMTRAX Error ................6744
Failure code [D862KA] GPS Antenna Open Circuit ................6745
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ................6746
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ................6748
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ................6750
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ................6751
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ................6753
Failure code [DAF0MB] Monitor ROM Abnormality ................6754
Failure code [DAF0MC] Monitor Error ................6755
Failure code [DAF3KK] Controller Power Source Low (MON) ................6756
Failure code [DAF8KB] Camera Power Supply Short Circuit ................6758
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ................6759
Failure code [DAFGMC] GPS Module Error ................6760
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ................6761
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ................6763
Failure code [DAFQKR] CAN2 Discon (Monitor) ................6765
Failure code [DAJ0KK] Controller Power Source Low (HST) ................6766
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ................6769
Failure code [DAJ0MC] HST Con Error ................6770
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ................6771
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ................6773
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ................6776
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay ................6778
Failure code [DAJ5KX] Failure of 5V Power Source 0 ................6780
Failure code [DAJ6KX] Failure of 5V Power Source 1 ................6782
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) ................6784
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ................6785
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ................6787
Failure code [DAJQKR] CAN2 Discon ( HST Con) ................6789
Failure code [DAJRKR] CAN1 Discon ( HST Con) ................6790
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ................6791
Failure code [DAZ9KQ] A/C Model Selection Abnormality ................6792
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ................6793
Failure code [DB2QKR] CAN2 Discon (Engine Con) ................6794
Failure code [DB2RKR] CAN1 Discon (Engine Con) ................6799
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ................6803
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................6805
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................6807
Failure code [DDB6L4] Parking Brake Signal Malfunction ................6809
Failure code [DDD7KA] Failure of Variable Speed Control ................6812
Failure code [DDD7KY] Hot Short of Variable Speed Control ................6814
Failure code [DDK3KA] FNR SW Input Signal Disconnection ................6816
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ................6818
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ................6820
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ................6823
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ................6825
Failure code [DF10KA] Disconnection of Speed Range Input ................6827
Failure code [DF10KB] Ground Fault of Speed Range Input ................6830
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ................6833
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ................6835
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ................6837
Failure code [DHG1KX] Out of Range of HST Oil Temp. Sensor ................6839
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ................6841
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) ................6843
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ................6845
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) ................6847
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ................6849
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ................6851
Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ................6853
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. ................6855
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ................6857
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ................6859
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ................6861
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ................6863
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ................6865
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit ................6867
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ................6869
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ................6871
Failure code [DHT8ZG] Steering Oil Pressure Low ................6873
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ................6874
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................6876
Failure code [DK55KA] Failure of FNR Lever Potentio ................6878
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ................6881
Failure code [DK55L5] Failure of FNR Lever Potentio ................6883
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................6884
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ................6887
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ................6890
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................6893
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ................6896
Failure code [DK70KA] Failure of inching sensor Circuit ................6899
Failure code [DK70KY] Hot Short of inching sensor Circuit ................6902
Failure code [DKA0KA] Failure of Boom Angle Sensor ................6904
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ................6906
Failure code [DKA0L0] Boom Angle Sensor Dislocation ................6908
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................6910
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ................6912
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ................6914
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ................6916
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ................6918
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ................6921
Failure code [DPQ1KR] LIN Discon (Switch Panel) ................6923
Failure code [DPQ2KR] LIN Discon (LED Unit) ................6926
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ................6929
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ................6932
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ................6934
Failure code [DV00KB] Ground Fault of Buzzer Output ................6936
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ................6938
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ................6940
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ................6942
Failure code [DW4BKA] Disconnection of Parking Brake Valve ................6943
Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................6945
Failure code [DW4BKY] Hot Short of Parking Brake Valve ................6947
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ................6948
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................6950
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ................6952
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ................6953
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ................6955
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................6957
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ................6958
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ................6960
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................6962
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ................6964
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ................6966
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ................6968
Failure code [DX19KA] Disconnection of Motor 1 Solenoid ................6969
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ................6971
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ................6973
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ................6975
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ................6977
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ................6979
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ................6981
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ................6983
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. ................6985
Failure code [DXH7KA] Disconnection of Reverse Solenoid ................6987
Failure code [DXH7KB] Ground Fault of Reverse Solenoid ................6989
Failure code [DXH7KY] Hot Short of Reverse Solenoid ................6991
Failure code [DXH8KA] Disconnection of Forward Solenoid ................6993
Failure code [DXH8KB] Ground Fault of Forward Solenoid ................6995
Failure code [DXH8KY] Hot Short of Forward Solenoid ................6997
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ................6999
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ................7001
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................7003
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ................7004
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ................7006
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................7008
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ................7009
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ................7012
Failure code [J141N1] Steering Pump Over Run ................7014
Failure code [LA00L3] Failure of Fan Reverse ................7015
Failure code [M100N1] HST Pump Over Run ................7016
Failure code [M400N1] HST Motor 1 Over Run ................7017
Troubleshooting of electrical system (E-mode) ................7018
E-1 Engine does not start ................7018
E-2 Manual preheating system does not work ................7025
E-3 Automatic preheating system does not work ................7028
E-4 While preheating is working, preheating monitor does not light up ................7030
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................7032
E-6 LCD unit on machine monitor displays nothing ................7035
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................7037
E-8 LCD on machine monitor does not display properly ................7039
E-9 Meter unit display on machine monitor is abnormal ................7041
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................7044
E-11 Caution LED on machine monitor is abnormal ................7047
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ................7049
E-13 Two switches operation of switch panel on machine monitor does not function ................7051
E-14 Switch panel buzzer of machine monitor is abnormal ................7054
E-15 Rearview monitor does not light up or backlight flickers ................7056
E-16 Rearview monitor images are not displayed clearly ................7059
E-17 Rearview monitor brightness cannot be adjusted ................7062
E-18 Night lighting lamp of rearview monitor is abnormal ................7065
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................7067
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ................7068
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ................7072
E-22 Air cleaner clogging indicator lamp does not light ................7074
E-23 Radiator coolant level caution lamp does not light ................7076
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light ................7078
E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel speed or traction force does not lower), or while not depressed, inching function operates ................7079
E-26 Fuel level gauge does not indicate correct level ................7081
E-27 Seat belt caution lamp indication is abnormal ................7083
E-28 Horn does not sound ................7084
E-29 Horn does not stop sounding ................7087
E-30 Alarm buzzer does not sound ................7089
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................7091
E-32 When emergency HST pump drive switch is operated, emergency HST pump does not work or when emergency HST pump drive switch is not operated, emergency HST pump works ................7092
E-33 Setting does not change while operating traction control switch ................7094
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake is released and FR drive is operated ................7096
E-35 Remote positioner does not work or cannot be released ................7099
E-36 Bucket positioner does not work or cannot be released ................7101
E-37 Direction selector (FNR) switch mode is not selected or not released ................7104
E-38 PZ auto tilt-in does not work ................7106
E-39 Tracktion level does not display MAX when max traction switch is turned ON ................7109
E-40 ECSS function cannot be selected or cannot be released ................7111
E-41 None of headlamp, clearance lamp, and tail lamp lights ................7113
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ................7115
E-43 Both High and Low beams of headlamp do not light up or go out ................7119
E-44 Low beam of headlamp does not light up or go out ................7123
E-45 High beam of headlamp does not light up or go out ................7125
E-46 Front working lamp does not light up or go out ................7127
E-47 Rear working lamp does not light up or go out ................7131
E-48 All of turn signal lamps and hazard lamps do not flash or go out ................7135
E-49 Turn signal lamps do not flash or go out ................7138
E-50 Hazard lamp does not flash or go out ................7141
E-51 Brake lamp does not light or stays lighted ................7144
E-52 Backup lamp does not light up or does not go out ................7147
E-53 Backup buzzer does not sound or continues to sound ................7150
E-54 Front wiper does not operate ................7152
E-55 Rear wiper does not operate ................7155
E-56 Window washer does not operate ................7157
E-57 KOMTRAX system does not operate normally ................7160
Troubleshooting of hydraulic and mechanical system (H-mode) ................7162
Information described in troubleshooting table (H-mode) ................7162
System chart of hydraulic and mechanical systems ................7163
Failure mode and cause table ................7165
H-1 Machine does not travel forward or backward ................7172
H-2 Machine does not travel forward (Machine travels backward normally) ................7175
H-3 Machine does not travel backward (Machine travels forward normally) ................7176
H-4 Machine does not travel forward or backward fast ................7177
H-5 Machine does not travel forward fast (Machine travel backward fast) ................7181
H-6 Machine does not travel backward fast (Machine travel forward fast) ................7182
H-7 Machine lacks power neither when traveling forward nor backward ................7183
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ................7186
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ................7187
H-10 Engine stalls during travel or engine speed drops significantly ................7188
H-11 Steering wheel is too heavy to turn ................7189
H-12 Steering wheel is heavy to turn ................7191
H-13 Machine sways or large shocks are made while machine turns ................7192
H-14 Machine unintentionally turns when machine travels ................7193
H-15 Wheel brakes do not work or are weak ................7194
H-16 Wheel brakes are not released or drag ................7195
H-17 Parking brake does not work or it is weak ................7196
H-18 Parking brake is not released or drags. ................7197
H-19 Boom does not rise ................7198
H-20 Boom moves slow or boom lacks lifting force ................7200
H-21 Rising boom slows down at certain height ................7202
H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................7203
H-23 Hydraulic drift of boom is large ................7204
H-24 Boom moves up and down during operation ................7205
H-25 Bucket does not tilt back ................7206
H-26 Bucket moves slow or lacks tilt-back force ................7208
H-27 Bucket decelerates during tilt-back operation ................7210
H-28 Bucket cylinder does not hold bucket on ground ................7211
H-29 Hydraulic drift of bucket is large ................7212
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ................7213
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ................7214
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ................7215
H-33 Large shocks are made when work equipment starts to move and stops ................7216
H-34 When certain work equipment is relieved hydraulically, other work equipment moves ................7217
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ................7218
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ................7219
H-37 Unusual noise is heard from around fan ................7221
Troubleshooting of engine (S-mode) ................7222
Information described in troubleshooting table (S mode) ................7222
S-1 Engine does not crank when starting switch is turned to START position ................7223
S-2 Engine cranks but no exhaust smoke comes out ................7224
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ................7225
S-4 Engine startability is poor ................7226
S-5 Engine does not pick up smoothly ................7228
S-6 Engine stops during operation ................7230
S-7 Engine runs rough or is unstable ................7232
S-8 Engine lacks power ................7233
S-9 KDPF gets clogged in a short time ................7235
S-10 Engine oil consumption is excessive ................7237
S-11 Engine oil becomes contaminated early ................7238
S-12 Fuel consumption is excessive ................7239
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ................7240
S-14 Oil pressure drops ................7241
S-15 Fuel mixes into engine oil ................7242
S-16 Water mixes into engine oil (milky) ................7243
S-17 Coolant temperature rises too high (overheating) ................7244
S-18 Unusual noise is heard ................7245
S-19 Vibration is excessive ................7246
S-20 Air cannot be bled from fuel circuit ................7248
S-21 Active regeneration is executed frequently ................7249
S-22 Active regeneration takes time ................7250
S-23 White smoke is exhausted during active regeneration ................7251
50 Disassembly and assembly ................7253
Table of contents ................7254
General information on disassembly and assembly ................7256
How to read this manual ................7256
Coating materials list ................7258
Special tools list ................7262
Sketches of special tools ................7267
Engine and cooling system ................7280
Removal and installation of supply pump assembly ................7280
Removal and installation of injector assembly ................7283
Removal and installation of cylinder head assembly ................7292
Removal and installation of engine hood assembly ................7305
Removal and installation of radiator core assembly ................7307
Removal and installation of aftercooler ................7309
Removal and installation of hydraulic oil cooler ................7310
Removal and installation of engine assembly ................7311
Removal and installation of engine front oil seal ................7319
Removal and installation of engine rear oil seal ................7322
Removal and installation of cooling fan and fan motor assembly ................7325
Removal and installation of KDPF assembly ................7327
Disassembly and assembly of KDPF assembly ................7330
Removal and installation of KCCV assembly ................7339
Removal and installation of air cleaner assembly ................7340
Removal and installation of KVGT assembly ................7341
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ................7344
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ................7345
Removal and installation of alternator belt ................7347
Removal and installation of fuel tank assembly ................7348
Power train ................7351
Removal and installation of transfer assembly ................7351
Disassembly and assembly of transfer assembly ................7355
Removal and installation of front axle assembly ................7386
Removal and installation of rear axle assembly ................7388
Disassembly and assembly of axle housing assembly ................7391
Disassembly and assembly of differential assembly ................7403
Undercarriage and frame ................7425
Removal and installation of center hinge pin ................7425
Removal and installation of counterweight assembly ................7434
Hydraulic system ................7438
Removal and installation of hydraulic tank assembly ................7438
Removal and installation of control valve assembly ................7442
Disassembly and assembly of control valve assembly ................7446
Removal and installation of hydraulic pump assembly ................7449
Removal and installation of HST motor1 assembly ................7454
Removal and installation of HST motor2 assembly ................7456
Disassembly and assembly of hydraulic cylinder assembly ................7458
Work equipment ................7465
Removal and installation of work equipment assembly ................7465
Cab and its attachments ................7471
Removal and installation of operator's cab and floor frame assembly ................7471
Removal and installation of operator's cab glass (adhered glass) ................7476
Removal and installation of operator's seat assembly ................7484
Removal and installation of seat belt ................7486
Removal and installation of air conditioner unit assembly ................7487
Removal and installation of air conditioner compressor ................7492
Removal and installation of air conditioner condenser ................7494
Electrical system ................7496
Removal and installation of machine monitor assembly ................7496
Removal and installation of engine controller assembly ................7498
Removal and installation of HST controller assembly ................7500
Removal and installation of air conditioner controller assembly ................7502
Removal and installation of monitor controller assembly ................7503
Removal and installation of mass air flow and temperature sensor ................7505
Removal and installation of KOMTRAX terminal assembly ................7506
60 Maintenance standard ................7507
Table of contents ................7508
Engine and cooling system ................7509
Engine related parts ................7509
Cooling fan motor ................7510
Power train ................7512
Damper ................7512
Transfer ................7513
Drive shaft ................7520
Axle ................7521
Differential ................7523
Limited slip differential ................7527
Final drive ................7529
Steering system ................7531
Steering column ................7531
Priority valve ................7532
Emergency steering valve ................7533
Steering cylinder ................7534
Brake system ................7536
Brake accumulator charge valve ................7536
Slack adjuster ................7537
Brake ................7538
Parking brake ................7540
Parking brake solenoid valve ................7541
Undercarriage and frame ................7542
Axle mount ................7542
Center hinge pin ................7544
Hydraulic system ................7547
Hydraulic tank ................7547
Double type gear pump ................7548
Steering and work equipment pump ................7549
Control valve ................7553
Self-pressure reducing valve ................7566
Work equipment PPC valve ................7568
Work equipment lock solenoid valve ................7570
Work equipment ................7571
Work equipment linkage ................7571
Bucket ................7575
Work equipment cylinder ................7577
Cab and its attachments ................7578
Cab mount ................7578
Electrical system ................7579
Bucket positioner ................7579
Fork positioner ................7580
Remote boom positioner ................7581
80 Appendix ................7583
Table of contents ................7584
Air conditioner components ................7585
Precautions for refrigerant ................7585
Air conditioner component ................7586
Configuration and function of refrigeration cycle ................7588
Outline of refrigeration cycle ................7589
Air conditioner unit ................7591
Dual pressure switch ................7596
Air conditioner controller ................7597
Compressor ................7598
Condenser ................7599
Receiver drier ................7600
Sunlight sensor ................7602
Outer temperature sensor (outside air temperature sensor) ................7603
Procedure for testing and troubleshooting ................7604
Circuit diagram and arrangement of connector pins ................7606
System diagram ................7609
Parts and connectors layout ................7612
Testing with self-diagnosis function ................7617
How to open the electrical system abnormality record screen in service mode of the machine monitor ................7618
Testing temperature control system ................7620
Testing vent (mode) changeover ................7622
Testing FRESH/RECIRC air changeover ................7624
Testing evaporator temperature sensor ................7626
Testing relays ................7628
Troubleshooting chart 1 ................7630
Troubleshooting chart 2 ................7631
Information in troubleshooting table ................7633
Failure code list related to air conditioner ................7634
Failure code [879AKA] A/C Inner Sensor Open Circuit ................7635
Failure code [879AKB] A/C Inner Sensor Short Circuit ................7637
Failure code [879BKA] A/C Outer Sensor Open Circuit ................7639
Failure code [879BKB] A/C Outer Sensor Short Circuit ................7641
Failure code [879CKA] Ventilating Sensor Open Circuit ................7643
Failure code [879CKB] Ventilating Sensor Short Circuit ................7645
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................7647
Failure code [879EMC] Ventilation Damper Abnormality ................7649
Failure code [879FMC] Air Mix Damper Abnormality ................7652
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ................7655
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ................7658
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................7661
A-4 Troubleshooting for FRESH/RECIRC air changeover ................7664
Troubleshooting with gauge pressure ................7666
Connection of service tool ................7669
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ................7671
Handling of compressor oil ................7673
90 Diagrams and drawings ................7675
Table of contents ................7676
Hydraulic circuit diagram ................7677
Symbols in hydraulic circuit diagram ................7677
Electric circuit diagram ................7682
Symbols in electric circuit diagram ................7682
CEBMW19071 - Wheel Loader WA320-3 Shop Manual................7712
CONTENTS................7713
01 GENERAL................7735
SPECIFICATION DRAWINGS................7736
SPECIFICATIONS................7737
WEIGHT TABLE................7740
FUEL, COOLANT AND LUBRICANTS................7741
ENGINE OIL SPECIFICATIONS................7742
DIESEL FUEL SPECIFICATIONS................7743
COOLANT SPECIFICATIONS................7744
10 STRUCTURE AND FUNCTION................7749
POWER TRAIN................7750
POWER TRAIN SYSTEM................7751
TORQUE CONVERTER, TRANSMISSION PIPING................7753
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM................7754
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................7755
TORQUE CONVERTER................7756
TORQUE CONVERTER OIL FILTER................7758
TRANSMISSION................7759
TRANSMISSION CONTROL VALVE................7770
DRIVE SHAFT................7792
AXLE................7793
DIFFERENTIAL................7795
FINAL DRIVE................7799
AXLE MOUNT, CENTER HINGE PIN................7800
STEERING PIPING................7802
STEERING COLUMN................7803
PRIORITY VALVE................7804
STEERING VALVE (ORBIT-ROLL)................7809
CUSHION VALVE................7817
2-WAY RESTRICTOR VALVE................7818
BRAKE PIPING................7819
BRAKE HYDRAULIC CIRCUIT DIAGRAM................7820
BRAKE VALVE................7821
ACCUMULATOR CHARGE VALVE................7826
ACCUMULATOR (FOR BRAKE)................7830
BRAKE................7832
PARKING BRAKE CONTROL................7835
PARKING BRAKE................7836
PARKING BRAKE SOLENOID VALVE................7837
PARKING BRAKE VALVE................7838
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE................7839
HYDRAULIC PIPING................7840
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM................7842
WORK EQUIPEMENT HYDRAULIC CIRCUIT DIAGRAM................7843
WORK EQUIPMENT LEVER LINKAGE................7845
HYDRAULIC TANK................7846
PPC VALVE................7848
PPC RELIEF VALVE................7853
ACCUMULATOR (FOR PPC VALVE)................7854
MAIN CONTROL VALVE................7855
WORK EQUIPMENT LINKAGE................7870
BUCKET................7872
BUCKET POSITIONER AND BOOM KICK-OUT................7873
CAB................7879
AIR CONDITIONER................7880
ELECTRIC CIRCUIT DIAGRAM................7881
MACHINE MONITOR SYSTEM................7886
MAIN MONITOR................7887
MAINTENANCE MONITOR................7891
E.C.S.S. (ELECTRONICALLY CONTROL SUSPENSION SYSTEM)................7893
SENSORS................7897
ENGINE STARTING CIRCUIT................7901
ENGINE STOP CIRCUIT................7902
ETHER START CIRCUIT................7903
ELECTRIC TRANSMISSION CONTROL................7904
KICK-DOWN SWITCH................7907
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM................7908
TRANSMISSION CUT-OFF SWITCH................7913
TRANSMISSION CUT-OFF FUNCTION................7914
ELECTRIC PARKING BRAKE CONTROL................7916
20 STRUCTURE AND FUNCTION................7928
STANDARD VALUE TABLE FOR ENGINE................7929
STANDARD VALUE TABLE FOR CHASSIS................7930
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM................7934
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING................7938
MEASURING ENGINE SPEEDS................7939
MEASURING INTAKE MANIFOLD PRESSURE................7939
MEASURING INTAKE AIR RESTRICTION................7939
MEASURING ENGINE LUBRICATING OIL PRESSURE................7940
MEASURING FUEL FILTER INLET RESTRICTION................7940
MEASURING BLOW-BY PRESSURE................7940
MEASURING EXHAUST BACK PRESSURE................7941
MEASURING EXHAUST GAS COLOR................7942
MEASURING COOLANT TEMPERATURE................7943
MEASURING AND ADJUSTING VALVE CLEARANCE................7943
MEASURING WASTEGATE ACTUATOR................7943
MEASURING STALL SPEEDS................7944
MEASURING ACCELERATOR PEDAL................7946
MEASURING OPERATING FORCE & TRAVEL OF DIRECTIONAL & SPEED LEVERS................7948
MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE................7949
METHOD OF OPERATING EMERGENCY MANUAL SPOOL................7951
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL................7953
TESTING AND ADJUSTING STEERING WHEEL................7954
MEASURING STEERING OIL PRESSURE................7956
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL................7958
MEASURING BRAKE PERFORMANCE................7959
TESTING BRAKE OIL PRESSURE................7960
TESTING FOR BRAKE DISC WEAR................7961
BLEEDING AIR FROM BRAKE SYSTEM................7962
MEASURING PARKING BRAKE PERFORMANCE................7963
MANUAL RELEASE METHOD FOR PARKING BRAKE................7964
TESTING WEAR OF PARKING BRAKE DISC................7965
MEASURING WORK EQUIPMENT CONTROL LEVER................7966
MEASURING WORK EQUIPMENT HYDRAULIC PRESURE................7968
MEASURING PPC VALVE PRESSURE................7970
MEASURING WORK EQUIPMENT................7972
TESTING AND ADJUSTING BUCKET POSITIONER................7974
TESTING AND ADJUSTING BOOM KICK-OUT................7975
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)................7977
TROUBLESHOOTING................7978
POINTS TO REMEMBER WHEN TROUBLESHOOTING................7979
SEQUENCE OF EVENTS IN TROUBLESHOOTING................7980
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................7981
HANDLING CONNECTORS................7988
CHECKS BEFORE TROUBLESHOOTING................7989
METHOD OF USING TROUBLESHOOTING CHARTS................7990
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................7998
S-1 Starting performance is poor (Staring always takes time)................7999
S-2 Engine does not start................8000
(1) Engine does not turn................8000
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................8001
(3) Exhaust gas comes out but engine does not start (Fuel is being injected)................8002
S-3 Engine does not pick up smoothly (Follow-up is poor)................8003
S-4 Engine stops during operations................8004
S-5 Engine does not rotate smoothly (hunting)................8005
S-6 Engine lacks output (no power)................8006
S-7 Exhaust gas is black (incomplete combustion)................8007
S-8 Oil consumption is excessive (or exhaust gas is blue)................8008
S-9 Oil becomes contaminated quickly................8009
S-I0 Fuel consumption is excessive................8010
S-11 Oil is in cooling water, or water spurts back, or water level goes down................8011
S-12 Oil pressure lamp lights up (drop in oil pressure)................8012
S-13 Oil level rises................8013
S-14 Water temperature becomes too high (overheating)................8014
S-15 Abnormal noise is made................8015
S-16 Vibration is excessive................8016
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)................8017
TROUBLE DATA DISPLAY................8019
M-1 Main monitor does not work................8021
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up................8022
M-3 Speedometer display does not work properly................8023
M-4 Abnormality in shift indicator................8024
(a) Stays at N even when directional lever is at F................8024
(b) Stays at N even when directional lever is at R................8024
(c) Does not display N even when directional lever is at N and displays R when directional lever is at F................8024
(d) Does not display N even when directional lever is at N and displays F when directional lever is at R................8025
(e) Does not display 1st, 4th................8025
(f) Does not display 3rd, 4th................8025
(g) Does not display 2nd, 3rd................8026
(h) Does not display 1st, 2nd................8026
M-5 High beam does not light up................8027
M-6 Turn signal display does not light up................8028
(a) L.H. turn signal does not light up................8028
(b) R.H. turn signal does not light up................8028
M-7 Abnormality in parking display................8029
(a) Parking lamp does not light up................8029
(b) Parking lamp stays lighted up................8029
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)................8047
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec., does not work ................8048
(a) All lamps on maintenance monitor do not light up for 3 seconds................8048
(b) Some lamps do not light up................8049
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out ................8049
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), all lamps on maintenance monitor do not go out ................8050
K-4 When starting switch is turned ON (engine stopped), CHECK items................8051
(a) Engine oil level display flashes................8051
(b) Engine water level display flashes................8052
K-5 When starting switch is turned ON (engine started), CAUTION items flash ................8053
(a) Engine oil pressure display flashes................8053
(b) Battery charge level display flashes................8054
(c) Brake oil pressure display flashes................8055
(d) Air cleaner display flashes................8056
K-6 CAUTION items are flashing but alarm buzzer does not sound................8057
K-7 There is no abnormality in monitor display but alarm buzzer sounds ................8058
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up ................8059
(a) CHECK lamp................8059
(b) CAUTION lamp................8059
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up ................8060
(a) CHECK lamp................8060
(b) CAUTION lamp................8060
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) ................8061
K-11 Night lighting does not light up even when lamp switch is OFF, night lighting stays lighted up ................8062
K-12 Service meter does not work ................8063
K-13 Service meter is running even when engine is stopped ................8063
K-14 Abnormality in gauge items ................8064
(a) Abnormality in torque converter oil temperature gauge................8064
(b) Abnormality in engine water temperature gauge................8065
(c) Abnormality in torque converter oil temperature gauge................8066
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................8067
E-1 Engine does not start ................8068
(a) Starting motor does not turn................8068
(b) Starting motor turns................8072
E-2 Engine does not stop ................8074
E-3 Engine stops when machine is traveling................8074
E-4 Parking brake does not work ................8075
(a) Parking brake has no effect when parking brake switch is turned ON (parking)................8075
(b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)................8075
E-5 Parking brake is applied when machine is traveling ................8076
E-6 Parking brake is released when starting switch is turned ON ................8078
E-7 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) ................8078
E-8 Transmission does not work normally ................8079
(a) Problem in common circuit for transmission (always stays in 2nd)................8081
(b) Problem in H-L circuit................8081
(c) Problem in speed circuit................8082
(d) Problem in 4th circuit (does not enter 4th)................8082
(e) Contact in H-L circuit................8083
(f) Contact in speed circuit................8085
(g) Contact in 4th circuit (always stays in 4th)................8087
(h) Problem in FORWARD circuit (REVERSE is normal)................8088
(i) Problem in REVERSE circuit (FORWARD is normal)................8090
(j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal)................8092
(k) Contact in FORWARD circuit................8094
(I) Contact in REVERSE circuit................8096
(m) Problem in common circuit for FORWARD and REVERSE................8098
E-9 Kick-down switch does not work (the regular Fl to F4 shifts normally)................8099
E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding feature)................8101
E-11 Kick-down operation cannot be canceled ................8101
(a) Not canceled even when directional lever is moved from F to N or R................8101
(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)................8102
E-12 Kick-down switch is actuated by mistake when traveling in 2nd ................8104
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) ................8105
POWER TRAIN................8106
T-1 Machine does not start ................8106
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes ................8108
T-3 Excessive shock when starting machine or shifting gear ................8110
T-4 Excessive time lag when starting machine or shifting gear ................8111
T-5 Torque converter oil temperature is high ................8112
STEERING SYSTEM................8113
T-6 Steering does not turn ................8113
T-7 Steering wheel is heavy ................8114
T-8 Steering wheel wobbles or there is excessive shock ................8115
T-9 Machine steers to one side when traveling ................8115
T-10 Turning radius to left and right is different ................8115
BRAKE SYSTEM................8116
T-11 Brakes do not work or braking effect is poor ................8116
T-12 Brakes are not released or brakes drag ................8117
T-13 Parking brake is not released or brake drags ................8118
WORK EQUIPMENT................8119
T-14 Boom does not rise ................8119
T-15 Boom movement is slow or boom lacks lifting power ................8120
T-16 When boom is raised, it moves slowly at a certain height ................8121
T-17 Bucket cannot be pushed with boom cylinder (bucket floats) ................8121
T-18 Excessive hydraulic drift of boom ................8121
T-19 Boom shakes during operation ................8121
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ................8122
T-21 Bucket does not tilt back ................8123
T-22 Bucket movement is slow or tilt-back lacks power ................8124
T-23 Bucket movement during tilt-back operation ................8125
T-24 Bucket cannot be pushed with bucket cylinder ................8125
T-25 Excessive hydraulic drift of bucket ................8125
T-26 Bucket shakes during loading operation (Main control valve at HOLD) ................8126
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ................8126
T-28 Boom, bucket control levers are heavy or do not move smoothly ................8127
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) ................8128
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM................8129
D-1 ECSS does not work ................8130
(a) Error code [d0] is displayed................8131
(b) Error code [d1] is displayed................8131
(c) Error code [d2] is displayed................8132
(d) Error code [d3] is displayed................8132
(e) Error code [d4] is displayed................8133
(f) No abnormality display is given................8133
D-2 ECSS cannot be canceled ................8137
D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h) ................8138
D-4 Output is turned ON when transmission is in 1st ................8138
D-5 Output is turned ON when transmission is in 4th ................8139
D-6 Controller LED code is not displayed ................8140
D-7 ECSS is abnormal but main monitor does not give abnormality display ................8140
TROUBLESHOOTING - EAGLE AIR CONDITIONER................8141
30 DISASSEMBLY AND ASSEMBLY................8145
METHOD OF USING MANUAL ................8147
PRECAUTIONS WHEN CARRYING OUT OPERATION ................8148
SPECIAL TOOL LIST ................8150
SKETCHES OF SPECIAL TOOLS ................8152
TORQUE CONVERTER CHARGING PUMP ................8153
TORQUE CONVERTER................8153
DISASSEMBLY................8154
ASSEMBLY................8156
TRANSMISSION................8158
DISASSEMBLY................8158
ASSEMBLY................8168
TRANSMISSION CLUTCH PACK................8182
DISASSEMBLY ................8182
ASSEMBLY ................8188
TRANSMISSION CONTROL VALVE................8200
REMOVAL................8200
INSTALLATION ................8202
DISASSEMBLY ................8203
ASSEMBLY................8205
TRANSMISSION ACCUMULATOR VALVE................8208
DISASSEMBLY................8208
ASSEMBLY ................8209
TRANSMISSION MODULATING VALVE................8210
DISASSEMBLY ................8210
ASSEMBLY ................8211
DRIVE SHAFT................8212
DISASSEMBLY ................8212
ASSEMBLY ................8214
FRONT AXLE................8216
REMOVAL ................8216
INSTALLATION ................8218
REAR AXLE................8219
REMOVAL................8219
INSTALLATION................8223
DIFFERENTIAL................8224
DISASSEMBLY ................8224
ASSEMBLY................8229
AXLE HOUSING................8239
DISASSEMBLY ................8239
ASSEMBLY ................8245
CENTER HINGE PIN................8254
REMOVAL ................8254
INSTALLATION ................8259
PRIORITY VALVE................8263
REMOVAL................8263
INSTALLATION ................8264
STEERING VALVE................8265
REMOVAL................8265
INSTALLATION ................8266
DISASSEMBLY ................8267
ASSEMBLY ................8270
STEERING CYLINDER................8275
REMOVAL ................8275
INSTALLATION ................8276
RIGHT BRAKE VALVE (TANDEM)................8277
DISASSEMBLY ................8277
ASSEMBLY................8278
LEFT BRAKE VALVE (SINGLE)................8279
DISASSEMBLY ................8279
ASSEMBLY ................8280
PARKING BRAKE DISC................8281
REMOVAL................8281
INSTALLATION ................8283
HYDRAULIC TANK................8284
REMOVAL ................8284
INSTALLATION................8285
HYDRAULIC FILTER................8286
HYDRAULIC STEERING PUMP................8287
REMOVAL................8287
INSTALLATION................8293
MAIN CONTROL VALVE................8294
REMOVAL ................8294
INSTALLATION ................8295
DISASSEMBLY................8296
ASSEMBLY ................8298
3-SPOOL CONTROL VALVE................8301
DISASSEMBLY................8301
ASSEMBLY ................8303
PPC VALVE................8306
REMOVAL................8306
INSTALLATION ................8307
DISASSEMBLY ................8308
ASSEMBLY ................8309
BUCKET CYLINDER................8310
REMOVAL ................8310
INSTALLATION ................8311
BOOM CYLINDER................8312
REMOVAL ................8312
INSTALLATION ................8313
HYDRAULIC CYLINDER................8314
DISASSEMBLY ................8314
ASSEMBLY ................8317
WORK EQUIPMENT................8320
REMOVAL ................8320
INSTALLATION................8323
COUNTERWEIGHT................8325
REMOVAL AND INSTALLATION................8325
CAB................8326
REMOVAL ................8326
INSTALLATION ................8328
MAIN MONITOR................8330
REMOVAL ................8330
INSTALLATION ................8331
MAINTENANCE MONITOR................8332
REMOVAL AND INSTALLATION................8332
40 MAINTENANCE STANDARD................8333
ENGINE MOUNT, TRANSMISSION MOUNT ................8334
TORQUE CONVERTER CHARGING PUMP ................8335
TORQUE CONVERTER ................8336
TRANSMISSION ................8337
TRANSMISSION CONTROL VALVE ................8346
MODULATION VALVE ASSEMBLY ................8350
ACCUMULATOR VALVE ................8351
DRIVE SHAFT ................8352
DIFFERENTIAL ................8353
FINAL DRIVE ................8356
AXLE MOUNT ................8358
CENTER HINGE PIN ................8359
STEERING COLUMN ................8361
PRIORITY VALVE ................8362
STEERING CYLINDER MOUNT ................8363
BRAKE................8364
BRAKE VALVE ................8365
PARKING BRAKE................8368
HYDRAULIC PUMP ................8369
MAIN CONTROL VALVE ................8370
PPC VALVE................8374
HYDRAULIC CYLINDER ................8375
WORK EQUIPMENT LINKAGE ................8376
BUCKET ................8378
BUCKET POSITIONER AND BOOM KICK-OUT ................8379
SEAM006101 - Wheel Loader WA320-3 Operation & Maintenance Manual................8381
1. FOREWORD................8382
2. SAFETY INFORMATION................8383
3. INTRODUCTION................8384
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................8385
5. CONTENTS................8386
SAFETY................8390
6. GENERAL PRECAUTIONS ................8391
7. PRECAUTIONS DURING OPERATION ................8396
7.1 BEFORE STARTING ENGINE ................8396
7.2 OPERATING MACHINE ................8398
7.3 TRANSPORTATION ................8402
7.4 BATTERY ................8403
7.5 TOWING ................8404
8. PRECAUTIONS FOR A MAINTENANCE ................8405
8.1 BEFORE CARRYING OUT MAINTENANCE ................8405
8.2 DURING MAINTENANCE ................8407
8.3 TIRES ................8411
9. POSITION FOR ATTACHING SAFETY LABELS ................8413
OPERATION ................8417
10. GENERAL VIEW ................8418
10.1 GENERAL VIEW OF MACHINE ................8418
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ................8419
11. EXPLANATION OF COMPONENTS ................8420
11.1 MACHINE MONITOR ................8420
11.2 SWITCHES ................8430
11.3 CONTROL LEVERS, PEDALS ................8436
11.4 STEERING COLUMN TILT LEVER ................8440
11.5 CAP WITH LOCK ................8441
11.6 SAFETY BAR................8442
11.7 TOWING PIN ................8442
11.8 GREASE PUMP ................8443
11.9 BACKUP ALARM ................8443
11.10 FUSE ................8444
11.11 SLOW-BLOW FUSE ................8445
12. OPERATION ................8446
12.1 CHECK BEFORE STARTING ENGINE ................8446
12.2 STARTING ENGINE ................8459
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ................8460
12.4 MOVING MACHINE OFF................8461
12.5 CHANGING GEAR SPEED ................8463
12.6 CHANGING DIRECTION ................8463
12.7 TURNING ................8464
12.8 STOPPING MACHINE................8465
12.9 OPERATION OF WORK EQUIPMENT ................8466
12.10 WORK POSSIBLE USING WHEEL LOADER ................8467
12.11 PRECAUTIONS FOR OPERATION................8472
12.12 ADJUSTING WORK EQUIPMENT POSTURE ................8474
12.13 PARKING MACHINE................8476
12.14 CHECKS AFTER COMPLETION OPERATION ................8477
12.15 STOPPING ENGINE ................8477
12.16 CHECK AFTER STOPPING ENGINE ................8478
12.17 LOCKING ................8478
12.18 HANDLING THE TIRES................8479
13. TRANSPORTATION ................8481
13.1 LOADING, UNLOADING WORK ................8481
13.2 PRECAUTIONS FOR LOADING ................8482
13.3 PRECAUTIONS FOR TRANSPORTATION ................8482
14. COLD WEATHER OPERATION ................8483
14.1 PRECAUTIONS FOR LOW TEMPERATURE ................8483
14.2 PRECAUTIONS AFTER COMPLETION OF WORK................8485
14.3 AFTER COLD WEATHER ................8485
15. LONG-TERM STORAGE ................8486
15.1 BEFORE STORAGE ................8486
15.2 DURING STORAGE ................8486
15.3 AFTER STORAGE ................8486
16. TROUBLESHOOTING ................8487
16.1 WHEN MACHINE RUNS OUT OF FUEL ................8487
16.2 TOWING THE MACHINE ................8488
16.3 IF BATTERY IS DISCHARGED ................8493
16.4 OTHER TROUBLE................8497
MAINTENANCE ................8503
17. GUIDES TO MAINTENANCE ................8504
18. OUTLINES OF SERVICE ................8507
18.1 OUTLINE OF OIL, FUEL, COOLANT ................8507
18.2 OUTLINE OF ELECTRIC SYSTEM ................8510
19. WEAR PARTS LIST ................8511
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ................8512
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................8516
21.1 INTRODUCTION OF NECESSARY TOOLS ................8516
21.2 TORQUE LIST ................8517
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................8518
23. MAINTENANCE SCHEDULE CHART ................8522
23.1 MAINTENANCE SCHEDULE CHART ................8522
24. SERVICE PROCEDURE ................8526
24.1 INITIAL 250 HOURS SERVICE ................8526
24.2 WHEN REQUIRED ................8527
24.3 CHECK BEFORE STARTING................8540
24.4 EVERY 50 HOURS SERVICE................8545
24.5 EVERY 100 HOURS SERVICE ................8546
24.6 EVERY 250 HOURS SERVICE ................8548
24.7 EVERY 500 HOURS SERVICE ................8555
24.8 EVERY 1000 HOURS SERVICE ................8559
24.9 EVERY 2000 HOURS SERVICE ................8564
24.10 EVERY 4000 HOURS SERVICE ................8570
SPECIFICATIONS ................8571
25. SPECIFICATIONS ................8572
OPTIONS, ATTACHMENTS ................8574
26. OPTIONAL PARTS AND ATTACHMENTS ................8575
27. SELECTING BUCKETS AND TIRES ................8576
28. CAR RADIO ................8577
28.1 EXPLANATION OF COMPONENTS ................8577
28.2 METHOD OF USE ................8579
28.3 PRECAUTIONS WHEN USING RADIO ................8580
29. AIR CONDITIONER ................8581
29.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................8581
29.2 METHOD OF OPERATION ................8583
29.3 COOL BOX ................8583
30. HANDLING E.C.S.S. (Electronic controlled suspension system)................8584
30.1 STRUCTURE AND FUNCTION OF E.C.S.S. ................8584
30.2 METHOD OF OPERATING E.C.S.S. ................8585
30.3 PRECAUTIONS WHEN OPERATING E.C.S.S. ................8585
30.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR ................8586
31. HANDLING AUTO-GREASING SYSTEM ................8587
31.1 METHOD OF OPERATING AUTO-GREASING ................8587
31.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM ................8595
31.3 TROUBLESHOOTING ................8596
31.4 SPECIFICATIONS ................8596
32. OPTION DISPLAY ................8597
33. HANDLING AUTO-LEVELING, REMOTE POSITIONER ................8598
33.1 STRUCTURE AND FUNCTION OF AUTO-LEVELING, REMOTE POSITIONER ................8598
33.2 GENERAL LOCATIONS ................8599
33.3 METHOD OF OPERATING AUTO-LEVELING, REMOTE POSITIONER................8600
33.4 ADJUSTING AUTO-LEVELING, REMOTE POSITIONER ................8602
SEAM011604 - Wheel Loader WA320-3 Operation & Maintenance Manual................8604
COVER................8604
1. FOREWARD................8605
2. SAFETY INFORMATION................8608
3. INTRODUCTION................8609
3.1 INTENDED USE................8609
3.2 FEATURES................8609
3.3 BREAKING IN THE MACHINE................8609
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................8610
4.1 MACHINE SERIAL NO. PLATE POSITION................8610
4.2 ENGINE SERIAL NO. PLATE POSITION................8610
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................8610
5. CONTENTS................8611
SAFTEY................8615
6. GENERAL PRECAUTIONS................8616
7. PRECAUTIONS DURING OPERATION................8622
7.1 BEFORE STARTING ENGINE................8622
7.2 AFTER STARTING ENGINE................8624
7.3 TRANSPORTATION................8633
7.4 BATTERY................8634
7.5 TOWING................8636
8. PRECAUTIONS FOR MAINTENANCE................8637
8.1 BEFORE CARRYING OUT MAINTENANCE................8637
8.2 DURING MAINTENANCE................8641
8.3 TIRES................8647
9. POSITION FOR ATTACHING SAFETY LABELS................8649
OPERATION................8655
10. GENERAL VIEW................8656
10.1 GENERAL VIEW OF MACHINE................8656
10.2 GENERAL VIEW OF CONTROLS AND GAUGES................8657
11. EXPLANATION OF COMPONENTS................8658
11.1 METER, LAMPS................8658
11.2 SWITCHES................8662
11.3 CONTROL LEVERS, PEDALS................8666
11.4 CAP WITH LOCK................8670
11.5 SAFETY BAR................8671
11.6 TOWING PIN................8671
11.7 GREASE PUMP................8672
11.8 BACKUP ALARM................8672
11.9 FUSE................8673
11.10 SLOW-BLOW FUSE................8674
12. OPERATION................8675
12.1 CHECK BEFORE STARTING ENGINE................8675
12.2 STARTING ENGINE................8689
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE................8690
12.4 MOVING MACHINE OFF................8691
12.5 CHANGING GEAR SPEED................8693
12.6 CHANGING DIRECTION................8693
12.7 TURNING................8694
12.8 STOPPING MACHINE................8695
12.9 OPERATION OF WORK EQUIPMENT................8696
12.10 WORK POSSIBLE USING WHEEL LOADER................8697
12.11 PRECAUTIONS FOR OPERATION................8702
12.12 ADJUSTING WORK EQUIPMENT POSTURE................8704
12.13 PARKING MACHINE................8706
12.14 CHECKS AFTER COMPLETION OF OPERATION................8707
12.15 STOPPING ENGINE................8707
12.16 CHECK AFTER STOPPING ENGINE................8708
12.17 LOCKING................8708
12.18 HANDLING THE TIRES................8709
13. TRANSPORTATION................8711
13.1 LOADING, UNLOADING WORK................8711
13.2 PRECAUTIONS FOR LOADING................8712
13.3 PRECAUTIONS FOR TRANSPORTATION................8712
14. COLD WEATHER OPERATION................8713
14.1 PRECAUTIONS FOR LOW TEMPERATURE................8713
14.2 PRECAUTIONS AFTER COMPLETION OF WORK................8715
14.3 AFTER COLD WEATHER................8715
15. LONG-TERM STORAGE................8716
15.1 BEFORE STORAGE................8716
15.2 DURING STORAGE................8716
15.3 AFTER STORAGE................8716
16. TROUBLESHOOTING................8717
16.1 WHEN MACHINE RUNS OUT OF FUEL................8717
16.2 TOWING THE MACHINE................8718
16.3 IF BATTERY IS DISCHARGED................8722
16.4 OTHER TROUBLE................8726
MAINTENANCE................8733
17. GUIDES TO MAINTENANCE................8734
18. OUTLINES OF SERVICE................8737
18.1 OUTLINE OF OIL, FUEL, COOLANT................8737
18.2 OUTLINE OF ELECTRIC SYSTEM................8740
19. WEAR PARTS LIST................8741
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................8742
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................8746
21.1 INTRODUCTION OF NECESSARY TOOLS................8746
21.2 TORQUE LIST................8747
22. PERIODIC REPLACEMENT OF SAFETY CRICITAL PARTS................8748
23. MAINTENANCE SCHEDULE CHART................8752
23.1 MAINTENANCE SCHEDULE CHART................8752
24. SERVICE PROCEDURE................8756
24.1 INITIAL 250 HOURS SERVICE................8756
REPLACE FUEL FILTER CARTRIDGE................8756
REPLACE TRANSMISSION OIL FILTER ELEMENT................8756
REPLACE HYDRAULIC TANK FILTER ELEMENT................8756
CHECK ENGINE VALVE CLEARANCE, ADJUST................8756
24.2 WHEN REQUIRED................8757
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT................8757
CLEAN INSIDE OF COOLING SYSTEM................8759
CHECK TRANSMISSION OIL LEVEL, ADD OIL................8763
CHECK AXLE OIL LEVEL, ADD OIL................8764
CLEAN AXLE CASE BREATHER................8765
CLEAN RADIATOR FINS................8765
REPLACE BOLT ON CUTTING EDGE................8766
REPLACE BUCKET TEETH................8767
CHECK AIR CONDITIONER................8768
CLEAN CONDENSER OF AIR CONDITIONER................8769
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID................8769
LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 POINTS)................8769
ADJUST PARKING BRAKE................8770
DRAIN WATER FROM WATER SEPARATOR, DRAIN WATER (MACHINE EQUIPPED WITH ADDITIONAL FUEL FILTER)................8770
24.3 CHECK BEFORE STARTING................8771
CHECK COOLANT LEVEL, ADD WATER................8771
CHECK FUEL LEVEL, ADD FUEL................8771
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL................8772
CHECK DUST INDICATOR................8772
CHECK ELECTRIC WIRING................8773
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR (MACHINE EQUIPPED WITH ADDITIONAL FUEL FILTER)................8773
CHECK EFFECT OF PARKING BRAKE................8774
CHECK EFFECT OF BRAKE................8774
CHECK SOUND OF HORN AND BACKUP ALARM................8774
CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE................8774
CHECK ENGINE EXHAUST COLOR AND SOUND................8774
CHECK OPERATION OF GAUGES................8774
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING................8774
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................8774
24.4 EVERY 50 HOURS SERVICE................8775
CHECK TIRE INFLATION PRESSURE................8775
DRAIN WATER, SEDIMENT FROM FUEL TANK................8775
24.5 EVERY 100 HOURS SERVICE................8776
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................8776
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................8777
LUBRICATE REAR AXLE PIVOT PIN (3 POINTS)................8777
24.6 EVERY 250 HOURS SERVICE................8778
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE................8778
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN................8779
CHECK FOR AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................8780
CHECK BATTERY ELECTROLYTE LEVEL................8781
LUBRICATING................8782
24.7 EVERY 500 HOURS SERVICE................8783
REPLACE FUEL FILTER CARTRIDGE................8783
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (MACHINE EQUIPPED WITH ADDITIONAL FUEL FILTER)................8785
REPLACE TRANSMISSION OIL FILTER ELEMENT................8787
LUBRICATE CENTER DRIVE SHAFT SPLINE (1 POINT)................8787
24.8 EVERY 1000 HOURS SERVICE................8788
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER................8788
CLEAN TRANSMISSION CASE BREATHER................8789
LUBRICATING................8790
CHECK TIGHTENING PARTS OF TURBOCHARGER................8791
CHECK PLAY OF TURBOCHARGER ROTOR................8791
CHECK FAN BELT TENSION, REPLACE................8791
24.9 EVERY 2000 HOURS SERVICE................8792
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT................8792
REPLACE HYDRAULIC TANK BREATHER ELEMENT................8794
CHANGE AXLE OIL................8795
CHECK BRAKE DISC WEAR................8796
CHECK ALTERNATOR, STARTING MOTOR................8796
CHECK ENGINE VALVE CLEARANCE, ADJUST................8796
CHECK VIBRATION DAMPER................8796
REPLACE ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................8796
CLEAN AND CHECK TURBOCHARGER................8796
CLEAN BRAKE CIRCUIT STRAINER................8797
CHECK ACCUMULATOR GAS PRESSURE................8797
24.10 EVERY 4000 HOURS SERVICE................8798
CHECK WATER PUMP................8798
SPECIFICATIONS................8799
25. SPECIFICATIONS................8800
OPTIONS, ATTACHMENTS................8803
26. OPTIONAL PARTS AND ATTACHMENTS................8804
27. SELECTING BUCKETS AND TIRES................8805
28. CAR RADIO................8806
28.1 EXPLANATION OF COMPONENTS................8806
28.2 METHOD OF USE................8808
28.3 PRECAUTIONS WHEN USING RADIO................8809
29. AIR CONDITIONER................8810
29.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................8810
29.2 METHOD OF OPERATION................8812
SEAM033202 - Wheel Loader WA320L-3 Operation & Maintenance Manual................8815
COVER................8815
1. FOREWORD................8819
2. SAFETY INFORMATION................8822
3. INTRODUCTION................8823
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................8824
5. CONTENTS................8825
SAFETY................8829
6. GENERAL PRECUATIONS................8830
7. PRECAUTIONS FOR OPERATION................8839
7.1 BEFORE STARTING ENGINE................8839
7.2 AFTER STARTING ENGINE................8840
7.3 TRANSPORATION................8845
7.4 BATTERY ................8846
7.5 TOWING................8848
8. PRECAUTIONS FOR MAINTENANCE................8849
8.1 BEFORE CARRYING OUT MAINTENANCE................8849
8.2 DURING MAINTENANCE................8851
8.3 PRECAUTIONS WITH TIRES................8855
9. POSITION FOR ATTACHING SAFETY LABELS................8856
9.1 POSITION FOR ATTACHING SAFETY LABELS................8856
OPERATION................8861
10. GENERAL VIEW................8862
10.1 GENERAL VIEW OF MACHINE................8862
10.2 GENERAL VIEW OF CONTROLS AND GAUGES................8863
11. EXPLANATION OF COMPONENTS................8865
11.1 METER, LAMPS................8865
11.2 SWITCHES................8868
11.3 CONTROL LEVERS, PEDALS................8873
11.4 CAP WITH LOCK................8878
11.5 SAFETY BAR................8879
11.6 TOWING PIN................8879
11.7 GREASE PUMP (IF EQUIPPED)................8880
11.8 BACKUP ALARM................8880
11.9 FUSE................8881
11.10 SLOW-BLOW FUSE................8882
11.11 TAKING OFF POWER (WITH ROPS CAB)................8882
11.12 CAR HEATER................8883
12. OPERATION ................8885
12.1 CHECK BEFORE STARTING ENGINE................8885
12.2 STARTING ENGINE................8898
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE................8899
12.4 MOVING MACHINE OFF................8900
12.5 CHANGING GEAR SPEED................8902
12.6 CHANGING DIRECTION................8902
12.7 TURNING................8903
12.8 STOPPING MACHINE................8904
12.9 OPERATION OF WORK EQUIPMENT................8905
12.10 WORK POSSIBLE USING WHEEL LOADER ................8906
12.11 PRECAUTIONS FOR OPERATION................8911
12.12 ADJUSTING WORK EQUIPMENT POSTURE ................8913
12.13 PARKING MACHINE................8915
12.14 CHECKS AFTER COMPLETION OF WORK................8916
12.15 STOPPING ENGINE................8916
12.16 CHECK AFTER STOPPING ENGINE................8917
12.17 LOCKING................8917
12.18 HANDLING THE TIRES................8918
13. TRANSPORTATION................8920
13.1 LOADING UNLOADING WORK................8920
13.2 PRECAUTIONS FOR LOADING................8921
13.3 PRECAUTIONS FOR TRANSPORATION................8921
14. COLD WEATHER OPERATION................8922
14.1 PRECAUTIONS FOR LOW TEMPERATURE................8922
14.2 PRECAUTIONS AFTER COMPLETION OF WORK................8924
14.3 AFTER COLD WEATHER................8924
15. LONG-TERM STORAGE................8925
15.1 BEFORE STORAGE................8925
15.2 DURING STORAGE................8925
15.3 AFTER STORAGE................8925
16. TROUBLESHOOTING................8926
16.1 WHEN MACHINE RUNS OUT OF FUEL................8926
16.2 WHEN AUTOMATICALLY RESET SPRING FOR REAR LIGHT SUPPORT BREAKS................8926
16.3 TOWING THE MACHINE................8927
16.4 IF BATTERY IS DISCHARGED................8930
16.5 OTHER TROUBLE................8934
MAINTENANCE................8941
17. GUIDES TO MAINTENANCE................8942
18. OUTLINES OF SERVICE................8945
18.1 OUTLINE OF OIL, FUEL, COOLANT................8945
18.2 OUTLINE ELECTRIC SYSTEM................8948
19. WEAR PARTS LIST................8949
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................8950
21. STANDARD TIGHENING TORQUES FOR BOLTS AND NUTS................8954
21.1 INTRODUCTION OF NECESSARY TOOLS................8954
21.2 TORQUE LIST................8955
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................8956
23. MAINTENANCE SCHEDULE CHART................8958
23.1 MAINTENANCE SCHEDULE CHART................8958
24. SERVICE PROCEDURE................8962
24.1 INITIAL 250 HOURS SERVICE................8962
24.2 WHEN REQUIRED................8963
24.3 CHECK BEFORE STARTING................8978
24.4 EVERY 50 HOURS SERVICE................8984
24.5 EVERY 100 HOURS SERVICE................8985
24.6 EVERY 250 HOURS SERVICE................8987
24.7 EVERY 500 HOURS SERVICE................8992
24.8 EVERY 1000 HOURS SERVICE................8997
24.9 EVERY 2000 HOURS SERVICE................9001
24.10 EVERY 4000 HOURS SERVICE................9006
SPECIFICATIONS................9007
25. SPECIFICATIONS................9008
25. SPECIFICATIONS................8827
OPTIONAL PARTS AND ATTACHMENTS................9009
26. OPTIONAL PARTS AND ATTACHMENTS................9010
27. SELECTING BUCKETS AND TIRES................9011
28. AM/FM CAR RADIO................9012
28.1 EXPLANATION OF COMPONENTS................9012
28.2 METHOD OF OPERATION................9014
28.3 PRECAUTIONS WHEN USING RADIO................9015
29. AIR CONDITIONER................9016
29.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................9016
29.2 METHOD OF OPERATION................9018
29.3 COOL BOX................9018
SEAMU4190106 - Wheel Loader WA320-1 Operation & Maintenance Manual................9021
COVER................9021
FOREWORD................9022
BREAKING IN YOUR NEW MACHINE................9023
CONTENTS................9024
GENERAL LOCATIONS AND SPECIFICATIONS................9025
INSTRUMENTS AND CONTROLS................9026
CHECK BEFORE STARTING................9052
OPERATING YOUR MACHINE................9057
ADJUSTMENT OF WORK EQUIPMENT................9066
USING ACCUMULATORS................9068
HANDLING THE TIRES................9069
TOWING................9072
COLD WEATHER OPERATION................9073
PERIODIC MAINTENANCE................9078
BLEEDING AIR FROM CIRCUIT................9079
PERIODICAL REPLACEMENT OF SAFETY PARTS................9080
MAINTENANCE TABLE................9081
OIL FILLER AND LEVEL GAUGE POSITIONS................9084
CHECK BEFORE STARTING................9085
EVERY 50 HOURS SERVICE................9085
EVERY 100 HOURS SERVICE................9086
EVERY 250 HOURS SERVICE................9089
EVERY 500 HOURS SERVICE................9095
EVERY 1000 HOURS SERVICE................9097
EVERY 2000 HOURS SERVICE................9101
EVERY 4000 HOURS SERVICE................9107
WHEN REQUIRED................9108
ADJUSTMENT................9122
TROUBLE SHOOTING GUIDE................9125
SERVICE METER................9129
MACHINE AND ENGINE SERIAL NUMBERS................9130
FUEL,COOLANT AND LUBRICANTS................9131
SAFETY AND OPERATION................9133
CONTENTS................9134
SAFETY HINTS................9135
PRECAUTIONS FOR MAINTENANCE................9149
BUCKET OPERATION................9156
OPERATING THE AIR CONDITIONER................9162
OPERATING THE CAR HEATER................9165
LOCKING CAP................9167
HANDLING OF BATTERY................9168
TRANSPORTATION................9171
STORAGE................9172
COOLANT AND LUBRICANTS................9174
SEBM006006 - Wheel Loader WA320-3 avance Shop Manual................9177
COVER................9177
CONTENTS................9178
01 GENERAL................9200
GENERAL ASSEMBLY DRAWING................9201
SPECIFICATIONS................9203
WEIGHT TABLE................9206
LIST OF LUBRICANT AND WATER................9208
10 STRUCTURE AND FUNCTION................9210
POWER TRAIN................9211
POWER TRAIN SYSTEM................9212
TORQUE CONVERTER, TRANSMISSION PIPING................9214
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM................9215
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................9216
TORQUE CONVERTER................9217
TORQUE CONVERTER OIL FILTER................9219
TRANSMISSION................9220
TRANSMISSION CONTROL VALVE................9230
DRIVE SHAFT................9252
AXLE................9253
DIFFERENTIAL................9257
FINAL DRIVE................9263
AXLE MOUNT, CENTER HINGE PIN................9265
STEERING PIPING................9267
STEERING COLUMN................9268
PRIORITY VALVE................9269
STEERING VALVE (ORBIT-ROLL)................9274
CUSHION VALVE................9282
2-WAY RESTRICTOR VALVE................9283
BRAKE PIPING................9284
BRAKE HYDRAULIC CIRCUIT DIAGRAM................9285
BRAKE VALVE................9287
ACCUMULATOR CHARGE VALVE................9292
ACCUMULATOR (FOR BRAKE)................9298
BRAKE................9300
PARKING BRAKE CONTROL................9305
PARKING BRAKE................9306
PARKING BRAKE SOLENOID VALVE................9307
PARKING BRAKE VALVE................9308
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE................9309
HYDRAULIC PIPING................9310
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM................9311
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................9312
WORK EQUIPMENT LEVER LINKAGE................9316
HYDRAULIC TANK................9317
PPC VALVE................9319
PPC RELIEF VALVE................9324
ACCUMULATOR (FOR PPC VALVE)................9325
MAIN CONTROL VALVE................9326
WORK EQUIPMENT LINKAGE................9341
BUCKET................9343
BUCKET POSITIONER AND BOOM KICK-OUT................9344
CAB................9350
ROPS CAB................9352
AIR CONDITIONER................9353
ELECTRIC CIRCUIT DIAGRAM ................9354
MACHINE MONITOR SYSTEM................9369
MAIN MONITOR................9370
MAINTENANCE MONITOR................9375
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM................9378
WORK EQUIPMENT CONTROL SYSTEM................9386
E.C.S.S.(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)................9393
SENSORS................9397
ENGINE STARTING CIRCUIT................9401
ENGINE STOP CIRCUIT................9402
PREHEATING CIRCUIT................9403
ELECTRIC TRANSMISSION CONTROL................9404
KICK-DOWN, HOLD SWITCH................9407
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM................9408
TRANSMISSION CUT-OFF SWITCH................9417
TRANSMISSION CUT-OFF FUNCTION................9418
ELECTRIC PARKING BRAKE CONTROL ................9422
20 TESTING AND ADJUSTING ................9435
STANDARD VALUE TABLE FOR ENGINE................9436
STANDARD VALUE TABLE FOR CHASSIS................9437
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM................9441
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................9445
ADJUSTING VALVE CLEARANCE................9446
MEASURING COMPRESSION PRESSURE................9447
MEASURING BLOW-BY PRESSURE................9448
TESTING AND ADJUSTING FUEL INJECTION TIMING................9449
MEASURING EXHAUST COLOR................9451
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................9452
MEASURING EXHAUST GAS TEMPERATURE................9453
MEASURING ENGINE OIL PRESSURE................9454
MEASURING ENGINE SPEED................9455
TESTING AND ADJUSTING FAN BELT TENSION................9456
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE................9457
MEASURING ACCELERATOR PEDAL................9459
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER................9461
MEASURING STALL SPEED................9462
MEASURING TORQUE CONVERTER, TRANSMISSION,PARKING BRAKE OIL PRESSURE................9464
METHOD OF OPERATING EMERGENCY MANUAL SPOOL................9466
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL ................9468
TESTING AND ADJUSTING STEERING WHEEL ................9469
MEASURING STEERING OIL PRESSURE................9471
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL ................9473
MEASURING BRAKE PERFORMANCE................9474
TESTING BRAKE OIL PRESSURE................9475
TESTING FOR BRAKE DISC WEAR................9476
BLEEDING AIR FROM BRAKE SYSTEM................9477
MEASURING PARKING BRAKE PERFORMANCE................9478
MANUAL RELEASE METHOD FOR PARKING BRAKE................9479
TESTING WEAR OF PARKING BRAKE DISC................9480
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................9481
MEASURING WORK EQUIPMENT CONTROL LEVER................9482
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE................9484
MEASURING PPC VALVE PRESSURE................9486
MEASURING WORK EQUIPMENT ................9488
TESTING AND ADJUSTING BUCKET POSITIONER................9490
TESTING AND ADJUSTING BOOM KICK-OUT................9491
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)................9493
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER................9494
TROUBLESHOOTING................9495
POINTS TO REMEMBER WHEN TROUBLESHOOTING................9496
SEQUENCE OF EVENTS IN TROUBLESHOOTING................9497
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................9498
HANDLING CONNECTORS................9505
CHECKS BEFORE TROUBLESHOOTING................9506
METHOD OF USING TROUBLESHOOTING CHARTS................9507
CONNECTOR TYPES AND MOUNTING LOCATIONS................9515
CONNECTOR PIN ARRANGEMENT DIAGRAM................9516
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................9521
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................9528
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................9529
S-2 ENGINE DOES NOT START ................9530
(1) ENGINE DOES NOT TURN................9530
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)................9531
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................9532
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................9533
S-4 ENGINE STOPS DURING OPERATIONS................9534
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................9535
S-6 ENGINE LACKS OUTPUT (NO POWER)................9536
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)................9537
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)................9538
S-9 OIL BECOMES CONTAMINATED QUICKLY................9539
S-10 FUEL CONSUMPTION IS EXCESSIVE................9540
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN................9541
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)................9542
S-13 OIL LEVEL RISES................9543
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................9544
S-15 ABNORMAL NOISE IS MADE................9545
S-16 VIBRATION IS EXCESSIVE................9546
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)................9547
TROUBLE DATA DISPLAY................9549
M-1 MAIN MONITOR DOES NOT WORK................9551
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP................9552
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY................9553
M-4 ABNORMALITY IN SHIFT INDICATOR................9554
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F................9554
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R................9554
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F................9554
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R ................9555
(e) DOES NOT DISPLAY 1ST, 4TH................9555
(f) DOES NOT DISPLAY 3RD, 4TH................9555
(g) DOES NOT DISPLAY 2ND, 3RD................9556
(h) DOES NOT DISPLAY 1ST, 2ND................9556
M-5 HIGH BEAM DOES NOT LIGHT UP................9557
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP................9558
(a) L.H. TURN SIGNAL DOES NOT LIGHT UP................9558
(b) R.H. TURN SIGNAL DOES NOT LIGHT UP................9558
M-7 ABNORMALITY IN PARKING DISPLAY................9559
(a) PARKING LAMP DOES NOT LIGHT UP................9559
(b) PARKING LAMP STAYS LIGHTED UP................9559
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS)................9560
(a) DOES NOT CARRY OUT PREHEATING ................9560
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE................9561
(c) PREHEATING STAYS ON ................9561
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION................9562
M-9 NIGHT LIGHTING DOES NOT LIGHT UP................9563
M-10 ABNORMALITY IN FRONT WORKING LAMP................9564
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP................9564
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................9564
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP................9564
M-11 ABNORMALITY IN REAR WORKING LAMP................9565
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP................9565
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................9565
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP................9565
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF................9567
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN ................9567
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON ................9567
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED................9568
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ................9569
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES................9569
(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................9569
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED ................9570
(a) ACTUATED CONTINUOUSLY................9570
(b) NOT ACTUATED................9570
M-15 ABNORMALITY IN BUZZER ................9571
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)................9571
(b) BUZZER ALWAYS SOUNDS................9571
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY................9572
M-17 ABNORMALITY IN FAILURE DISPLAY MODE................9573
(a) DOES NOT ENTER FAILURE DISPLAY MODE ................9573
(b) TIMES FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE ................9573
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY................9574
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP................9574
(b) EMERGENCY STEERING NORMAL DISPLAY LIGHTED UP................9574
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY................9575
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP................9575
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP................9575
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM................9576
(a) FORCED GREASING CANNOT BE CARRIED OUT................9576
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)................9576
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)................9576
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)................9577
(e) MONITOR DISPLAY GOES OUT ................9577
M-21 ABNORMALITY IN ECSS SYSTEM................9578
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED................9578
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK................9578
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED................9578
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)................9579
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)................9580
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK................9581
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS................9581
(b) SOME LAMPS DO NOT LIGHT UP................9582
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT................9582
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT................9583
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH................9584
(a) ENGINE OIL LEVEL DISPLAY FLASHES................9584
(b) ENGINE WATER LEVEL DISPLAY FLASHES ................9585
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH................9586
(a) ENGINE OIL PRESSURE DISPLAY FLASHES................9586
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES................9587
(c) BRAKE OIL PRESSURE DISPLAY FLASHES................9588
(d) AIR CLEANER DISPLAY FLASHES................9589
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND................9590
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS................9591
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP................9592
(a) CHECK LAMP................9592
(b) CAUTION LAMP................9592
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP................9593
(a) CHECK LAMP................9593
(b) CAUTION LAMP................9593
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)................9594
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP................9595
K-12 SERVICE METER DOES NOT WORK................9596
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED................9596
K-14 ABNORMALITY IN GAUGE ITEMS ................9597
(a) ABNORMALITY IN FUEL GAUGE................9597
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE................9598
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE................9599
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................9600
E-1 ENGINE DOES NOT START ................9601
(a) STARTING MOTOR DOES NOT TURN ................9601
(b) STARTING MOTOR TURNS................9605
E-2 ENGINE DOES NOT STOP................9607
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING ................9607
E-4 PARKING BRAKE DOES NOT WORK ................9608
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (PARKING)................9608
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE)................9608
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING ................9609
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON ................9611
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (WITHOUT AUTO-SIFT TRANSMISSION)................9611
E-8 TRANSMISSION DOES NOT WORK NORMALLY (WITHOUT AUTO-SIFT TRANSMISSION)................9612
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)................9614
(b) PROBLEM IN H-L CIRCUIT................9614
(c) PROBLEM IN SPEED CIRCUIT ................9615
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)................9615
(e) CONTACT IN H-L CIRCUIT................9616
(f) CONTACT IN SPEED CIRCUIT................9618
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)................9620
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)................9621
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)................9623
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL)................9625
(k) CONTACT IN FORWARD CIRCUIT................9627
(l) CONTACT IN REVERSE CIRCUIT ................9629
(m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE................9631
E-9 KICK-DOWN SWITCH DOES NOT WORK (WITHOUT AUTO-SIFT TRANSMISSION) (THE REGULAR F1 TO F4 SHIFTS NORMALLY)................9632
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION (SELF-HOLDING FUNCTION))(WITHOUT AUTO-SIFT TRANSMISSION)................9634
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED (WITHOUT AUTO-SIFT TRANSMISSION)................9634
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R ................9634
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH)................9635
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND (WITHOUT AUTO-SIFT TRANSMISSION)................9637
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)(T MODE)................9638
POWER TRAIN ................9639
T-1 MACHINE DOES NOT START................9639
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES ................9641
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR................9643
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR................9644
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH................9645
STEERING SYSTEM................9646
T-6 STEERING WHEEL DOES NOT TURN ................9646
T-7 STEERING IS HEAVY................9647
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK................9648
BRAKE SYSTEM................9649
T-9 BRAKE DO NOT WORK OR BRAKING EFFECT IS POOR................9649
T-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG................9650
T-11 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS................9651
WORK EQUIPMENT ................9652
T-12 BOOM DOES NOT RISE................9652
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER................9653
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT ................9654
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)................9654
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM................9654
T-17 BOOM SHAKES DURING OPERATION................9654
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE................9655
T-19 BUCKET DOES NOT TILT BACK................9656
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER................9657
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION ................9658
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER ................9658
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET................9658
T-24 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)................9659
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT................9659
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY ................9660
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE)................9661
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM)................9662
D-1 ECSS DOES NOT WORK................9663
(a) ERROR CODE [d0] IS DISPLAYED ................9664
(b) ERROR CODE [d1] IS DISPLAYED ................9664
(c) ERROR CODE [d2] IS DISPLAYED ................9665
(d) ERROR CODE [d3] IS DISPLAYED ................9665
(e) ERROR CODE [d4] IS DISPLAYED ................9666
(f) NO ABNORMALITY DISPLAY IS GIVEN................9666
D-2 ECSS CANNOT BE CANCELED................9670
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 KM/H)(DEVIATES AROUND 5 KM/H)................9671
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST ................9671
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH................9672
D-6 CONTROLLER LED CODE IS NOT DISPLAYED ................9673
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY................9673
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)................9674
OUTLINE................9676
1. FUNCTION................9676
2. WHEN CARRYING OUT TROUBLESHOOTING ................9676
3. FAILURE CODE TABLE................9676
4. TABEL OF TROUBLESHOOTING MODES AND CAUSES................9677
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM................9679
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF................9680
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM................9681
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM................9682
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID ................9683
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID................9683
W-7 FAILURE CODE [48] ANMORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM................9684
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM................9686
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM................9687
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH................9688
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIONMETER SYSTEM................9689
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM................9689
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS................9691
W-14 SENSOR CANNOT BE ADJUSTED................9692
W-15 DOES NOT CARRY OUT AUTO-LEVELING................9693
(a) AUTO-LEVELER SWITCH SYSTEM................9693
(b) AUTO-LEVELER LED SYSTEM................9693
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM................9694
(d) ENGINE SPEED SIGNAL SYSTEM................9695
W-16 AUTO-LEVELER CANNOT BE SET ................9696
(a) AUTO-LEVELER SET SWITCH SYSTEM................9696
(b) AUTO-LEVELER SET LED SYSTEM................9696
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP................9697
(a) REMOTE POSITIONER SWITCH SYSTEM................9697
(b) REMOTE POSITIONER LED SYSTEM................9697
W-18 REMOTE POSITIONER SET LEDS DO NOT FLASH................9698
(a) REMOTE POSITIONER SWITCH SYSTEM................9698
(b) REMOTE POSITIONER LED SYSTEM................9698
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONER IS AT RAISE AND AUTO MODE IS ON ................9699
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND................9700
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW................9701
W-22 BUCKET (LEVER) CONTROL ................9702
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT ................9702
(b) LEVER IS NOT HELD BY DETENT ................9703
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR................9705
W-24 MAINTENANCE MONITOR CHECK................9706
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (WITH AUTO-SIFT TRANSMISSION)(A MODE)................9707
OUTLINE................9708
1. FUNCTION................9708
2. WHEN CARRYING OUT TROUBLESHOOTING................9708
3. FAILURE CODE TABLE................9708
4. ACTION CODE TABLE................9709
5. TABLE OF TROUBLESHOOTING MODES AND CAUSES................9710
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLER SYSTEM................9711
A-1 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM................9713
A-2 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM................9713
A-3 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM................9714
A-4 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM................9715
A-5 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM................9716
A-6 TROUBLESHOOTING CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM................9717
A-7 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM................9718
A-8 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL................9719
A-9 HOLD SWITCH SYSTEM................9720
A-10 KICK-DOWN SWITCH SYSTEM................9720
A-11 TRANSMISSION CUT-OFF SIGNAL SYSTEM................9721
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM................9722
A-13 BUZZER SIGNAL SYSTEM................9723
A-14 NETWORK SIGNAL SYSTEM................9724
A-15 CONTROLLER POWER SOURCE SYSTEM................9725
30 DISASSEMBLY AND ASSEMBLY................9726
METHOD OF USING MANUAL ................9728
PRECAUTIONS WHEN CARRYING OUT OPERATION ................9729
SPECIAL TOOL LIST................9731
SKETCHES OF SPECIAL TOOLS................9733
STARTING MOTOR................9734
REMOVAL AND INSTALLATION................9734
ALTERNATOR................9735
REMOVAL AND INSTALLATION................9735
ENGINE OIL COOLER................9736
REMOVAL AND INSTALLATION................9736
FUEL INJECTION PUMP................9737
REMOVAL................9737
INSTALLATION................9738
WATER PUMP................9739
REMOVAL AND INSTALLATION................9739
TURBOCHARGER................9741
REMOVAL AND INSTALLATION................9741
NOZZLE HOLDER ................9742
REMOVAL AND INSTALLATION................9742
THERMOSTAT................9743
REMOVAL AND INSTALLATION................9743
CYLINDER HEAD................9744
REMOVAL ................9744
INSTALLATION................9749
RADIATOR................9751
REMOVAL................9751
INSTALLATION................9756
ENGINE................9757
REMOVAL................9757
INSTALLATION................9761
TORQUE CONVERTER CHARGING PUMP................9762
REMOVAL AND INSTALLATION................9762
TORQUE CONVERTER, TRANSMISSION ................9763
REMOVAL................9763
INSTALLATION................9776
TORQUE CONVERTER................9779
DISASSEMBLY................9779
ASSEMBLY................9781
TRANSMISSION................9783
DISASSEMBLY................9783
ASSEMBLY................9793
TRANSMISSION CLUTCH PACK................9807
DISASSEMBLY................9807
ASSEMBLY................9813
TRANSMISSION CONTROL VALVE................9825
REMOVAL................9825
INSTALLATION................9827
DISASSEMBLY................9828
ASSEMBLY................9830
TRANSMISSION ACCUMULATOR VALVE................9833
DISASSEMBLY................9833
ASSEMBLY................9834
TRANSMISSION MODULATING VALVE................9835
DISASSEMBLY................9835
ASSEMBLY................9836
DRIVE SHAFT................9837
DISASSEMBLY................9837
ASSEMBLY................9839
FRONT AXLE................9841
REMOVAL................9841
INSTALLATION................9843
REAR AXLE ................9844
REMOVAL................9844
INSTALLATION................9848
DIFFERENTIAL................9849
DISASSEMBLY................9849
ASSEMBLY................9854
AXLE HOUSING ................9864
DISASSEMBLY................9864
ASSEMBLY................9870
CENTER HINGE PIN ................9879
REMOVAL................9879
INSTALLATION................9884
PRIORITY VALVE................9888
REMOVAL................9888
INSTALLATION................9889
STEERING VALVE................9890
REMOVAL................9890
INSTALLATION................9891
DISASSEMBLY................9892
ASSEMBLY................9895
STEERING CYLINDER................9900
REMOVAL................9900
INSTALLATION................9901
RIGHT BRAKE VALVE (TANDEM)................9902
DISASSEMBLY................9902
ASSEMBLY................9903
LEFT BRAKE VALVE (SINGLE)................9904
DISASSEMBLY................9904
ASSEMBLY................9905
PARKING BRAKE DISC................9906
REMOVAL................9906
INSTALLATION................9908
ACCUMULATOR CHARGE VALVE................9909
REMOVAL................9909
INSTALLATION................9909
DISASSEMBLY................9910
ASSEMBLY................9912
HYDRAULIC TANK................9914
REMOVAL................9914
INSTALLATION................9915
HYDRAULIC FILTER................9916
REMOVAL AND INSTALLATION................9916
HYDRAULIC, STEERING PUMP................9917
REMOVAL................9917
INSTALLATION................9923
MAIN CONTROL VALVE................9924
REMOVAL................9924
INSTALLATION................9925
DISASSEMBLY................9926
ASSEMBLY................9928
PPC VALVE................9931
REMOVAL................9931
INSTALLATION................9932
DISASSEMBLY................9933
ASSEMBLY................9934
BUCKET CYLINDER................9935
REMOVAL................9935
INSTALLATION................9936
BOOM CYLINDER................9937
REMOVAL................9937
INSTALLATION................9938
HYDRAULIC CYLINDER................9939
DISASSEMBLY................9939
ASSEMBLY................9942
WORK EQUIPMENT ................9945
REMOVAL................9945
INSTALLATION................9948
COUNTERWEIGHT................9950
REMOVAL AND INSTALLATION................9950
FUEL TANK................9951
REMOVAL................9951
INSTALLATION................9953
CAB ................9954
REMOVAL................9954
INSTALLATION................9955
MAIN MONITOR................9956
REMOVAL................9956
INSTALLATION................9957
MAINTENANCE MONITOR................9958
REMOVAL AND INSTALLATION................9958
AIR CONDITIONER UNIT................9959
REMOVAL................9959
INSTALLATION................9964
AIR CONDITIONER CONDENSER................9965
REMOVAL................9965
INSTALLATION................9966
DRY RECEIVER ................9967
REMOVAL AND INSTALLATION................9967
AIR CONDITIONER COMPRESSOR................9968
REMOVAL................9968
INSTALLATION................9969
40 MAINTENANCE STANDARD................9970
ENGINE MOUNT, TRANSMISSION MOUNT................9971
TORQUE CONVERTER CHARGING PUMP................9972
TORQUE CONVERTER................9973
TRANSMISSION................9974
TRANSMISSION CONTROL VALVE................9982
MODULATION VALVE ASSEMBLY................9986
ACCUMULATOR VALVE................9987
DRIVE SHAFT................9988
DIFFERENTIAL................9989
FINAL DRIVE................9995
AXLE MOUNT................9999
CENTER HINGE PIN................10000
STEERING COLUMN................10002
PRIORITY VALVE................10003
STEERING CYLINDER MOUNT................10004
BRAKE ................10005
BRAKE VALVE................10007
PARKING BRAKE................10010
HYDRAULIC PUMP ................10011
MAIN CONTROL VALVE................10012
PPC VALVE................10016
HYDRAULIC CYLINDER................10017
WORK EQUIPMENT LINKAGE................10018
BUCKET................10020
BUCKET POSITIONER AND BOOM KICK-OUT................10021
SEBM017300 - Wheel Loader WA320L-3 avance Shop Manual................10022
COVER................10022
CONTENTS................10023
01 GENERAL................10024
GENERAL ASSEMBLY DRAWING................10025
SPECIFICATIONS................10026
WEIGHT TABLE................10029
LIST OF LUBRICANT AND WATER................10030
10 STRUCTURE AND FUNCTION................10032
POWER TRAIN................10033
POWER TRAIN SYSTEM................10034
TORQUE CONVERTER,TRANSMISSION PIPING................10036
TORQUE CONVERTER................10037
TORQUE CONVERTER OIL FILTER................10039
TRANSMISSION................10040
TRANSMISSION CONTROL VALVE................10051
DRIVE SHAFT................10071
AXLE................10072
DIFFERENTIAL................10074
FINAL DRIVE................10078
AXLE MOUNT,CENTER HINGE PIN................10079
STEERING PIPING................10081
STEERING COLUMN................10082
PRIORITY VALVE................10083
STEERING VALVE (ORBIT-ROLL)................10087
2-WAY RESTRICTOR VALVE................10095
BRAKE PIPING................10096
BRAKE VALVE................10097
BRAKE CHARGER VALVE................10102
ACCUMULATOR (FOR BRAKE)................10106
BRAKE................10107
PARKING BRAKE CONTROL................10110
PARKING BRAKE................10111
HYDRAULIC PIPING................10112
WORK EQUIPMENT LEVER LINKAGE................10114
HYDRAULIC TANK................10115
MAIN CONTROL VALVE................10117
WORK EQUIPMENT LINKAGE................10130
BUCKET POSITIONER AND BOOM KICK-OUT................10132
AIR CONDITIONER (OPT)................10136
CENTRAL PANEL (CLUSTER GAUGE)................10137
SENSORS................10138
ENGINE STARTING CIRCUIT................10141
ENGINE STOP CIRCUIT................10142
ENGINE STOP SOLENOID................10143
AUTOMATIC PREHEATING CIRCUIT (Q.H.S. CONTROLLER)................10144
ELECTRIC TRANSMISSION CONTROL................10148
KICK-DOWN SWITCH................10151
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM................10152
TRANSMISSION CUT-OFF SWITCH................10156
TRANSMISSION CUT-OFF FUNCTION................10157
20 TESTING AND ADJUSTING................10159
STANDARD VALUE TABLE FOR ENGINE................10160
STANDARD VALUE TABLE FOR CHASSIS................10161
STANDARD VALUE TABLE FOR ELECTRICAL PARTS................10167
TABLE OF TOOLS FOR TESTINGS,ADJUSTING,AND TROUBLESHOOTING................10171
MEASURING ENGINE SPEED................10173
MEASURING EXHAUST GAS COLOR................10175
ADJUSTING VALVE CLEARANCE................10176
MEASURING COMPRESSION PRESSURE................10178
MEASURING BLOW-BY PRESSURE................10179
TESTING AND ADJUSTING FUEL INJECTION TIMING................10180
MEASURING ENGINE OIL PRESSURE................10181
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................10182
TESTING AND ADJUSTING ENGINE STOP SOLENOID LINKAGE................10183
ADJUSTING ACCELERATOR ACTUATOR CABLE................10184
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE................10185
PROCEDURE FOR MOVING MACHINE WHEN TRANSIMISSION VALVE FAILS................10189
TESTING AND ADJUSTING STEERING OIL PRESSURE................10190
BLEEDING AIR FROM STEERING CIRCUIT................10191
TESTING WHEEL BRAKE PERFORMANCE................10192
TESTING DROP IN WHEEL BRAKE OIL PRESSURE................10193
MEASURING WHEEL BRAKE DISC WEAR................10194
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT................10195
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE................10196
MEASURING PARKING BRAKE PERFORMANCE................10198
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE................10199
TESTING WEAR OF PARKING BRAKE DISC................10200
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE................10201
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT................10203
ADJUSTING WORK EQUIPMENT LEVER LINKAGE................10204
ADJUSTING SAFETY LOCK LEVER................10206
TESTING AND ADJUSTING OF BUCKET PROXIMITY SWITCH................10207
TESTING AND ADJUSTING OF BOOM PROXIMITY SWITCH................10208
TROUBLESHOOTING................10210
POINTS TO REMEMBER WHEN TROUBLESHOOTING................10211
SEQUENCE OF EVENTS IN TROUBLESHOOTING................10212
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................10213
CHECKS BEFORE TROUBLESHOOTING................10221
METHOD OF USING TROUBLESHOOTING CHARTS................10222
CONNECTOR TYPES AND MOUNTING LOCATIONS................10230
CONNECTOR PIN ARRANGEMENT DIAGRAM................10232
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................10236
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................10244
S-1 STARTING PERFORMANCE IS POOR (STARTNG ALWAYS TAKES TIME)................10245
S-2 ENGINE DOES NOT START................10246
(1) ENGINE DOES NOT TURN................10246
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)................10247
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................10248
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................10249
S-4 ENGINE STOPS DURING OPERATIONS................10250
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................10251
S-6 ENGINE LACKS OUTPUT (NO POWER)................10252
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)................10253
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)................10254
S-9 OIL BECOMES CONTAMINATED QUICKLY................10255
S-10 FUEL CONSUMPTION IS EXCESSIVE................10256
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN................10257
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)................10258
S-13 OIL LEVEL RISES................10259
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................10260
S-15 ABNORMAL NOISE IS MADE ................10261
S-16 VIBRATION IS EXCESSIVE................10262
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................10263
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING,STOP AND PREHEATING SYSTEM................10264
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM................10265
E-1 ENGINE DOES NOT START................10266
a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START................10266
b) ENGINE STOP SOLENOID DOES NOT WORK................10269
E-2 ENGINE DOES NOT STOP................10270
E-3 PREHEATING IS NOT CARRIED OUT................10271
E-4 PREHEATING REMAINS ACTUATED................10273
E-5 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT TRANSMISSION CUT-OFF WORKS NORMALLY)................10274
E-6 TRANSMISSION DOES NOT WORK NORMALLY................10275
a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)................10277
b) PROBLEM IN H-L CIRCUIT................10278
c) PROBLEM IN SPEED CIRCUIT................10279
d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)................10280
e) CONTACT IN H-L CIRCUIT................10281
f) CONTACT IN SPEED CIRCUIT................10282
g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)................10283
h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)................10284
i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)................10286
j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD OR IN REVERSE)................10288
k) CONTACT IN FORWARD CIRCUIT................10290
l) CONTACT IN REVERSE CIRCUIT................10292
m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE................10294
E-7 KICK-DOWN SWITCH DOES NOT WORK (THE REGULAR F1 TO F4 SHIFTS NORMALLY)................10295
E-8 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION)................10297
E-9 KICK-DOWN IS NOT CANCELED................10297
a) NOT CANCELED WHEN F/R LEVER IS OPERATED FROM F TO N OR R................10297
b) NOT CANCELED WHEN SPEED LEVER IS OPERATED FROM 2 TO OTHER POSITION................10298
E-10 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND................10300
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)................10301
POWER TRAIN................10302
H-1 MACHINE DOES NOT START................10302
H-2 TRAVEL SPEED IS SLOW,THRUSTING POWER IS WEAK,LACKS POWER ON SLOPES................10304
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR................10306
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR................10307
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH................10308
STEERING SYSTEM................10309
H-6 STEERING WHEEL DOES NOT TURN................10309
H-7 STEERING IS HEAVY................10310
H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK................10311
BRAKE SYSTEM................10312
H-9 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR................10312
H-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG................10313
WORK EQUIPMENT................10314
H-11 BOOM DOES NOT RISE................10314
H-12 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER................10315
H-13 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT................10316
H-14 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)................10316
H-15 EXCESSIVE HYDRAULIC DRIFT OF BOOM................10316
H-16 BOOM SHAKES DURING OPERATION................10316
H-17 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE................10317
H-18 BUCKET DOES NOT TILT BACK................10318
H-19 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER................10319
H-20 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION................10320
H-21 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER................10320
H-22 EXCESSIVE HYDRAULIC DRIFT OF BUCKET................10320
H-23 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)................10321
H-24 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT................10321
H-25 BOOM,BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY................10322
30 DISASSEMBLY AND ASSEMBLY................10323
METHOD OF USING MANUAL................10325
PRECAUTIONS WHEN CARRYING OUT OPERATION................10326
SPECIAL TOOL LIST................10328
SKETCHES OF SPECIAL TOOLS................10331
STARTING MOTOR................10333
REMOVAL AND INSTALLATION................10333
ALTERNATOR................10334
REMOVAL AND INSTALLATION................10334
ENGINE OIL COOLER CORE................10335
REMOVAL AND INSTALLATION................10335
FUEL INJECTION PUMP................10336
REMOVAL................10336
INSTALLATION................10338
WATER PUMP................10341
REMOVAL AND INSTALLATION................10341
TURBOCHARGER................10342
REMOVAL AND INSTALLATION................10342
NOZZLE HOLDER................10343
REMOVAL................10343
INSTALLATION................10344
THERMOSTAT................10345
REMOVAL AND INSTALLATION................10345
ENGINE HOOD................10346
REMOVAL................10346
INSTALLATION................10347
CYLINDER HEAD................10348
REMOVAL................10348
INSTALLATION................10352
RADIATOR................10355
REMOVAL................10355
INSTALLATION................10356
ENGINE................10357
REMOVAL................10357
INSTALLATION................10360
TORQUE CONVERTER CHARGING PUMP................10361
REMOVAL AND INSTALLATION................10361
TORQUE CONVERTER,TRANSMISSION................10362
REMOVAL................10362
INSTALLATION................10365
TORQUE CONVERTER................10366
DISASSEMBLY................10366
ASSEMBLY................10368
TRANSMISSION ................10370
DISASSEMBLY................10370
ASSEMBLY................10380
CLUTCH PACK................10393
DISASSEMBLY................10393
ASSEMBLY................10399
PARKING BRAKE................10412
DISASSEMBLY................10412
ASSEMBLY................10415
TRANSMISSION CONTROL VALVE................10418
REMOVAL................10418
INSTALLATION................10419
DISASSEMBLY................10420
ASSEMBLY................10422
DRIVE SHAFT................10424
DISASSEMBLY................10424
ASSEMBLY................10426
FRONT AXLE................10428
REMOVAL................10428
INSTALLATION................10430
REAR AXLE................10431
REMOVAL................10431
INSTALLATION................10435
DIFFERENTIAL................10436
DISASSEMBLY................10436
ASSEMBLY................10440
AXLE HOUSING................10450
DISASSEMBLY................10450
ASSEMBLY................10457
CENTER HINGE PIN................10466
REMOVAL................10466
INSTALLATION................10471
STEERING VALVE................10475
REMOVAL................10475
INSTALLATION................10476
DISASSEMBLY................10477
ASSEMBLY................10480
PRIORITY VALVE................10484
REMOVAL AND INSTALLATION................10484
STEERING CYLINDER................10485
REMOVAL AND INSTALLATION................10485
RIGHT BRAKE VALVE (TANDEM)................10486
DISASSEMBLY................10486
ASSEMBLY................10487
LEFT BRAKE VALVE (SINGLE)................10488
DISASSEMBLY................10488
ASSEMBLY................10489
PARKING BRAKE DISC................10490
REMOVAL................10490
INSTALLATION................10491
HYDRAULIC TANK................10492
REMOVAL AND INSTALLATION................10492
HYDRAULIC FILTER................10493
REMOVAL AND INSTALLATION................10493
HYDRAULIC COOLER................10494
REMOVAL AND INSTALLATION................10494
HYDRAULIC,STEERING PUMP................10495
REMOVAL AND INSTALLATION................10495
MAIN CONTROL VALVE................10496
REMOVAL................10496
INSTALLATION................10497
DISASSEMBLY................10498
ASSEMBLY................10500
BUCKET CYLINDER................10502
REMOVAL................10502
INSTALLATION................10503
BOOM CYLINDER................10504
REMOVAL................10504
INSTALLATION................10505
HYDRAULIC CYLINDER................10506
DISASSEMBLY................10506
ASSEMBLY................10509
WORK EQUIPMENT................10513
REMOVAL................10513
INSTALLATION................10516
COUNTERWEIGHT................10519
REMOVAL AND INSTALLATION................10519
FUEL TANK................10520
REMOVAL................10520
INSTALLATION................10521
CAB................10522
REMOVAL................10522
INSTALLATION................10523
FLOOR FRAME................10524
REMOVAL................10524
INSTALLATION................10526
ACCUMULATOR CHARGE VALVE................10527
REMOVAL AND INSTALLATION................10527
ACCUMULATOR UNIT................10528
REMOVAL AND INSTALLATION................10528
AIR CONDITIONER UNIT................10529
REMOVAL................10529
INSTALLATION................10534
AIR CONDITIONER CONDENSER................10535
REMOVAL................10535
INSTALLATION................10536
DRY RECEIVER................10537
REMOVAL AND INSTALLATION................10537
AIR CONDITIONER COMPRESSOR................10538
REMOVAL................10538
INSTALLATION................10539
MONITOR PANEL................10540
REMOVAL AND INSTALLATION................10540
40 MAINTENANCE STANDARD................10541
ENGINE MOUNT,TRANSMISSION MOUNT................10542
TORQUE CONVERTER CHARGING PUMP................10543
TORQUE CONVERTER................10544
TRANSMISSION................10545
TRANSMISSION CONTROL VALVE................10553
DRIVE SHAFT................10557
DIFFERENTIAL (1/2)................10558
DIFFERENTIAL (2/2)................10559
FINAL DRIVE................10561
AXLE MOUNT................10563
CENTER HINGE PIN................10564
STEERING COLUMN................10566
PRIORITY VALVE................10567
STEERING CYLINDER MOUNT................10568
BRAKE................10569
BRAKE VALVE................10570
PARKING BRAKE................10573
HYDRAULIC PUMP (STEERING,HYDRAULIC,BRAKE CHARGE PUMP)................10574
MAIN CONTROL VALVE................10575
HYDRAULIC CYLINDER................10579
WORK EQUIPMENT LINKAGE................10580
BUCKET................10582
BUCKET POSITIONER AND BOOM KICK-OUT................10583
90 OTHERS................10584
TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................10585
BRAKE HYDRAULIC CIRCUIT DIAGRAM................10586
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................10588
ELECTRIC CIRCUIT DIAGRAM (1/3)................10590
ELECTRIC CIRCUIT DIAGRAM (2/3)................10591
ELECTRIC CIRCUIT DIAGRAM (3/3)................10592
SEBM034604 - Wheel Loader WA320-5, WA320L-5 Shop Manual................10593
COVER................10593
CONTENTS................10594
SAFETY................10598
SAFETY NOTICE................10598
FOREWORD................10600
GENERAL................10600
HOW TO READ THE SHOP MANUAL................10601
HOISTING INSTRUCTIONS................10602
METHOD OF DISASSMBLING, CONNECTING PUSH-PULL TYPE COUPLER................10603
COATING MATERIALS................10605
STANDARD TIGHTING TORQUE................10607
ELECTRIC WIRE CODE................10610
CONVERSION TABLE................10611
UNITS................10617
01 GENERAL................10619
GENERAL ASSEMBLY DRAWINGS................10620
SPECIFICATIONS................10621
WEIGHT TABLE................10625
LIST OF LUBRICANT AND COOLANT................10627
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................10631
ENGINE MOUNT AND TRANSFER MOUNT................10632
DAMPER................10633
COOLING SYSTEM................10634
POWER TRAIN................10635
POWER TRAIN SYSTEM DIAGRAM................10636
DRIVE SHAFT (PROPELLER SHAFT)................10638
HST HYDRAULIC PIPING DIAGRAM................10639
HST PUMP................10640
HIGH PRESSURE RELIEF VALVE................10642
LOW PRESSURE RELIEF VALVE................10644
HST CHARGE PUMP................10645
SPEED RELATED VALVE (DA VALVE)................10646
HIGH PRESSURE CUT OFF VALVE................10647
HST MOTOR................10648
EP SERVO VALVE................10651
HA SERVO VALVE................10652
FORWARD-REVERSE SHUTTLE VALVE................10653
TRANSFER................10654
CLUTCH SOLENOID VALVE................10665
AXLE................10666
DIFFERENTIAL................10668
LIMITED SLIP DIFFERENTIAL................10676
FINAL DRIVE................10680
AXLE MOUNTING AND CENTER HINGE PIN................10682
STEERING PIPING................10687
STEERING COLUMN................10688
PRIORITY VALVE................10689
ORBIT ROLL VALVE................10692
CUSHION VALVE................10700
STEERING CYLINDER................10701
EMERGENCY STEERING PIPING................10703
EMERGENCY STEERING VALVE................10704
BRAKE PIPING................10707
BRAKE VALVE................10708
INCHING VALVE................10712
CHARGE VALVE................10714
ACCUMULATOR (FOR BRAKE)................10718
SLACK ADJUSTER................10720
BRAKE................10722
PARKING BRAKE CONTROL................10724
PARKING BRAKE................10725
HYDRAULIC PIPING................10726
WORK EQUIPMENT LEVER LINKAGE................10728
HYDRAULIC TANK................10730
4-GEAR PUMP UNIT................10732
ACCUMULATOR (FOR PPC CIRCUIT)................10734
LOCK VALVE................10735
E.C.S.S. VALVE................10736
ACCUMULATOR (FOR E.C.S.S.)................10738
HYDRAULIC PIPING OF COOLING SYSTEM................10739
COOLING FAN MOTOR................10740
WORK EQUIPMENT CONTROL VALVE................10743
WORK EQUIPMENT PPC VALVE................10764
ATTACHMENT PPC VALVE................10776
WORK EQUIPMENT LINKAGE................10780
BUCKET................10782
BUCKET POSITIONER AND BOOM KICK-OUT................10784
WORK EQUIPMENT CYLINDER................10790
AIR CONDITIONER................10791
MACHINE MONITORING SYSTEM................10792
MACHINE MONITOR................10802
LIST OF ITEMS DISPLAYED ON MONITOR................10803
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)................10829
HST CONTROLLER................10833
ENGINE START CIRCUIT................10834
ENGINE STOP CIRCUIT................10836
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)................10837
PARKING BRAKE CIRCUIT................10838
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM................10841
SENSORS................10842
20 TESTING AND ADJUSTING................10851
STANDARD VALUE TABLE FOR ENGINE................10852
STANDARD VALUE TABLE FOR CHASSIS................10853
TESTING AND ADJUSTING................10857
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................10858
MEASURING ENGINE SPEED................10860
MEASURING EXHAUST GAS COLOR................10861
ADJUSTING VALVE CLEARANCE................10863
MEASURING COMPRESSION PRESSURE................10864
MEASURING BLOW-BY PRESSURE................10865
TESTING AND ADJUSTING FUEL INJECTION TIMING................10866
MEASURING ENGINE OIL PRESSURE................10867
MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL................10868
ADJUSTING ENGINE STOP SOLENOID................10870
ADJUSTING ENGINE SPEED SENSOR................10871
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................10871
MEASURING DIRECTIONAL LEVER................10872
TESTING AND ADJUSTING HST OIL PRESSURE................10872
MEASURING CLUTCH CONTROL PRESSURE................10877
TESTING AND ADJUSTING STEERING WHEEL................10878
TESTING AND ADJUSTING STEERING OIL PRESSURE................10879
BLEEDING AIR FROM STEERING CIRCUIT................10880
TESTING HYDRAULIC FAN................10881
MEASURING BRAKE PEDAL................10882
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE................10883
MEASURING BRAKE PERFORMANCE................10884
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................10885
MEASURING BRAKE OIL PRESSURE................10886
MEASURING WEAR OF BRAKE DISC................10888
BLEEDING AIR FROM BRAKE CIRCUIT................10889
MEASURING PARKING BRAKE PERFORMANCE................10890
TESTING AND ADJUSTING PARKING BRAKE LINKAGE................10891
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER................10892
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE................10893
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE................10894
BLEEDING AIR................10896
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................10897
TESTING AND ADJUSTING BUCKET POSITIONER................10897
TESTING AND ADJUSTING OF BOOM KICK-OUT................10899
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................10900
PROCEDURE FOR CHECKING DIODE................10901
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER................10902
SPECIAL FUNCTIONS OF MACHINE MONITOR................10903
FLOW OF MODES AND FUNCTIONS................10904
FAILURE CODE TABLE................10912
PM CLINIC INSPECTION CHART................10922
TROUBLESHOOTING................10925
POINTS TO REMEMBER WHEN TROUBLESHOOTING................10926
SEQUENCE OF EVENTS IN TROUBLESHOOTING................10927
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................10928
CHECK BEFORE TROUBLESHOOTING................10936
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS................10937
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.................10938
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................10941
T-ADAPTER TABLE................10963
CONNECTOR TYPES AND MOUNTING LOCATIONS................10966
CONNECTOR LAYOUT DRAWING................10973
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)................10978
BEFORE TROUBLESHOOTING CODE DISPLAY................10979
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................10981
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................10982
FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))................10984
FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE REANGE (KX))................10985
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR SPEED SIGNAL MISMATCH (LC))................10987
FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................10989
FAILURE CODE [DX19LZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................10991
FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................10993
TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))................10995
TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFT)................10997
TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED................11001
TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEE SELECTOR SWITCH IS IN "1ST" POSITION)................11003
TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................11005
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE)................11008
RELATED ELECTRICAL CIRCUIT DIAGRAM................11009
ECSS-1 MALFUNCTION OF TRAVEL DAMPER................11010
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)................11015
BEFORE TROUBLESHOOTING CODE DISPLAY................11018
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................11020
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................11021
FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))................11023
FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE (ZG))................11024
FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))................11025
FAILURE CODE [989FN1] (HST OVERRUNNING (N1))................11026
FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX))................11028
FAILURE CODE [AB00L6] (DEFECTIVE BATTERY CHARGING CIRCUIT (L6))................11030
FAILURE CODE [AB00MA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))................11031
FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE (ZG))................11032
FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL (ZK)................11033
FAILURE CODE [B@BCNS] (ENGINE COOLANT TEMPERATURE OVERHEATING (NS))................11034
FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL (ZK))................11035
FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING (NS))................11036
FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING (NS))................11037
FAILURE CODE [D5ZHL6] (STARTING SWITCH "C" (IGN "C") INPUT FAILURE (L6))................11038
FAILURE CODE [DAF0KT] (CONTROLLER INSIDE FAILURE (KT))................11040
FAILURE CODE [DAJ0KR] (HST CONTROLLER COMMUNICATION FAILURE (KR))................11042
FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [ ] (PANEL SWITCH [] INPUT ERROR (LD)) ................11044
FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [<>] (PANEL SWITCH 2) INPUT ERROR (LD))................11045
FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3) INPUT ERROR (LD))................11046
FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4) INPUT ERROR (LD))................11047
FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB))................11048
FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6))................11050
FAILURE CODE [DGE2KX] (ENGINE COOLANT TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE (KX))................11051
FAILURE CODE [DGE3L6] (ENGINE COOLANT TEMPERATURE (LOW TEMPERTURE) SENSOR SYSTEM FAILURE (L6))................11052
FAILURE CODE [DGH1KX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))................11053
FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA))................11054
FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))................11055
FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))................11056
TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)................11058
TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)................11062
TROUBLESHOOTING CODE [MON-3] (THE ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT RISE).................11063
TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE HST OIL TEMPERATURE GAUGE DOE NOT RISE).................11064
TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE).................11065
TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)................11066
TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON]................11067
TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)................11068
TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [ ] (PANEL SWITCH 1))................11069
TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [} (PANEL SWITCH 2)................11070
TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3))................11071
TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4))................11072
TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)................11074
TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP................11076
TROUBLESHOOTING CODE [MON-15] AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP................11078
TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION................11080
TROUBLESHOOTING CODE [MON-17] THE LAMPS DO NOT WORK PROPERLY................11080
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................11081
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................11082
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................11083
TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START)................11086
TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)................11092
TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)................11094
TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)................11098
TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)................11104
TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)................11108
TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)................11111
TROUBLESHOOTING CODE [E-8] (TRAVEL DIRECTION IS NOT CHANGED NORMALLY)................11112
TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION)................11118
TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)................11124
TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY)................11128
TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)................11140
TROUBLESHOOTING CODE [E-13] (DEFECTIVE AIR CONDITIONER)................11142
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)................11155
METHOD OF USING TROUBLESHOOTING CHART................11156
FAILURE CODE AND CAUSE TABLE................11158
H-1 THE MACHINE DOES NOT START................11160
H-2 THE TRAVEL SPEED IS SLOW................11161
H-3 THE THRUSTING FORCE IS WEAK................11162
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY................11163
H-5 THE GEAR IS NOT SHIFTED................11164
H-6 THE STEERING WHEEL DOES NOT TURN................11165
H-7 THE STEERING WHEEL IS HEAVY................11166
H-8 STEERING WHEEL SHAKES OR JERKS................11167
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING................11167
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL................11168
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................11169
H-12 THE LIFT ARM DOES NOT RISE OR LOWER................11170
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT................11171
H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT................11172
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKT (THE BUCKET RISES IN THE AIR)................11172
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN................11172
H-17 THE LIFT ARM WOBBLES DURING OPERATION................11172
H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE," THE LIFT ARM FALLS TEMPORARILY................11173
H-19 THE BUCKET DOES OT TILT BACK................11174
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT................11175
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTINGBACK................11176
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET................11176
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN................11176
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")................11177
H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPRARILY................11177
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY................11177
H-27 TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES................11178
TROUBLESHOOTING OF ENGINE (S MODE)................11179
METHOD OF USING TROUBLESHOOTING CHARTS................11180
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................11184
S-2 ENGINE DOES NOT START................11186
(1) ENGINE DOES NOT TURN................11186
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................11187
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................11188
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................11189
S-4 ENGINE STOPS DURING OPERATIONS................11190
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................11191
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................11192
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................11193
S-8 OIL CONSUMPTION IS EXCESSIVE................11194
S-9 OIL BECOMES CONTAMINATED QUICKLY................11195
S-10 FUEL CONSUMPTION IS EXCESSIVE................11196
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN................11197
S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)................11198
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)................11199
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................11200
S-15 ABNORMAL NOISE IS MADE................11201
S-16 VIBRATION IS EXCESSIVE................11202
30 DISASSEMBLY AND ASSEMBLY................11203
HOW TO READ THIS MANUAL................11204
PRECAUTIONS WHEN CARRYING OUT OPERATION................11206
SPECIAL TOOL LIST................11208
SKETCH OF SPECIAL TOOLS................11211
REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................11217
REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY................11221
REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY................11223
REMOVAL, INSTALLATION OF ENGINE ASSEMBLY................11231
REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY................11238
REMOVAL, INSTALLATION OF AIR AFTERCOOLER................11239
REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY................11241
REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY................11243
REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY................11245
REMOVAL, INSTALLATION OF TRANSFER................11247
DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY................11249
REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY................11269
DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY................11271
REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY................11276
REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY................11278
DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY................11281
DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY................11294
REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY................11318
REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY................11321
REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY................11323
REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY................11325
REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY................11327
REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY................11329
REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY................11331
DISASSEMBLY AND ASSEMBLYOF HST PUMP ASSEMBLY................11338
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY................11365
DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY................11381
REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY................11388
REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)................11394
REMOVAL, INSTALLATION OF CENTER HINGE PIN................11402
REMOVAL, INSTALLATION OF COUNTERWEIGHT................11413
REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY................11415
REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY................11418
REMOVAL, INSTALLATION OF MONITOR PANEL................11419
REMOVAL, INSTALLATION OF HST CONTROLLER ASSEMBLY................11423
90 OTHERS................11424
HYDRAULIC CIRCUIT DIAGRAM................11425
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4)................11426
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4)................11427
ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4)................11428
ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4)................11429
ELECTRICAL CIRCUIT DIAGRAM 2/4................11430
ELECTRICAL CIRCUIT DIAGRAM 3/4................11431
ELECTRICAL CIRCUIT DIAGRAM 4/4................11432
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)1/2................11433
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)2/2................11434
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)................11435
SEBM034607 - Wheel Loader WA320-5 Shop Manual................11437
COVER................11437
CONTENTS ................11438
LIST OF REVISED PAGES................11439
01 GENERAL ................11463
GENERAL ASSEMBLY DRAWINGS................11464
SPECIFICATIONS................11465
WEIGHT TABLE ................11469
LIST OF LUBRICANT AND COOLANT................11471
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD................11472
ENGINE MOUNT AND TRANSFER MOUNT................11473
DAMPER................11474
COOLING SYSTEM................11475
POWER TRAIN................11478
POWER TRAIN SYSTEM DIAGRAM................11479
DRIVE SHAFT (PROPELLER SHAFT)................11481
HST HYDRAULIC PIPING DIAGRAM................11482
HST PUMP................11483
HIGH-PRESSURE RELIEF VALVE................11485
LOW-PRESSURE RELIEF VALVE................11487
HST CHARGE PUMP................11488
SPEED-RELATED VALVE (DA VALVE)................11489
HIGH-PRESSURE CUT-OFF VALVE................11490
HST MOTOR................11491
EP SERVO VALVE................11494
HA SERVO VALVE................11495
FORWARD-REVERSE SHUTTLE VALVE................11496
TRANSFER................11497
CLUTCH SOLENOID VALVE................11508
AXLE................11509
DIFFERENTIAL................11511
LIMITED-SLIP DIFFERENTIAL................11518
FINAL DRIVE................11522
AXLE MOUNTING AND CENTER HINGE PIN................11524
STEERING PIPING................11529
STEERING COLUMN................11530
PRIORITY VALVE................11531
ORBIT-ROLL VALVE................11534
CUSHION VALVE................11542
STEERING CYLINDER................11543
EMERGENCY STEERING PIPING................11545
EMERGENCY STEERING VALVE................11546
BRAKE PIPING................11549
BRAKE VALVE................11550
INCHING VALVE................11554
CHARGE VALVE................11555
ACCUMULATOR (FOR BRAKE)................11559
SLACK ADJUSTER................11560
BRAKE................11562
PARKING BRAKE CONTROL................11564
PARKING BRAKE................11565
HYDRAULIC PIPING................11566
WORK EQUIPMENT LEVEL LINKAGE................11568
HYDRAULIC TANK................11569
4-GEAR PUMP UNIT................11571
ACCUMULATOR (FOR PPC CIRCUIT)................11573
LOCK VALVE................11574
E.C.S.S. VALVE................11575
ACCUMULATOR (FOR E.C.S.S.)................11577
HYDRAULIC PIPING OF COOLING SYSTEM................11578
COOLING FAN MOTOR................11579
WORK EQUIPMENT CONTROL VALVE................11581
WORK EQUIPMENT PPC VALVE................11600
ATTACHMENT PPC VALVE................11612
WORK EQUIPMENT LINKAGE................11616
BUCKET................11618
BUCKET POSITIONER AND BOOM KICK-OUT................11619
WORK EQUIPMENT CYLINDER................11625
AIR CONDITIONER................11626
MACHINE MONITORING SYSTEM................11627
MACHINE MONITOR................11636
LIST OF ITEMS DISPLAYED ON MONITOR................11637
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)................11663
HST CONTROLLER................11667
KOMTRAX SYSTEM................11668
ENGINE START CIRCUIT................11670
ENGINE STOP CIRCUIT................11672
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)................11673
PARKING BRAKE CIRCUIT................11674
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM................11677
SENSORS................11678
20 TESTING AND ADJUSTING................11686
STANDARD VALUE TABLE FOR ENGINE................11687
STANDARD VALUE TABLE FOR CHASSIS................11688
TESTING AND ADJUSTING................11692
TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING................11693
MEASURING ENGINE SPEED................11695
MEASURING EXHAUST GAS COLOR................11696
ADJUSTING VALVE CLEARANCE................11698
MEASURING COMPRESSION PRESSURE................11699
MEASURING BLOW-BY PRESSURE................11700
TESTING AND ADJUSTING FUEL INJECTION TIMING................11701
MEASURING ENGINE OIL PRESSURE................11702
MEASURING, TESTING OPERATION FORCE OF ACCELERATOR PEDAL................11703
ADJUSTING ENGINE STOP SOLENOID................11705
ADJUSTING ENGINE SPEED SENSOR................11706
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................11706
MEASURING DIRECTIONAL LEVER................11707
TESTING AND ADJUSTING HST OIL PRESSURE................11707
MEASURING CLUTCH CONTROL PRESSURE................11712
TESTING AND ADJUSTING STEERING WHEEL................11713
TESTING AND ADJUSTING STEERING OIL PRESSURE................11714
BLEEDING AIR FROM STEERING CIRCUIT................11715
TESTING HYDRAULIC FAN................11716
MEASURING BRAKE PEDAL................11717
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE................11718
MEASURING BRAKE PERFORMANCE................11719
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................11720
MEASURING BRAKE OIL PRESSURE................11721
MEASURING WEAR OF BRAKE DISC................11723
BLEEDING AIR FROM BRAKE CIRCUIT................11724
MEASURING PARKING BRAKE PERFORMANCE................11725
TESTING AND ADJUSTING PARKING BRAKE LINKAGE................11726
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER................11727
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE................11728
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE................11729
BLEEDING AIR................11731
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................11732
TESTING AND ADJUSTING BUCKET POSITIONER................11732
TESTING AND ADJUSTING OF BOOM KICK-OUT................11734
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................11735
PROCEDURE FOR CHECKING DIODE................11736
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER................11737
STARTING KOMTRAX TERMINAL OPERATIONS................11738
SPECIAL FUNCTIONS OF MACHINE MONITOR................11746
FLOW OF MODES AND FUNCTIONS................11747
FAILURE CODE TABLE................11755
PM CLINIC INSPECTION CHART................11765
TROUBLESHOOTING................11767
POINTS TO REMEMBER WHEN TROUBLESHOOTING................11768
SEQUENCE OF EVENTS IN TROUBLESHOOTING................11769
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................11770
CHECKS BEFORE TROUBLESHOOTING................11778
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS................11779
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.................11780
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................11783
T-ADAPTER TABLE................11805
CONNECTOR TYPES AND MOUNTING LOCATIONS................11808
CONNECTOR LAYOUT DRAWING................11815
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)................11820
BEFORE TROUBLESHOOTING CODE DISPLAY................11821
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................11823
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................11824
FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION(00))................11826
FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX))................11827
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))................11829
FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ))................11830
FAILURE CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................11832
FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................11834
TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))................11836
TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)................11838
TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED................11841
TROUBLESHOOTING CODE [HSR-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)................11843
TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................11845
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM(ECSS MODE)................11846
RELATED ELECTRICAL CIRCUIT DIAGRAM................11847
ECSS-1 MALFUNCTION OF TRAVEL DAMPER................11848
TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE)................11853
BEFORE TROUBLESHOOTING CODE DISPLAY................11855
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................11857
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................11858
FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))................11860
FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE(ZG))................11861
FAILURE CODE [989FOO] (HST MOTOR PROTECTION CAUTION (OO))................11862
FAILURE CODE [989FN1] (HST OVERRUNNING (N1))................11863
FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX))................11864
FAILURE CODE [ABOOL6] (DEFECTIVE BATTERY CHARGING CIRCUIT(L6))................11866
FAILURE CODE [ABOOMA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))................11867
FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE(ZG))................11868
FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL(ZK)................11869
FAILURE CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING(NS))................11870
FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL(ZK))................11871
FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING(NS))................11872
FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING(NS))................11873
FAILURE CODE [D5ZHL6] (STARTING SWITCH "C"(IGN"C")INPUT FAILURE(L6))................11874
FAILURE CODE [DAFOKT] (CONTROLLER INSIDE FAILURE(KT))................11876
FAILURE CODE [DAJOKR] (HST CONTROLLER COMMUNICATION FAILURE(KR))................11877
FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)INPUT ERROR(LD))................11879
FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)INPUT ERROR (LD)................11880
FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)INPUT ERROR (LD)................11881
FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)INPUT ERROR (LD)................11882
FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB))................11883
FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE(L6))................11885
FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE(KX))................11886
FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6))................11887
FAILURE CODE [DGH1LX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))................11888
FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))................11889
FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))................11890
FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))................11891
TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)................11892
TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)................11896
TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.) ................11897
TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.) ................11898
TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)................11899
TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)................11900
TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)................11901
TROUBLESHOOTING CODE [MON-6] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)................11902
TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1))................11903
TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2))................11904
TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3))................11905
TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4))................11906
TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)................11907
TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP................11909
TROUBLESHOOTING CODE [MON-15] (AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP)................11910
TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION................11912
TROUBLESHOOTING CODE [MON-17] (THE LAMPS DO NOT WORK PROPERLY)................11912
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................11913
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................11914
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................11915
TROUBLESHOOTING CODE [E-1](THE ENGINE DOES NOT START)................11917
TROUBLESHOOTING CODE [E-2](THE ENGINE DOES NOT STOP)................11923
TROUBLESHOOTING CODE [E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT)................11925
TROUBLESHOOTING CODE [E-4](THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)................11929
TROUBLESHOOTING CODE [E-5](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)................11934
TROUBLESHOOTING CODE [E-6](DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)................11937
TROUBLESHOOTING CODE [E-7](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)................11940
TROUBLESHOOTING CODE [E-8](TRAVEL DIRECTION IS NOT CHANGED NORMALLY)................11941
TROUBLESHOOTING CODE [E-9](THE WIPER DOES NOT FUNCTION)................11947
TROUBLESHOOTING CODE [E-10](THE WINDOW WASHER DOES NOT FUNCTION)................11952
TROUBLESHOOTING CODE [E-11](LAMPS DO NOT WORK PROPERLY)................11955
TROUBLESHOOTING CODE [E-12](THE HORN DOES NOT SOUND)................11966
TROUBLESHOOTING CODE [E-13](DEFECTIVE THE AIR CONDITIONER)................11968
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE)................11980
METHOD OF USING TROUBLESHOOTING CHART................11981
FAILURE CODE AND CAUSE TABLE................11983
H-1 THE MACHINE DOES NOT START................11985
H-2 THE TRAVEL SPEED IS SLOW................11986
H-3 THE THRUSTING FORCE IS WEAK................11987
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY................11988
H-5 THE GEAR IS NOT SHIFTED ................11989
H-6 THE STEERING WHEEL DOES NOT TURN................11990
H-7 THE STEERING WHEEL IS HEAVY................11991
H-8 STEERING WHEEL SHAKES OR JERKS................11992
H-10 THE BRAKE DOES NOT WORK OR NOES NOT WORK WELL ................11993
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................11994
H-12 THE LIFT ARM DOES NOT RISE OR LOWER................11995
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT................11996
H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ................11997
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR)................11997
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN................11997
H-17 THE LIFT ARM WOBBLES DURING OPERATION................11997
H-18 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY ................11998
H-19 THE BUCKET DOES NOT TILT BACK................11999
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT................12000
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING BACK................12001
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET................12001
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN................12001
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")................12002
H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD"TO "TILT",THE BUCKET FALLS TEMPORARILY................12002
H-26 THE CONTROL LEVELS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY................12002
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES................12003
TROUBLESHOOTING OF ENGINE (S MODE)................12004
METHOD OF USING TROUBLESHOOTING CHARTS ................12005
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)................12009
S-2 ENGINE DOES NOT START................12011
(1)ENGINE DOES NOT TURN................12011
(2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)................12012
(3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)................12013
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)................12014
S-4 ENGINE STOPS DURING OPERATIONS................12015
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................12016
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)................12017
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)................12018
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................12019
S-9 OIL BECOMES CONTAMINATED QUICKLY................12020
S-10 FUEL CONSUMPTION IS EXCESSIVE................12021
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN................12022
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)................12023
S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) ................12024
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) ................12025
S-15 ABNORMAL NOISE IS MADE................12026
S-16 VIBRATION IS EXCESSIVE................12027
30 DISASSEMBLY AND ASSEMBLY................12028
HOW TO READ THIS MANUAL................12029
PRECAUTIONS WHEN CARRYING OUT OPERATION................12031
SPECIAL TOOL LIST................12033
SKETCH OF SPECIAL TOOLS................12036
REMOVAL,INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................12042
REMOVAL,INSTALLATION OF NOZZLE HOLDER ASSEMBLY................12046
REMOVAL,INSTALLATION OF CYLINDER HEAD ASSEMBLY................12048
REMOVAL,INSTALLATION OF ENGINE ASSEMBLY................12056
REMOVAL,INSTALLATION OF RADIATOR ASSEMBLY................12063
REMOVAL,INSTALLATION OF AIR AFTERCOOLER................12064
REMOVAL,INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY................12066
REMOVAL,INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY................12068
REMOVAL,INSTALLATION OF FUEL TANK ASSEMBLY................12070
REMOVAL,INSTALLATION OF TRANSFER................12072
DISASSEMBLY,ASSEMBLY OF TRANSFER ASSEMBLY................12074
REMOVAL,INSTALLATION OF PARKING BRAKE ASSEMBLY................12094
DISASSEMBLY,ASSEMBLY OF PARKING BRAKE ASSEMBLY................12096
REMOVAL,INSTALLATION OF FRONT AXLE ASSEMBLY................12101
REMOVAL,INSTALLATION OF REAR AXLE ASSEMBLY................12103
DISASSEMBLY,ASSEMBLY OF AXLE HOUSING ASSEMBLY................12106
DISASSEMBLY,ASSEMBLY OF DIFFERENTIAL ASSEMBLY................12119
REMOVAL,INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY................12143
REMOVAL,INSTALLATION OF HST MOTOR 1 ASSEMBLY................12146
REMOVAL,INSTALLATION OF HST MOTOR 2 ASSEMBLY................12148
REMOVAL,INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY................12150
REMOVAL,INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY(IF EQUIPPED)................12152
REMOVAL,INSTALLATION OF HYDRAULIC TANK ASSEMBLY................12154
REMOVAL,INSTALLATION OF WORK EQUIPMENT ASSEMBLY................12156
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY................12163
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY................12190
DISASSEMBLY,ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY................12206
REMOVAL,INSTALLATION OF OPERATOR'S CAB ASSEMBLY................12213
REMOVAL,INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)................12219
REMOVAL,INSTALLATION OF CENTER HINGE PIN................12227
REMOVAL,INSTALLATION OF COUNTERWEIGHT................12238
REMOVAL,INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY................12240
REMOVAL,INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY................12243
REMOVAL,INSTALLATION OF MONITOR PANEL................12244
REMOVAL,INSTALLATION OF HST CONTROLLER ASSEMBLY................12248
90 OTHERS................12249
HYDRAULIC CIRCUIT DIAGRAM................12250
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)................12251
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)................12252
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)................12253
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)................12254
ELECTRICAL CIRCUIT DIAGRAM 2/4................12255
ELECTRICAL CIRCUIT DIAGRAM 3/4................12256
ELECTRICAL CIRCUIT DIAGRAM 4/4................12257
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)................12258
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)................12259
SEBM034608 - Wheel Loader WA320-5 Shop Manual................12260
COVER................12260
CONTENTS ................12261
LIST OF REVISED PAGES................12262
SAFETY................12266
SAFETY NOTICE................12266
FOREWORD................12268
GENERAL................12268
HOW TO READ THE SHOP MANUAL................12269
HOISTING INSTRUCTIONS................12270
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................12271
COATING MATERIALS................12273
STANDARD TIGHTENING TORQUE................12275
ELECTRIC WIRE CODE................12278
CONVERSION TABLE................12279
UNITS................12285
01 GENERAL ................12286
GENERAL ASSEMBLY DRAWINGS................12287
SPECIFICATIONS................12288
WEIGHT TABLE ................12292
LIST OF LUBRICANT AND COOLANT................12294
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD................12296
ENGINE MOUNT AND TRANSFER MOUNT................12297
DAMPER................12298
COOLING SYSTEM................12299
POWER TRAIN................12302
POWER TRAIN SYSTEM DIAGRAM................12303
DRIVE SHAFT (PROPELLER SHAFT)................12305
HST HYDRAULIC PIPING DIAGRAM................12306
HST PUMP................12307
HIGH-PRESSURE RELIEF VALVE................12309
LOW-PRESSURE RELIEF VALVE................12311
HST CHARGE PUMP................12312
SPEED-RELATED VALVE (DA VALVE)................12313
HIGH-PRESSURE CUT-OFF VALVE................12314
HST MOTOR................12315
EP SERVO VALVE................12318
HA SERVO VALVE................12319
FORWARD-REVERSE SHUTTLE VALVE................12320
TRANSFER................12321
CLUTCH SOLENOID VALVE................12332
AXLE................12333
DIFFERENTIAL................12335
LIMITED-SLIP DIFFERENTIAL................12343
FINAL DRIVE................12347
AXLE MOUNTING AND CENTER HINGE PIN................12349
STEERING PIPING................12354
STEERING COLUMN................12355
PRIORITY VALVE................12356
ORBIT-ROLL VALVE................12359
CUSHION VALVE................12367
STEERING CYLINDER................12368
EMERGENCY STEERING PIPING................12370
EMERGENCY STEERING VALVE................12371
BRAKE PIPING................12374
BRAKE VALVE................12375
INCHING VALVE................12379
CHARGE VALVE................12381
ACCUMULATOR (FOR BRAKE)................12385
SLACK ADJUSTER................12387
BRAKE................12389
PARKING BRAKE CONTROL................12391
PARKING BRAKE................12392
HYDRAULIC PIPING................12393
WORK EQUIPMENT LEVEL LINKAGE................12395
HYDRAULIC TANK................12397
4-GEAR PUMP UNIT................12399
ACCUMULATOR (FOR PPC CIRCUIT)................12401
LOCK VALVE................12402
E.C.S.S. VALVE................12403
ACCUMULATOR (FOR E.C.S.S.)................12405
HYDRAULIC PIPING OF COOLING SYSTEM................12406
COOLING FAN MOTOR................12407
WORK EQUIPMENT CONTROL VALVE................12410
WORK EQUIPMENT PPC VALVE................12431
ATTACHMENT PPC VALVE................12443
WORK EQUIPMENT LINKAGE................12447
BUCKET................12449
BUCKET POSITIONER AND BOOM KICK-OUT................12451
WORK EQUIPMENT CYLINDER................12457
AIR CONDITIONER................12458
MACHINE MONITORING SYSTEM................12459
MACHINE MONITOR................12469
LIST OF ITEMS DISPLAYED ON MONITOR................12470
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)................12496
HST CONTROLLER................12500
KOMTRAX SYSTEM................12501
ENGINE START CIRCUIT................12503
ENGINE STOP CIRCUIT................12505
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)................12506
PARKING BRAKE CIRCUIT................12507
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM................12510
SENSORS................12511
20 TESTING AND ADJUSTING................12520
STANDARD VALUE TABLE FOR ENGINE................12521
STANDARD VALUE TABLE FOR CHASSIS................12522
TESTING AND ADJUSTING................12526
TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING................12527
MEASURING ENGINE SPEED................12529
MEASURING EXHAUST GAS COLOR................12530
ADJUSTING VALVE CLEARANCE................12532
MEASURING COMPRESSION PRESSURE................12533
MEASURING BLOW-BY PRESSURE................12534
TESTING AND ADJUSTING FUEL INJECTION TIMING................12535
MEASURING ENGINE OIL PRESSURE................12536
MEASURING, TESTING OPERATION FORCE OF ACCELERATOR PEDAL................12537
ADJUSTING ENGINE STOP SOLENOID................12539
ADJUSTING ENGINE SPEED SENSOR................12540
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................12540
MEASURING DIRECTIONAL LEVER................12541
TESTING AND ADJUSTING HST OIL PRESSURE................12541
MEASURING CLUTCH CONTROL PRESSURE................12546
TESTING AND ADJUSTING STEERING WHEEL................12547
TESTING AND ADJUSTING STEERING OIL PRESSURE................12548
BLEEDING AIR FROM STEERING CIRCUIT................12549
TESTING HYDRAULIC FAN................12550
MEASURING BRAKE PEDAL................12551
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE................12552
MEASURING BRAKE PERFORMANCE................12553
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................12554
MEASURING BRAKE OIL PRESSURE................12555
MEASURING WEAR OF BRAKE DISC................12557
BLEEDING AIR FROM BRAKE CIRCUIT................12558
MEASURING PARKING BRAKE PERFORMANCE................12559
TESTING AND ADJUSTING PARKING BRAKE LINKAGE................12560
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER................12561
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE................12562
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE................12563
BLEEDING AIR................12565
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................12566
TESTING AND ADJUSTING BUCKET POSITIONER................12566
TESTING AND ADJUSTING OF BOOM KICK-OUT................12568
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................12569
PROCEDURE FOR CHECKING DIODE................12570
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER................12571
STARTING KOMTRAX TERMINAL OPERATIONS................12572
INDICATOR LAMPS OF KOMTRAX TERMINAL................12576
SPECIAL FUNCTIONS OF MACHINE MONITOR................12580
FLOW OF MODES AND FUNCTIONS................12581
FAILURE CODE TABLE................12589
PM CLINIC INSPECTION CHART................12599
TROUBLESHOOTING................12602
POINTS TO REMEMBER WHEN TROUBLESHOOTING................12603
SEQUENCE OF EVENTS IN TROUBLESHOOTING................12604
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................12605
CHECKS BEFORE TROUBLESHOOTING................12613
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS................12614
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.................12615
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................12618
T-ADAPTER TABLE................12641
CONNECTOR TYPES AND MOUNTING LOCATIONS................12644
CONNECTOR LAYOUT DRAWING................12651
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)................12656
BEFORE TROUBLESHOOTING CODE DISPLAY................12657
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................12659
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................12660
FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION(00))................12662
FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX))................12663
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))................12665
FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ))................12667
FAILURE CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................12669
FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))................12671
TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))................12673
TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)................12675
TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED................12679
TROUBLESHOOTING CODE [HSR-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)................12681
TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................12683
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM(ECSS MODE)................12684
RELATED ELECTRICAL CIRCUIT DIAGRAM................12685
ECSS-1 MALFUNCTION OF TRAVEL DAMPER................12686
TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE)................12692
BEFORE TROUBLESHOOTING CODE DISPLAY................12695
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................12697
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................12698
FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))................12700
FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE(ZG))................12701
FAILURE CODE [989FOO] (HST MOTOR PROTECTION CAUTION (OO))................12702
FAILURE CODE [989FN1] (HST OVERRUNNING (N1))................12703
FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX))................12705
FAILURE CODE [ABOOL6] (DEFECTIVE BATTERY CHARGING CIRCUIT(L6))................12707
FAILURE CODE [ABOOMA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))................12708
FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE(ZG))................12709
FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL(ZK)................12710
FAILURE CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING(NS))................12711
FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL(ZK))................12712
FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING(NS))................12713
FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING(NS))................12714
FAILURE CODE [D5ZHL6] (STARTING SWITCH "C"(IGN"C")INPUT FAILURE(L6))................12715
FAILURE CODE [DAFOKT] (CONTROLLER INSIDE FAILURE(KT))................12717
FAILURE CODE [DAJOKR] (HST CONTROLLER COMMUNICATION FAILURE(KR))................12719
FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)INPUT ERROR(LD))................12721
FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)INPUT ERROR (LD)................12722
FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)INPUT ERROR (LD)................12723
FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)INPUT ERROR (LD)................12724
FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB))................12725
FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE(L6))................12727
FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE(KX))................12728
FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6))................12729
FAILURE CODE [DGH1LX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))................12730
FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))................12731
FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))................12732
FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))................12733
TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)................12735
TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)................12739
TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.) ................12740
TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.) ................12741
TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)................12742
TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)................12743
TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)................12744
TROUBLESHOOTING CODE [MON-6] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)................12745
TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1))................12746
TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2))................12747
TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3))................12748
TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4))................12749
TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)................12751
TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP................12753
TROUBLESHOOTING CODE [MON-15] (AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP)................12755
TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION................12757
TROUBLESHOOTING CODE [MON-17] (THE LAMPS DO NOT WORK PROPERLY)................12757
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................12758
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM................12759
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................12760
TROUBLESHOOTING CODE [E-1](THE ENGINE DOES NOT START)................12763
TROUBLESHOOTING CODE [E-2](THE ENGINE DOES NOT STOP)................12769
TROUBLESHOOTING CODE [E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT)................12771
TROUBLESHOOTING CODE [E-4](THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)................12775
TROUBLESHOOTING CODE [E-5](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)................12781
TROUBLESHOOTING CODE [E-6](DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)................12785
TROUBLESHOOTING CODE [E-7](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)................12788
TROUBLESHOOTING CODE [E-8](TRAVEL DIRECTION IS NOT CHANGED NORMALLY)................12789
TROUBLESHOOTING CODE [E-9](THE WIPER DOES NOT FUNCTION)................12795
TROUBLESHOOTING CODE [E-10](THE WINDOW WASHER DOES NOT FUNCTION)................12801
TROUBLESHOOTING CODE [E-11](LAMPS DO NOT WORK PROPERLY)................12805
TROUBLESHOOTING CODE [E-12](THE HORN DOES NOT SOUND)................12817
TROUBLESHOOTING CODE [E-13](DEFECTIVE THE AIR CONDITIONER)................12819
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE)................12832
METHOD OF USING TROUBLESHOOTING CHART................12833
FAILURE CODE AND CAUSE TABLE................12835
H-1 THE MACHINE DOES NOT START................12837
H-2 THE TRAVEL SPEED IS SLOW................12838
H-3 THE THRUSTING FORCE IS WEAK................12839
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY................12840
H-5 THE GEAR IS NOT SHIFTED ................12841
H-6 THE STEERING WHEEL DOES NOT TURN................12842
H-7 THE STEERING WHEEL IS HEAVY................12843
H-8 STEERING WHEEL SHAKES OR JERKS................12844
H-10 THE BRAKE DOES NOT WORK OR NOES NOT WORK WELL ................12845
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................12846
H-12 THE LIFT ARM DOES NOT RISE OR LOWER................12847
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT................12848
H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ................12849
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR)................12849
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN................12849
H-17 THE LIFT ARM WOBBLES DURING OPERATION................12849
H-18 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY ................12850
H-19 THE BUCKET DOES NOT TILT BACK................12851
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT................12852
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING BACK................12853
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET................12853
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN................12853
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")................12854
H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD"TO "TILT",THE BUCKET FALLS TEMPORARILY................12854
H-26 THE CONTROL LEVELS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY................12854
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES................12855
TROUBLESHOOTING OF ENGINE (S MODE)................12856
METHOD OF USING TROUBLESHOOTING CHARTS ................12857
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)................12861
S-2 ENGINE DOES NOT START................12863
(1)ENGINE DOES NOT TURN................12863
(2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)................12864
(3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)................12865
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)................12866
S-4 ENGINE STOPS DURING OPERATIONS................12867
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................12868
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)................12869
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)................12870
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................12871
S-9 OIL BECOMES CONTAMINATED QUICKLY................12872
S-10 FUEL CONSUMPTION IS EXCESSIVE................12873
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN................12874
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)................12875
S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) ................12876
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) ................12877
S-15 ABNORMAL NOISE IS MADE................12878
S-16 VIBRATION IS EXCESSIVE................12879
30 DISASSEMBLY AND ASSEMBLY................12880
HOW TO READ THIS MANUAL................12881
PRECAUTIONS WHEN CARRYING OUT OPERATION................12883
SPECIAL TOOL LIST................12885
SKETCH OF SPECIAL TOOLS................12888
REMOVAL,INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................12895
REMOVAL,INSTALLATION OF NOZZLE HOLDER ASSEMBLY................12899
REMOVAL,INSTALLATION OF CYLINDER HEAD ASSEMBLY................12901
REMOVAL,INSTALLATION OF ENGINE ASSEMBLY................12909
REMOVAL,INSTALLATION OF RADIATOR ASSEMBLY................12916
REMOVAL,INSTALLATION OF AIR AFTERCOOLER................12917
REMOVAL,INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY................12919
REMOVAL,INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY................12921
REMOVAL,INSTALLATION OF FUEL TANK ASSEMBLY................12923
REMOVAL,INSTALLATION OF TRANSFER................12925
DISASSEMBLY,ASSEMBLY OF TRANSFER ASSEMBLY................12927
REMOVAL,INSTALLATION OF PARKING BRAKE ASSEMBLY................12947
DISASSEMBLY,ASSEMBLY OF PARKING BRAKE ASSEMBLY................12949
REMOVAL,INSTALLATION OF FRONT AXLE ASSEMBLY................12954
REMOVAL,INSTALLATION OF REAR AXLE ASSEMBLY................12956
DISASSEMBLY,ASSEMBLY OF AXLE HOUSING ASSEMBLY................12959
DISASSEMBLY,ASSEMBLY OF DIFFERENTIAL ASSEMBLY................12972
REMOVAL,INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY................12996
REMOVAL,INSTALLATION OF HST MOTOR 1 ASSEMBLY................12999
REMOVAL,INSTALLATION OF HST MOTOR 2 ASSEMBLY................13001
REMOVAL,INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY................13003
REMOVAL,INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY(IF EQUIPPED)................13005
REMOVAL,INSTALLATION OF HYDRAULIC TANK ASSEMBLY................13007
REMOVAL,INSTALLATION OF WORK EQUIPMENT ASSEMBLY................13009
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY................13016
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY................13043
DISASSEMBLY,ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY................13059
REMOVAL,INSTALLATION OF OPERATOR'S CAB ASSEMBLY................13066
REMOVAL,INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)................13072
REMOVAL,INSTALLATION OF CENTER HINGE PIN................13080
REMOVAL,INSTALLATION OF COUNTERWEIGHT................13091
REMOVAL,INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY................13093
REMOVAL,INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY................13096
REMOVAL,INSTALLATION OF MONITOR PANEL................13097
REMOVAL,INSTALLATION OF HST CONTROLLER ASSEMBLY................13101
90 OTHERS................13102
HYDRAULIC CIRCUIT DIAGRAM................13104
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)................13105
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)................13106
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)................13107
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)................13108
ELECTRICAL CIRCUIT DIAGRAM 2/4................13109
ELECTRICAL CIRCUIT DIAGRAM 3/4................13110
ELECTRICAL CIRCUIT DIAGRAM 4/4................13111
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)................13112
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)................13113
SEBM04190107 - Wheel Loader WA300-1, WA320-1 Shop Manual................13114
COVER................13114
CONTENTS................13115
01 GENERAL................13151
GENERAL VIEW................13152
GENERAL ASSEMBLY DRAWING................13153
SPECIFICATIONS................13154
ENGINE ASSEMBLY DRAWING................13156
ENGINE SPECIFICATIONS................13157
WEIGHT TABLE................13158
TABLE OF OIL AND COOLANT QUANTITIES................13159
LOCATION OF SERIAL NUMBERS................13160
10 ENGINE................13161
11 STRUCTURE AND FUNCTION................13161
ENGINE AND TRANSMISSION MOUNT................13162
RADIATOR AND COOLER................13163
FUEL TANK AND PIPING................13164
ENGINE CONTROL................13165
12 TESTING AND ADJUSTING................13166
TABLE OF JUDGEMENT STANDARD................13167
TESTING AND ADJUSTING TOOL LIST................13168
ADJUSTING VALVE CLEARANCE................13169
MEASURING COMPRESSION PRESSURE................13170
TESTING AND ADJUSTING FUEL INJECTION TIMING................13171
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE................13173
MEASURING BLOW-BY PRESSURE................13174
TESTING AND ADJUSTING FAN BELT TENSION................13175
MEASURING EXHAUST GAS COLOR................13176
MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL................13177
MEASURING ACCELERATOR PEDAL................13179
ADJUSTING FUEL CUT SOLENOID................13181
13 DISASSEMBLY AND ASSEMBLY................13182
STARTING MOTOR ASSEMBLY................13183
REMOVAL................13183
INSTALLATION................13183
ALTERNATOR ASSEMBLY................13184
REMOVAL................13184
INSTALLATION................13184
ENGINE OIL COOLER ASSEMBLY................13185
REMOVAL................13185
INSTALLATION................13185
FUEL INJECTION PUMP ASSEMBLY................13186
REMOVAL................13186
INSTALLATION................13186
WATER PUMP ASSEMBLY................13187
REMOVAL................13187
INSTALLATION................13187
NOZZLE HOLDER ASSEMBLY................13188
REMOVAL................13188
INSTALLATION................13188
TURBOCHARGER ASSEMBLY................13189
REMOVAL................13189
INSTALLATION................13189
CYLINDER HEAD ASSEMBLY................13190
REMOVAL................13190
INSTALLATION................13196
RADIATOR................13204
REMOVAL................13204
INSTALLATION................13206
ENGINE................13208
REMOVAL................13208
INSTALLATION................13214
FUEL TANK ASSEMBLY................13219
REMOVAL................13219
INSTALLATION................13220
20 POWER TRAIN................13221
21 STRUCTURE AND FUNCTION................13221
GENERAL................13222
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN................13224
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS................13226
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................13227
TORQUE CONVERTER AND TRANSMISSION PIPING................13228
TORQUE CONVERTER CHARGING PUMP................13229
TORQUE CONVERTER................13230
TORQUE CONVERTER OIL FILTER................13232
TORQUE CONVERTER OIL COOLER................13233
TORQUE CONVERTER REGULATOR VALVE................13234
TORQFLOW TRANSMISSION................13236
CLUTCH PACK................13240
TRANSMISSION CONTROL VALVE (SERIAL NO. 10001-19999)................13250
UPPER VALVE................13252
LOWER VALVE................13253
PILOT REDUCING VALVE................13254
TRANSMISSION SOLENOID VALVE................13255
PRIORITY RELIEF VALVE................13256
MODULATING RELIEF VALVE................13257
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE................13258
EMERGENCY MANUAL SPOOL................13262
SPEED SPOOL................13265
TRANSMISSION CONTROL VALVE (SERIAL NO. 20001 AND UP)................13266
TRANSMISSION SOLENOID VALVE................13267
UPPER VALVE................13268
LOWER VALVE................13269
TORQUE CONVERTER OIL OUTLET VALVE................13270
PILOT REDUCING VALVE................13271
TRANSMISSION SOLENOID VALVE................13272
PRIORITY AND MAIN REGULATOR VALVE................13273
MAIN REGULATOR VALVE................13274
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE................13275
EMERGENCY MANUAL SPOOL................13279
DIRECTIONAL SPOOL................13281
FILL VALVE................13282
PILOT OIL FILTER................13284
DIFFERENTIAL................13286
FINAL DRIVE................13290
AXLE MOUNT................13292
TIRE AND WHEEL................13296
22 TESTING AND ADJUSTING................13297
STANDARD VALUE TABLE................13298
TOOL LIST FOR TESTING AND ADJUSTING................13299
MEASURING ENGINE STALL SPEED................13300
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION................13302
MEASURING SHIFT LEVER................13306
TIRE AND WHEEL................13307
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL................13308
TROUBLESHOOTING ................13309
PRECAUTIONS WHEN TROUBLESHOOTING................13310
METHOD OF READING TROUBLESHOOTING TABLE................13312
PREVENTING RECURRENCE OF TROUBLE................13314
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM................13315
TROUBLESHOOTING TABLE................13316
1. MACHINE DOES NOT MOVE OFF................13316
2. MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF................13318
4. LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR................13319
5. OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH................13320
23 DISASSEMBLY AND ASSEMBLY................13321
TORQUE CONVERTER CHARGING PUMP................13322
REMOVAL................13322
INSTALLATION................13322
TRANSMISSION, TORQUE CONVERTER................13323
REMOVAL................13323
INSTALLATION................13330
TORQUE CONVERTER................13336
DISASSEMBLY................13336
ASSEMBLY................13339
TRANSMISSION................13342
DISASSEMBLY................13342
ASSEMBLY................13351
CLUTCH PACK................13364
DISASSEMBLY................13364
ASSEMBLY................13372
TRANSMISSION CONTROL VALVE................13387
REMOVAL................13387
INSTALLATION................13388
DISASSEMBLY................13390
ASSEMBLY................13392
DRIVE SHAFT................13399
DISASSEMBLY................13399
ASSEMBLY................13401
FRONT AXLE................13403
REMOVAL................13403
INSTALLATION................13405
REAR AXLE................13407
REMOVAL................13407
INSTALLATION................13410
DIFFERENTIAL................13413
DISASSEMBLY................13413
ASSEMBLY................13417
AXLE HOUSING................13428
DISASSEMBLY................13428
ASSEMBLY................13432
24 MAINTENANCE STANDARD................13438
ENGINE AND TRANSMISSION MOUNT................13439
TORQUE CONVERTER CHARGING PUMP................13440
TORQUE CONVERTER................13441
TORQUE CONVERTER REGULATOR VALVE................13442
TRANSMISSION................13443
TRANSMISSION CLUTCH ASSEMBLY................13446
TRANSMISSION CONTROL VALVE................13448
UPPER VALVE................13448
LOWER VALVE................13454
SOLENOID VALVE................13456
AXLE................13458
DIFFERENTIAL................13460
FINAL DRIVE................13462
DRIVE SHAFT................13463
AXLE MOUNT................13464
40 STEERING SYSTEM................13467
41 STRUCTURE AND FUNCTION................13467
GENERAL................13468
HYDRAULIC CIRCUIT FOR STEERING................13470
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING................13471
OPERATION OF STEERING VALVE................13472
STEERING VALVE................13474
STEERING RELIEF VALVE................13476
SAFETY VALVE (WITH SUCTION VALVE)................13477
OPERATION OF DEMAND VALVE................13479
TWO-WAY RESTRICTOR VALVE................13481
STEERING COLUMN AND GEAR BOX................13482
STEERING LINKAGE................13483
STEERING CYLINDER................13484
CENTER HINGE PIN................13485
EMERGENCY STEERING PUMP (IF EQUIPPED)................13486
DIVERTER VALVE (IF EQUIPPED)................13487
SECURITY VALVE (IF EQUIPPED)................13490
42 TESTING AND ADJUSTING................13493
STANDARD VALUE TABLE................13494
TOOL LIST FOR TESTING AND ADJUSTING................13494
MEASURING STEERING WHEEL PLAY................13495
MEASURING OPERATING FORCE OF STEERING WHEEL................13496
OPERATING TIME OF STEERING WHEEL LOCK TO LOCK................13497
TESTING STEERING LINKAGE................13498
ADJUSTING STEERING LINKAGE................13499
STEERING OIL PRESSURE................13500
TROUBLESHOOTING................13501
TROUBLESHOOTING TABLE................13502
1. STEERING WHEEL DOES NOT TURN................13502
2. STEERING WHEEL IS SLUGGISH................13503
3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK................13504
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING................13504
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT................13504
43 DISASSEMBLY AND ASSEMBLY................13505
STEERING GEAR BOX................13506
REMOVAL................13506
INSTALLATION................13507
DISASSEMBLY................13508
ASSEMBLY................13509
STEERING VALVE................13512
REMOVAL................13512
INSTALLATION................13514
DISASSEMBLY................13516
ASSEMBLY................13518
STEERING CYLINDER................13520
REMOVAL................13520
INSTALLATION................13521
DISASSEMBLY................13522
ASSEMBLY................13524
CENTER HINGE PIN................13527
REMOVAL................13527
INSTALLATION................13534
44 MAINTENANCE STANDARD................13541
STEERING VALVE................13542
STEERING CYLINDER MOUNT................13544
STEERING CYLINDER................13545
CENTER HINGE PIN................13546
STEERING LINKAGE................13548
STEERING COLUMN AND GEAR BOX................13550
EMERGENCY STEERING PUMP (IF EQUIPPED)................13551
DIVERTER VALVE (IF EQUIPPED)................13552
SECURITY VALVE (IF EQUIPPED)................13554
50 BRAKE SYSTEM................13555
51 STRUCTURE AND FUNCTION................13555
GENERAL................13556
ACCUMULATOR................13557
BRAKE BOOSTER................13558
BRAKE................13563
PARKING BRAKE................13565
BRAKE CALIPER................13567
52 TESTING AND ADJUSTING................13568
STANDARD VALUE TABLE................13569
TOOL LIST FOR TESTING AND ADJUSTING................13570
MEASURING BRAKE PEDAL................13571
BRAKE PERFORMANCE................13572
CHECKING BRAKE PISTON LEAKAGE................13573
MEASURING WEAR OF BRAKE DISC................13574
AIR BLEEDING FROM BRAKE LINE................13575
PARKING BRAKE PERFORMANCE................13576
CHECKING AND ADJUSTING PARKING BRAKE................13577
MEASURING CLEARANCE................13579
TROUBLESHOOTING................13580
TROUBLESHOOTING TABLE................13581
1. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE................13581
2. BRAKE CANNOT BE RELEASED OR DRAGS................13582
53 DISASSEMBLY AND ASSEMBLY................13583
BRAKE BOOSTER................13584
REMOVAL................13584
INSTALLATION................13585
DISASSEMBLY................13586
ASSEMBLY................13588
PARKING BRAKE................13590
REMOVAL................13590
INSTALLATION................13592
PARKING BRAKE PAD................13594
REMOVAL................13594
INSTALLATION................13594
54 MAINTENANCE STANDARD................13595
BRAKE BOOSTER................13596
BRAKE................13597
PARKING BRAKE................13598
60 WORK EQUIPMENT SYSTEM................13599
61 STRUCTURE AND FUNCTION................13599
GENERAL................13600
HYDRAULIC CIRCUIT SYSTEM................13602
HYDRAULIC CIRCUIT DIAGRAM (FOR 2-SPOOL)................13603
HYDRAULIC CIRCUIT DIAGRAM (FOR 3-SPOOL)................13604
WORK EQUIPMENT LEVER LINKAGE................13605
BUCKET LINKAGE................13606
BUCKET POSITIONER AND BOOM KICK-OUT................13608
HYDRAULIC TANK................13610
OIL FILTER BYPASS VALVE................13612
BREATHER................13612
HYDRAULIC AND STEERING PUMPS................13613
MAIN CONTROL VALVE (FOR 2-SPOOL)................13614
MAIN CONTROL VALVE (FOR 3-SPOOL)................13616
RELIEF VALVE................13618
SAFETY VALVE (WITH SUCTION VALVE)................13619
SUCTION VALVE................13620
HYDRAULIC CYLINDER................13627
62 TESTING AND ADJUSTING................13628
STANDARD VALUE TABLE................13629
TOOL LIST FOR TESTING AND ADJUSTING................13630
MEASURING DUMP AND LIFT CONTROL LEVERS................13631
ADJUSTING DUMP AND LIFT CONTROL LEVERS................13632
MEASURING HYDRAULIC PRESSURE................13633
MEASURING LIFT ARM AND BUCKET................13635
MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET................13636
ADJUSTING BUCKET POSITIONER................13637
ADJUSTING BOOM KICK-OUT................13638
TROUBLESHOOTING................13639
TROUBLESHOOTING TABLE................13640
1. LIFT ARM DOES NOT RISE................13640
2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER................13641
3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT................13642
4. BUCKET CANNOT BE HOLD DOWN WITH LIFT CYLINDER................13642
5. LIFT ARM HAS LARGE HYDRAULIC DRIFT................13642
6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK................13642
7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"................13642
8. BUCKET DOES NOT TILT BACK................13643
9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER................13644
10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK................13645
11. BUCKET CANNOT BE HELD DOWN BY THE DUMP CYLINDER................13645
12. BUCKET HAS LARGE HYDRAULIC DRIFT................13645
13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD................13645
14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"................13645
15. CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY................13646
63 DISASSEMBLY AND ASSEMBLY................13647
HYDRAULIC TANK................13648
REMOVAL................13648
INSTALLATION................13650
HYDRAULIC FILTER................13652
REMOVAL................13652
INSTALLATION................13652
HYDRAULIC, STEERING PUMP................13653
REMOVAL................13653
INSTALLATION................13654
MAIN CONTROL VALVE................13655
REMOVAL................13655
INSTALLATION................13656
DISASSEMBLY................13657
ASSEMBLY................13659
DUMP CYLINDER................13661
REMOVAL................13661
INSTALLATION................13663
LIFT CYLINDER................13664
REMOVAL................13664
INSTALLATION................13665
LIFT AND DUMP CYLINDER................13666
DISASSEMBLY................13666
ASSEMBLY................13668
WORK EQUIPMENT................13671
REMOVAL................13671
INSTALLATION................13674
COUNTERWEIGHT................13677
REMOVAL................13677
INSTALLATION................13677
64 MAINTENANCE STANDARD................13678
MAIN CONTROL VALVE (FOR 2-SPOOL)................13679
MAIN CONTROL VALVE (FOR 3-SPOOL)................13681
DUMP CYLINDER................13683
LIFT CYLINDER................13684
BUCKET LINKAGE................13685
BUCKET POSITIONER AND BOOM KICK-OUT................13687
BUCKET................13688
HYDRAULIC AND STEERING PUMP................13689
80 ELECTRIC AND ELECTRONIC SYSTEM................13690
81 STRUCTURE AND FUNCTION................13690
ELECTRIC AND ELECTRONIC SYSTEM................13691
ELECTRICAL CIRCUIT DIAGRAM................13692
ENGINE STARTING CIRCUIT................13694
ENGINE STOP CIRCUIT................13695
PREHEATING CIRCUIT................13696
PREHEATING AND AFTER-HEATING WITH HEATER SWITCH................13696
PREHEATING WITH STARTING SWITCH................13697
COMBINATION SWITCH................13698
ELECTRICAL TRANSMISSION CONTROL................13699
ELECTRICAL TRANSMISSION CONTROL DIAGRAM................13700
TRANSMISSION CUT-OFF SELECTOR SWITCH................13701
NEUTRALIZER RELAY................13702
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)................13703
MONITOR PANEL................13704
INDICATION ON MONITOR PANEL................13705
CONTROLLER................13707
SENSOR................13708
PROXIMITY SWITCH................13713
82 TESTING AND ADJUSTING................13717
ADJUSTING SPEEDOMETER MODULE................13718
TROUBLESHOOTING................13720
CHECKS BEFORE TROUBLESHOOTING................13721
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART................13722
CONNECTOR TERMINAL NUMBERS................13724
PRECAUTION WHEN HANDLING CONNECTOR................13729
ELECTRICAL WIRING DIAGRAM................13731
ELECTRICAL CIRCUIT SYSTEM................13732
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-16)................13737
E-1. ENGINE DOES NOT START................13738
E-2. ENGINE DOES NOT STOP................13741
E-3. ENGINE STOPS WHEN MACHINE IS TRAVELING................13741
E-4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED................13743
E-5. MACHINE MOVES NEITHER IN FORWARD NOR IN REVERSE................13745
E-6. MACHINE MOVES IN REVERSE BUT NOT IN FORWARD................13749
E-7. MACHINE MOVES IN FORWARD BUT NOT IN REVERSE................13751
E-8. MACHINE MOVES FORWARD EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL................13751
E-9. MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL................13753
E-10. MACHINE ALWAYS TRAVELS IN 1ST................13753
E-11. TRANSMISSION DOES NOT CHANGE GEAR ................13755
E-12. MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS ON ................13757
E-13. TRANSMISSION CANNOT BE CUT-OFF................13758
E-14. TRANSMISSION DOES NOT RETURN TO NEUTRAL................13759
E-15. PREHEATING DOES NOT WORK................13762
E-16. PREHEATING DOES NOT STOP................13765
ELECTRONIC VEHICLE MONITORING SYSTEM................13766
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-16)................13767
E-1. ENGINE DOES NOT START................13768
E-2. ENGINE DOES NOT STOP................13771
E-3. ENGINE STOPS WHEN MACHINE IS TRAVELING................13771
E-4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED................13773
E-5. MACHINE MOVES NEITHER IN FORWARD NOR IN REVERSE................13775
E-6. MACHINE MOVES IN REVERSE BUT NOT IN FORWARD................13779
E-7. MACHINE MOVES IN FORWARD BUT NOT IN REVERSE................13781
E-8. MACHINE MOVES FORWARD EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL................13781
E-9. MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL................13783
E-10. MACHINE ALWAYS TRAVELS IN 2ND................13783
E-11. TRANSMISSION DOES NOT CHANGE GEAR ................13785
E-12. TRANSMISSION CANNOT BE CUT-OFF................13787
E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL................13788
E-14. PREHEATING DOES NOT WORK................13791
E-15. PREHEATING DOES NOT STOP................13794
TROUBLESHOOTING TABLE FOR MONITORING SYSTEM................13796
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 TO M-32)(SERIAL NO. 10001-19999)................13797
M-1 EVEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES................13798
M-2 EVEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES................13798
M-3 EVEN ENGINE IS STOPPED, COOLANT LEVEL DISPLAY FLASHES................13801
M-4 BATTERY CHARGE DISPLAY FLASHES................13801
M-5 FUEL LEVEL DISPLAY FLASHES................13803
M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE OIL LEVEL DISPLAY FLASHES................13803
M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, ENGINE OIL PRESSURE DISPLAY FLASHES................13805
M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT LEVEL DISPLAY FLASHES................13805
M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE SERVO PRESSURE DISPLAY FLASHES (IF EQUIPPED)................13807
M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT TEMPERATURE DISPLAY FLASHES................13807
M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, TORQUE CONVERTER OIL TEMPERATURE DISPLAY FLASHES................13809
M-12 PARKING BRAKE DISPLAY LIGHTS UP, OR DOES NOT LIGHT UP................13810
M-13 WORKING LAMP DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP................13812
M-14 PREHEAT DISPLAY LIGHTS UP OR DOES NOT LIGHT UP................13814
M-15 FAILURE IN MAIN STEERING DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)................13816
M-16 EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)................13818
M-17 TRANSMISSION CUT-OFF DISPLAY LIGHTS UP OR DOES NOT LIGHT UP................13820
M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP................13822
M-19 SPEEDOMETER DISPLAY DOES NOT WORK................13826
M-20 HOURMETER DOES NOT WORK NORMALLY................13828
M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK................13830
M-22 EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE DISPLAY FLASHES, OR BATTERY CHARGE DISPLAY FLASHES................13832
M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)................13833
M-24 CENTRAL WARNING LAMP DOES NOT GO OUT................13834
M-25 CENTRAL WARNING BUZZER DOES NOT STOP................13836
M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP................13838
M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP................13841
M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND................13843
M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH................13845
M-30 ABNORMALITY IN FUEL GAUGE................13847
M-30-1 ABNORMALITY IN FUEL LEVEL SENSOR................13848
M-31 ABNORMALITY IN COOLANT TEMPERATURE GAUGE................13849
M-32 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE................13851
TROUBLESHOOTING TABLE FOR MONITORING SYSTEM ................13853
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 TO M-32)(SERIAL NO. 20001 AND UP)................13854
M-1 EVEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES................13855
M-2 EVEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES................13855
M-3 EVEN ENGINE IS STOPPED, COOLANT LEVEL DISPLAY FLASHES................13857
M-4 BATTERY CHARGE DISPLAY FLASHES................13857
M-5 FUEL LEVEL DISPLAY FLASHES................13859
M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE OIL LEVEL DISPLAY FLASHES................13859
M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, ENGINE OIL PRESSURE DISPLAY FLASHES................13861
M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT LEVEL DISPLAY FLASHES................13861
M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE SERVO PRESSURE DISPLAY FLASHES (IF EQUIPPED)................13863
M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT TEMPERATURE DISPLAY FLASHES................13863
M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, TORQUE CONVERTER OIL TEMPERATURE DISPLAY FLASHES................13865
M-12 PARKING BRAKE DISPLAY LIGHTS UP, OR DOES NOT LIGHT UP................13866
M-13 WORKING LAMP DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP................13868
M-14 PREHEAT DISPLAY LIGHTS UP OR DOES NOT LIGHT UP................13870
M-15 FAILURE IN MAIN STEERING DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)................13872
M-16 EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)................13874
M-17 TRANSMISSION CUT-OFF DISPLAY LIGHTS UP OR DOES NOT LIGHT UP................13876
M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP................13878
M-19 SPEEDOMETER DISPLAY DOES NOT WORK................13882
M-20 HOURMETER DOES NOT WORK NORMALLY................13884
M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK................13886
M-22 EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE DISPLAY FLASHES, OR BATTERY CHARGE DISPLAY FLASHES................13887
M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)................13888
M-24 CENTRAL WARNING LAMP DOES NOT GO OUT................13889
M-25 CENTRAL WARNING BUZZER DOES NOT STOP................13890
M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP................13891
M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP................13894
M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND................13895
M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH................13896
M-30 ABNORMALITY IN FUEL GAUGE................13898
M-30-1 ABNORMALITY IN FUEL LEVEL SENSOR................13899
M-31 ABNORMALITY IN COOLANT TEMPERATURE GAUGE................13900
M-32 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE................13902
TABLE OF MONITOR REFERENCE VALUES................13904
83 DISASSEMBLY AND ASSEMBLY................13911
MACHINE MONITOR................13912
REMOVAL................13912
INSTALLATION................13912
90 OTHERS................13913
91 STRUCTURE AND FUNCTION................13913
CAB................13914
AIR CONDITIONER (OPTION)................13915
AIR CONDITIONER PIPING................13915
AIR CONDITIONER WIRING DIAGRAM................13916
AIR CONDITIONER ELECTRIC CIRCUIT................13916
AIR CONDITIONER UNIT................13917
AIR CONDITIONER COMPRESSOR................13918
AIR CONDITIONER CONDENSOR................13918
AIR CONDITIONER DRY RESERVOIR................13919
93 DISASSEMBLY AND ASSEMBLY................13920
CAB................13921
REMOVAL................13921
INSTALLATION................13922
AIR CONDITIONER UNIT ................13923
REMOVAL................13923
INSTALLATION................13925
CONDENSER FOR AIR CONDITIONER................13927
REMOVAL................13927
INSTALLATION................13927
DRY RECEIVER ................13928
REMOVAL................13928
INSTALLATION................13928
COMPRESSOR FOR AIR CONDITIONER................13929
REMOVAL................13929
INSTALLATION................13929
97 GEAR PUMP................13930
GENERAL................13930
GENERAL................13931
PRINCIPLE OF OPERATION................13932
PRESSURE LOADED TYPE GEAR PUMP................13935
FIXED SIDE PLATE TYPE GEAR PUMP................13937
SA SERIES................13938
STRUCTURE................13939
TESTING AND ADJUSTING................13942
DISASSEMBLY................13945
ASSEMBLY................13949
MAINTENANCE STANDARD................13954
SEN06202-00 - Wheel Loader WA320-7 Shop Manual................13955
Cover................13955
00 Index and foreword ................13957
Index ................13958
Foreword, safety and general information ................13973
Important safety notice ................13973
How to read the shop manual ................13980
Explanation of terms for maintenance standard ................13982
Handling equipment of fuel system devices ................13984
Handling of intake system parts ................13985
Handling of hydraulic equipment ................13986
Method of disconnecting and connecting of push-pull type coupler ................13988
Handling of electrical equipment ................13991
How to read electric wire code ................13999
Precautions when performing operation ................14002
Practical use of KOMTRAX ................14007
Standard tightening torque table ................14008
List of abbreviation ................14014
Conversion table ................14019
01 Specification ................14025
Table of contents ................14026
Specifications ................14027
Specification drawing ................14027
Specifications ................14029
Weight table ................14034
Table of fuel, coolant, and lubricants ................14036
10 Structure and function ................14037
Table of contents ................14038
Engine and cooling system ................14040
Engine related parts ................14040
KVGT ................14042
EGR system piping drawing ................14049
EGR system circuit diagram ................14051
EGR valve ................14053
EGR cooler ................14055
KCCV layout drawing ................14056
KCCV ventilator ................14058
KDPF ................14060
Cooling system ................14064
Cooling fan motor ................14066
Power train ................14076
Power train system ................14076
Layout of power train parts ................14078
Damper ................14079
HST pump ................14080
HST motor1 ................14093
HST motor2 ................14095
Transfer ................14100
Clutch solenoid valve ................14107
Drive shaft ................14109
Axle ................14110
Differential ................14112
Torque proportional differential ................14116
Limited slip differential ................14118
Final drive ................14123
Steering system ................14125
Layout of steering devices ................14125
Steering column ................14126
Priority valve ................14127
Cushion valve ................14131
Emergency steering valve ................14132
Orbitrol valve ................14135
Brake system ................14141
Layout of brake parts ................14141
Brake accumulator charge valve ................14143
Brake valve ................14148
Brake accumulator ................14152
Slack adjuster ................14153
Brake ................14155
Parking brake control ................14158
Parking brake ................14159
Parking brake solenoid valve ................14160
Undercarriage and frame ................14162
Axle mount ................14162
Center hinge pin ................14164
Tire ................14165
Hydraulic system ................14167
Hydraulic component layout ................14167
Work equipment control ................14169
Hydraulic tank ................14170
Double type gear pump ................14173
Steering and work equipment pump ................14174
Control valve ................14186
CLSS ................14196
Hydraulic circuit diagram and names of valves ................14200
Self-pressure reducing valve ................14213
Work equipment PPC valve ................14218
Work equipment lock solenoid valve ................14226
PPC circuit accumulator ................14227
ECSS accumulator ................14228
Work equipment ................14229
Work equipment linkage ................14229
Bucket ................14230
Cab and its attachments ................14231
ROPS cab ................14231
Cab mount ................14233
Electrical system ................14234
Engine control system ................14234
Preheating system ................14237
Engine output limit function ................14239
Automatic warm-up function ................14240
Parking brake control system ................14241
System operating lamp function ................14245
Battery disconnect switch function ................14246
HST controller system ................14248
Machine monitor system ................14288
Rearview monitor system ................14309
KOMTRAX system ................14312
System component parts ................14315
Sensor ................14338
20 Standard value tables ................14359
Table of contents ................14360
Standard service value table ................14361
Standard value table for engine ................14361
Standard value table for machine ................14363
Standard value table for electrical system ................14375
30 Testing and adjusting ................14385
Table of contents ................14386
General information on testing and adjusting ................14388
Tools for testing and adjusting ................14388
Sketch of tools for testing and adjusting ................14394
Engine and cooling system ................14395
Testing engine speed ................14395
Testing boost pressure ................14396
Testing exhaust gas temperature ................14398
Testing exhaust gas color ................14399
Testing and adjusting valve clearance ................14401
Testing compression pressure ................14404
Testing blowby pressure ................14408
Testing engine oil pressure ................14409
Testing EGR valve and KVGT driving oil pressure ................14410
Testing fuel pressure ................14411
Testing fuel discharge, return and leakage ................14416
Bleeding air from fuel system ................14421
Testing fuel circuit for leakage ................14423
Handling cylinder cutout mode operation ................14424
Handling no-injection cranking operation ................14425
Testing of KDPF and muffler stack for looseness and damage ................14426
Testing of installed condition of cylinder heads and manifolds ................14427
Testing engine piping for damage and looseness ................14428
Testing and adjusting air conditioner compressor belt tension ................14429
Replacing alternator belt ................14430
Power train ................14431
Testing oil leakage from axle final drive ................14431
Testing drive shaft for looseness, backlash, and damage ................14432
Testing accelerator pedal ................14433
Testing and adjusting HST oil pressure ................14434
Testing transfer clutch control pressure ................14437
Steering system ................14438
Testing directional lever ................14438
Testing steering wheel ................14439
Testing work equipment control lever ................14441
Testing and adjusting steering circuit oil pressure ................14443
Bleeding air from steering cylinder circuit ................14445
Brake system ................14446
Testing brake pedal ................14446
Testing braking performance ................14447
Testing and adjusting of accumulator charge pressure ................14448
Testing wheel brake oil pressure ................14450
Testing lowering of wheel brake pressure ................14451
Testing wear of wheel brake disc ................14453
Bleeding air from wheel brake circuit ................14454
Releasing remaining pressure in brake accumulator circuit ................14455
Testing parking brake performance ................14456
Testing wear of parking brake disc ................14457
Testing parking brake release pressure ................14458
Method of releasing parking brake manually ................14459
Hydraulic system ................14460
Testing fan speed ................14460
Testing fan circuit oil pressure ................14461
Bleeding air from hydraulic fan circuit ................14463
Testing and adjusting work equipment PPC oil pressure ................14464
Testing and adjusting work equipment oil pressure ................14466
Bleeding air from work equipment circuit ................14470
Releasing remaining pressure from work equipment circuit ................14471
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ................14473
Work equipment ................14477
Testing and adjusting bucket positioner and bucket proximity switch ................14477
Testing and adjusting boom position detection lever ................14479
Electrical system ................14480
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................14480
Special functions of machine monitor ................14481
Angle adjustment of rear view camera ................14559
Handling voltage circuit of engine controller ................14560
Handling battery disconnect switch ................14561
Testing diodes ................14562
Pm clinic ................14563
Pm Clinic service ................14563
Check sheet ................14564
40 Troubleshooting ................14569
Table of contents ................14570
General information on troubleshooting ................14579
Troubleshooting points ................14579
Sequence of events in troubleshooting ................14581
Checks before troubleshooting ................14583
Inspection procedure before troubleshooting ................14585
Preparation for troubleshooting of electrical system ................14602
Classification and procedures for troubleshooting ................14608
Symptom and troubleshooting numbers ................14611
Information in troubleshooting table ................14614
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ................14616
Connector list and layout ................14619
Connector contact identification ................14633
T-branch box and T-branch adapter table ................14671
Fuse location table ................14676
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................14679
Precautions when performing troubleshooting of machine monitor ................14682
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ................14684
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................14689
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ................14690
Failure codes table ................14691
Troubleshooting by failure code (Display of code) ................14703
Failure code [2F00MA] Failure of Parking Brake Circuit ................14703
Failure code [2F00MB] Malfunction of Parking Brake ................14706
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ................14708
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................14710
Failure code [6091NX] HST Oil Filter Clogging ................14712
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ................14714
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. ................14716
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ................14718
Failure code [879AKA] A/C Inner Sensor Open Circuit ................14720
Failure code [879AKB] A/C Inner Sensor Short Circuit ................14721
Failure code [879BKA] A/C Outer Sensor Open Circuit ................14722
Failure code [879BKB] A/C Outer Sensor Short Circuit ................14723
Failure code [879CKA] Ventilating Sensor Open Circuit ................14724
Failure code [879CKB] Ventilating Sensor Short Circuit ................14725
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................14726
Failure code [879EMC] Ventilation Damper Abnormality ................14727
Failure code [879FMC] Air Mix Damper Abnormality ................14728
Failure code [989L00] Engine Controller Lock Caution 1 ................14729
Failure code [989M00] Engine Controller Lock Caution 2 ................14730
Failure code [989N00] Engine Controller Lock Caution 3 ................14731
Failure code [A1U0N3] HC Desorb Request 1 ................14732
Failure code [A1U0N4] HC Desorb Request 2 ................14734
Failure code [AA10NX] Air Cleaner Clogging ................14736
Failure code [B@BAZG] Eng Oil Press Low ................14738
Failure code [B@BAZK] Engine Oil Level Low ................14739
Failure code [B@BCNS] Eng Water Overheat ................14741
Failure code [B@BCZK] Eng Water Level Low ................14742
Failure code [B@CRNS] HST Oil Temp. Overheat ................14744
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................14745
Failure code [CA122] Chg Air Press Sensor High Error ................14746
Failure code [CA123] Chg Air Press Sensor Low Error ................14748
Failure code [CA131] Throttle Sensor High Error ................14750
Failure code [CA132] Throttle Sensor Low Error ................14752
Failure code [CA144] Coolant Temp Sens High Error ................14754
Failure code [CA145] Coolant Temp Sens Low Error ................14756
Failure code [CA153] Chg Air Temp Sensor High Error ................14758
Failure code [CA154] Chg Air Temp Sensor Low Error ................14760
Failure code [CA187] Sensor 2 Supply Volt Low Error ................14762
Failure code [CA221] Ambient Press Sensor High Error ................14764
Failure code [CA222] Ambient Press Sensor Low Error ................14766
Failure code [CA227] Sensor 2 Supply Volt High Error ................14768
Failure code [CA234] Eng Overspeed ................14769
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................14770
Failure code [CA239] Ne Speed Sens Supply Volt High Error ................14771
Failure code [CA271] IMV/PCV1 Short Error ................14772
Failure code [CA272] IMV/PCV1 Open Error ................14774
Failure code [CA295] Ambient Press Sens In Range Error ................14776
Failure code [CA322] Inj #1(L#1) Open/Short Error ................14777
Failure code [CA323] Inj #5(L#5) Open/Short Error ................14779
Failure code [CA324] Inj #3(L#3) Open/Short Error ................14781
Failure code [CA325] Inj #6(L#6) Open/Short Error ................14783
Failure code [CA331] Inj #2(L#2) Open/Short Error ................14785
Failure code [CA332] Inj #4(L#4) Open/Short Error ................14787
Failure code [CA343] ECM Critical Internal Failure ................14789
Failure code [CA351] Injectors Drive Circuit Error ................14790
Failure code [CA352] Sensor 1 Supply Volt Low Error ................14791
Failure code [CA356] Mass Air Flow Sensor High Error ................14793
Failure code [CA357] Mass Air Flow Sensor Low Error ................14795
Failure code [CA386] Sensor 1 Supply Volt High Error ................14797
Failure code [CA428] Water in Fuel Sensor High Error ................14798
Failure code [CA429] Water in Fuel Sensor Low Error ................14800
Failure code [CA431] Idle Validation Sw Error ................14802
Failure code [CA432] Idle Validation Process Error ................14805
Failure code [CA435] Eng Oil Press Sw Error ................14808
Failure code [CA441] Battery Voltage Low Error ................14809
Failure code [CA442] Battery Voltage High Error ................14811
Failure code [CA449] Rail Press Very High Error ................14812
Failure code [CA451] Rail Press Sensor High Error ................14813
Failure code [CA452] Rail Press Sensor Low Error ................14815
Failure code [CA488] Chg Air Temp High Torque Derate ................14817
Failure code [CA515] Rail Press Sens Sup Volt High Error ................14818
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................14820
Failure code [CA553] Rail Press High Error ................14822
Failure code [CA555] Crankcase Press High Error 1 ................14823
Failure code [CA556] Crankcase Press High Error 2 ................14824
Failure code [CA559] Rail Press Low Error ................14825
Failure code [CA595] Turbo Speed High Error 2 ................14827
Failure code [CA687] Turbo Speed Low Error ................14828
Failure code [CA689] Eng Ne Speed Sensor Error ................14830
Failure code [CA691] Intake Air Temp Sens High Error ................14832
Failure code [CA692] Intake Air Temp Sens Low Error ................14834
Failure code [CA697] ECM Internal Temp Sensor High Error ................14836
Failure code [CA698] ECM Int Temp Sensor Low Error ................14837
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................14838
Failure code [CA778] Eng Bkup Speed Sensor Error ................14840
Failure code [CA1117] Persistent Data Lost Error ................14845
Failure code [CA1664] KDOC Malfunction ................14846
Failure code [CA1691] Regeneration Ineffective ................14849
Failure code [CA1695] Sensor 5 Supply Volt High Error ................14852
Failure code [CA1696] Sensor 5 Supply Volt Low Error ................14853
Failure code [CA1843] Crankcase Press Sens High Error ................14855
Failure code [CA1844] Crankcase Press Sens Low Error ................14857
Failure code [CA1879] KDPF Delta P Sensor High Error ................14859
Failure code [CA1881] KDPF Delta P Sensor Low Error ................14861
Failure code [CA1883] KDPF Delta P Sens In Range Error ................14863
Failure code [CA1921] KDPF Soot Load High Error 1 ................14867
Failure code [CA1922] KDPF Soot Load High Error 2 ................14870
Failure code [CA1942] Crankcase Press Sens In Range Error ................14875
Failure code [CA1993] KDPF Delta Pressure Low Error ................14876
Failure code [CA2185] Throt Sensor Sup Volt High Error ................14879
Failure code [CA2186] Throt Sensor Sup Volt Low Error ................14881
Failure code [CA2249] Rail Press Very Low Error ................14883
Failure code [CA2271] EGR Valve Pos Sens High Error ................14884
Failure code [CA2272] EGR Valve Pos Sens Low Error ................14886
Failure code [CA2288] Turbo Speed High Error 1 ................14889
Failure code [CA2311] IMV Solenoid Error ................14890
Failure code [CA2349] EGR Valve Solenoid Open Error ................14891
Failure code [CA2353] EGR Valve Solenoid Short Error ................14893
Failure code [CA2357] EGR Valve Servo Error ................14895
Failure code [CA2373] Exhaust Manifold Press Sens High error ................14896
Failure code [CA2374] Exhaust Manifold Press Sens Low error ................14898
Failure code [CA2375] EGR Orifice Temp Sens High Error ................14900
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................14902
Failure code [CA2381] KVGT Pos Sens High Error ................14904
Failure code [CA2382] KVGT Pos Sens Low Error ................14906
Failure code [CA2383] KVGT Solenoid Open Error ................14909
Failure code [CA2386] KVGT Solenoid Short Error ................14911
Failure code [CA2387] KVGT Servo Error ................14913
Failure code [CA2554] Exh Manifold Press Sens In Range Error ................14914
Failure code [CA2555] Grid Htr Relay Volt Low Error ................14915
Failure code [CA2556] Grid Htr Relay Volt High Error ................14917
Failure code [CA2637] KDOC Face Plugging ................14919
Failure code [CA2639] Manual Stationary Regeneration Request ................14921
Failure code [CA2961] EGR Orifice Temp High Error 1 ................14924
Failure code [CA2973] Chg Air Press Sensor In Range Error ................14925
Failure code [CA3133] KDPF Outlet Press Sens High Error ................14926
Failure code [CA3134] KDPF Outlet Press Sens Low Error ................14928
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ................14930
Failure code [CA3251] KDOC Inlet Temp High Error ................14934
Failure code [CA3253] KDOC Temp Error - Non Regeneration ................14937
Failure code [CA3254] KDOC Outlet Temp High Error 1 ................14940
Failure code [CA3255] KDPF Temp Error - Non Regeneration ................14943
Failure code [CA3256] KDPF Outlet Temp High Error 1 ................14946
Failure code [CA3311] KDOC Outlet Temp High Error 2 ................14949
Failure code [CA3312] KDPF Outlet Temp High Error 2 ................14952
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................14955
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................14958
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................14961
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................14965
Failure code [CA3317] KDOC Outlet Temp Sens High Error ................14968
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ................14971
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................14975
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ................14978
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ................14981
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ................14985
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ................14987
Failure code [CA3741] Rail Press Valve Trip Error ................14989
Failure code [D110L4] Disconnection of Battery Relay Signal ................14990
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................14992
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ................14994
Failure code [D191KA] Disconnection of Neutral Output Relay ................14996
Failure code [D191KB] Ground Fault of Neutral Output Relay ................14998
Failure code [D191KY] Hot Short of Neutral Output Relay ................15000
Failure code [D192KA] Disconnection of ECSS Solenoid ................15002
Failure code [D192KB] Ground Fault of ECSS Solenoid ................15004
Failure code [D192KY] Hot Short of ECSS Solenoid ................15005
Failure code [D19JKZ] Personal Code Relay Abnormality ................15006
Failure code [D1B0KA] Disconnection of HST Safety Relay ................15008
Failure code [D1B0KB] Ground Fault of HST Safety Relay ................15010
Failure code [D1B0KY] Hot Short of HST Safety Relay ................15012
Failure code [D1B0MC] Malfunction of HST Safety Relay ................15014
Failure code [D1E6KA] Disconnection of Parking Brake Relay ................15015
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................15017
Failure code [D1E6KY] Hot Short of Parking Brake Relay ................15019
Failure code [D5ZHKA] Failure of Key SW C Signal ................15021
Failure code [D5ZHKB] Key SW C Signal Short Circuit ................15023
Failure code [D5ZHL6] Disconnection of Key SW C ................15025
Failure code [D811MC] KOMTRAX Error ................15026
Failure code [D862KA] GPS Antenna Open Circuit ................15027
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ................15028
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ................15030
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ................15032
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ................15033
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ................15035
Failure code [DAF0MB] Monitor ROM Abnormality ................15036
Failure code [DAF0MC] Monitor Error ................15037
Failure code [DAF3KK] Controller Power Source Low (MON) ................15038
Failure code [DAF8KB] Camera Power Supply Short Circuit ................15040
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ................15041
Failure code [DAFGMC] GPS Module Error ................15042
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ................15043
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ................15045
Failure code [DAFQKR] CAN2 Discon (Monitor) ................15047
Failure code [DAJ0KK] Controller Power Source Low (HST) ................15048
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ................15051
Failure code [DAJ0MC] HST Con Error ................15052
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ................15053
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ................15055
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ................15058
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay ................15060
Failure code [DAJ5KX] Failure of 5V Power Source 0 ................15062
Failure code [DAJ6KX] Failure of 5V Power Source 1 ................15064
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) ................15066
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ................15067
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ................15069
Failure code [DAJQKR] CAN2 Discon ( HST Con) ................15071
Failure code [DAJRKR] CAN1 Discon ( HST Con) ................15072
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ................15073
Failure code [DAZ9KQ] A/C Model Selection Abnormality ................15074
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ................15075
Failure code [DB2QKR] CAN2 Discon (Engine Con) ................15076
Failure code [DB2RKR] CAN1 Discon (Engine Con) ................15081
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ................15085
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................15087
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................15089
Failure code [DDB6L4] Parking Brake Signal Malfunction ................15091
Failure code [DDD7KA] Failure of Variable Speed Control ................15094
Failure code [DDD7KY] Hot Short of Variable Speed Control ................15096
Failure code [DDK3KA] FNR SW Input Signal Disconnection ................15098
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ................15100
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ................15102
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ................15105
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ................15107
Failure code [DF10KA] Disconnection of Speed Range Input ................15109
Failure code [DF10KB] Ground Fault of Speed Range Input ................15112
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ................15115
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ................15117
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ................15119
Failure code [DHG1KX] Out of Range of HST Oil Temp. Sensor ................15121
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ................15123
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) ................15125
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ................15127
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) ................15129
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ................15131
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ................15133
Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ................15135
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. ................15137
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ................15139
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ................15141
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ................15143
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ................15145
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ................15147
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit ................15149
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ................15151
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ................15153
Failure code [DHT8ZG] Steering Oil Pressure Low ................15155
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ................15156
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................15158
Failure code [DK55KA] Failure of FNR Lever Potentio ................15160
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ................15163
Failure code [DK55L5] Failure of FNR Lever Potentio ................15165
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................15166
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ................15169
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ................15172
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................15175
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ................15178
Failure code [DK70KA] Failure of inching sensor Circuit ................15181
Failure code [DK70KY] Hot Short of inching sensor Circuit ................15184
Failure code [DKA0KA] Failure of Boom Angle Sensor ................15186
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ................15188
Failure code [DKA0L0] Boom Angle Sensor Dislocation ................15190
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................15192
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ................15194
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ................15196
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ................15198
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ................15200
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ................15203
Failure code [DPQ1KR] LIN Discon (Switch Panel) ................15205
Failure code [DPQ2KR] LIN Discon (LED Unit) ................15208
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ................15211
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ................15214
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ................15216
Failure code [DV00KB] Ground Fault of Buzzer Output ................15218
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ................15220
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ................15222
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ................15224
Failure code [DW4BKA] Disconnection of Parking Brake Valve ................15225
Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................15227
Failure code [DW4BKY] Hot Short of Parking Brake Valve ................15229
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ................15230
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................15232
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ................15234
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ................15235
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ................15237
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................15239
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ................15240
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ................15242
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................15244
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ................15246
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ................15248
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ................15250
Failure code [DX19KA] Disconnection of Motor 1 Solenoid ................15251
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ................15253
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ................15255
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ................15257
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ................15259
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ................15261
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ................15263
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ................15265
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. ................15267
Failure code [DXH7KA] Disconnection of Reverse Solenoid ................15269
Failure code [DXH7KB] Ground Fault of Reverse Solenoid ................15271
Failure code [DXH7KY] Hot Short of Reverse Solenoid ................15273
Failure code [DXH8KA] Disconnection of Forward Solenoid ................15275
Failure code [DXH8KB] Ground Fault of Forward Solenoid ................15277
Failure code [DXH8KY] Hot Short of Forward Solenoid ................15279
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ................15281
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ................15283
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................15285
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ................15286
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ................15288
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................15290
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ................15291
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ................15294
Failure code [J141N1] Steering Pump Over Run ................15296
Failure code [LA00L3] Failure of Fan Reverse ................15297
Failure code [M100N1] HST Pump Over Run ................15298
Failure code [M400N1] HST Motor 1 Over Run ................15299
Troubleshooting of electrical system (E-mode) ................15300
E-1 Engine does not start ................15300
E-2 Manual preheating system does not work ................15307
E-3 Automatic preheating system does not work ................15310
E-4 While preheating is working, preheating monitor does not light up ................15312
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................15314
E-6 LCD unit on machine monitor displays nothing ................15317
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................15319
E-8 LCD on machine monitor does not display properly ................15321
E-9 Meter unit display on machine monitor is abnormal ................15323
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................15326
E-11 Caution LED on machine monitor is abnormal ................15329
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ................15331
E-13 Two switches operation of switch panel on machine monitor does not function ................15333
E-14 Switch panel buzzer of machine monitor is abnormal ................15336
E-15 Rearview monitor does not light up or backlight flickers ................15338
E-16 Rearview monitor images are not displayed clearly ................15341
E-17 Rearview monitor brightness cannot be adjusted ................15344
E-18 Night lighting lamp of rearview monitor is abnormal ................15347
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................15349
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ................15350
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ................15354
E-22 Air cleaner clogging indicator lamp does not light ................15356
E-23 Radiator coolant level caution lamp does not light ................15358
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light ................15360
E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel speed or traction force does not lower), or while not depressed, inching function operates ................15361
E-26 Fuel level gauge does not indicate correct level ................15363
E-27 Seat belt caution lamp indication is abnormal ................15365
E-28 Horn does not sound ................15366
E-29 Horn does not stop sounding ................15369
E-30 Alarm buzzer does not sound ................15371
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................15373
E-32 When emergency HST pump drive switch is operated, emergency HST pump does not work or when emergency HST pump drive switch is not operated, emergency HST pump works ................15374
E-33 Setting does not change while operating traction control switch ................15376
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake is released and FR drive is operated ................15378
E-35 Remote positioner does not work or cannot be released ................15381
E-36 Bucket positioner does not work or cannot be released ................15383
E-37 Direction selector (FNR) switch mode is not selected or not released ................15386
E-38 PZ auto tilt-in does not work ................15388
E-39 Tracktion level does not display MAX when max traction switch is turned ON ................15391
E-40 ECSS function cannot be selected or cannot be released ................15393
E-41 None of headlamp, clearance lamp, and tail lamp lights ................15395
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ................15397
E-43 Both High and Low beams of headlamp do not light up or go out ................15401
E-44 Low beam of headlamp does not light up or go out ................15405
E-45 High beam of headlamp does not light up or go out ................15407
E-46 Front working lamp does not light up or go out ................15409
E-47 Rear working lamp does not light up or go out ................15413
E-48 All of turn signal lamps and hazard lamps do not flash or go out ................15417
E-49 Turn signal lamps do not flash or go out ................15420
E-50 Hazard lamp does not flash or go out ................15423
E-51 Brake lamp does not light or stays lighted ................15426
E-52 Backup lamp does not light up or does not go out ................15429
E-53 Backup buzzer does not sound or continues to sound ................15432
E-54 Front wiper does not operate ................15434
E-55 Rear wiper does not operate ................15437
E-56 Window washer does not operate ................15439
E-57 KOMTRAX system does not operate normally ................15442
Troubleshooting of hydraulic and mechanical system (H-mode) ................15444
Information described in troubleshooting table (H-mode) ................15444
System chart of hydraulic and mechanical systems ................15445
Failure mode and cause table ................15447
H-1 Machine does not travel forward or backward ................15454
H-2 Machine does not travel forward (Machine travels backward normally) ................15457
H-3 Machine does not travel backward (Machine travels forward normally) ................15458
H-4 Machine does not travel forward or backward fast ................15459
H-5 Machine does not travel forward fast (Machine travel backward fast) ................15463
H-6 Machine does not travel backward fast (Machine travel forward fast) ................15464
H-7 Machine lacks power neither when traveling forward nor backward ................15465
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ................15468
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ................15469
H-10 Engine stalls during travel or engine speed drops significantly ................15470
H-11 Steering wheel is too heavy to turn ................15471
H-12 Steering wheel is heavy to turn ................15473
H-13 Machine sways or large shocks are made while machine turns ................15474
H-14 Machine unintentionally turns when machine travels ................15475
H-15 Wheel brakes do not work or are weak ................15476
H-16 Wheel brakes are not released or drag ................15477
H-17 Parking brake does not work or it is weak ................15478
H-18 Parking brake is not released or drags. ................15479
H-19 Boom does not rise ................15480
H-20 Boom moves slow or boom lacks lifting force ................15482
H-21 Rising boom slows down at certain height ................15484
H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................15485
H-23 Hydraulic drift of boom is large ................15486
H-24 Boom moves up and down during operation ................15487
H-25 Bucket does not tilt back ................15488
H-26 Bucket moves slow or lacks tilt-back force ................15490
H-27 Bucket decelerates during tilt-back operation ................15492
H-28 Bucket cylinder does not hold bucket on ground ................15493
H-29 Hydraulic drift of bucket is large ................15494
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ................15495
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ................15496
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ................15497
H-33 Large shocks are made when work equipment starts to move and stops ................15498
H-34 When certain work equipment is relieved hydraulically, other work equipment moves ................15499
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ................15500
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ................15501
H-37 Unusual noise is heard from around fan ................15503
Troubleshooting of engine (S-mode) ................15504
Information described in troubleshooting table (S mode) ................15504
S-1 Engine does not crank when starting switch is turned to START position ................15505
S-2 Engine cranks but no exhaust smoke comes out ................15506
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ................15507
S-4 Engine startability is poor ................15508
S-5 Engine does not pick up smoothly ................15510
S-6 Engine stops during operation ................15512
S-7 Engine runs rough or is unstable ................15514
S-8 Engine lacks power ................15515
S-9 KDPF gets clogged in a short time ................15517
S-10 Engine oil consumption is excessive ................15519
S-11 Engine oil becomes contaminated early ................15520
S-12 Fuel consumption is excessive ................15521
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ................15522
S-14 Oil pressure drops ................15523
S-15 Fuel mixes into engine oil ................15524
S-16 Water mixes into engine oil (milky) ................15525
S-17 Coolant temperature rises too high (overheating) ................15526
S-18 Unusual noise is heard ................15527
S-19 Vibration is excessive ................15528
S-20 Air cannot be bled from fuel circuit ................15530
S-21 Active regeneration is executed frequently ................15531
S-22 Active regeneration takes time ................15532
S-23 White smoke is exhausted during active regeneration ................15533
50 Disassembly and assembly ................15535
Table of contents ................15536
General information on disassembly and assembly ................15538
How to read this manual ................15538
Coating materials list ................15540
Special tools list ................15544
Sketches of special tools ................15549
Engine and cooling system ................15562
Removal and installation of supply pump assembly ................15562
Removal and installation of injector assembly ................15565
Removal and installation of cylinder head assembly ................15574
Removal and installation of engine hood assembly ................15587
Removal and installation of radiator core assembly ................15589
Removal and installation of aftercooler ................15591
Removal and installation of hydraulic oil cooler ................15592
Removal and installation of engine assembly ................15593
Removal and installation of engine front oil seal ................15601
Removal and installation of engine rear oil seal ................15604
Removal and installation of cooling fan and fan motor assembly ................15607
Removal and installation of KDPF assembly ................15609
Disassembly and assembly of KDPF assembly ................15612
Removal and installation of KCCV assembly ................15621
Removal and installation of air cleaner assembly ................15622
Removal and installation of KVGT assembly ................15623
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ................15626
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ................15627
Removal and installation of alternator belt ................15629
Removal and installation of fuel tank assembly ................15630
Power train ................15633
Removal and installation of transfer assembly ................15633
Disassembly and assembly of transfer assembly ................15637
Removal and installation of front axle assembly ................15668
Removal and installation of rear axle assembly ................15670
Disassembly and assembly of axle housing assembly ................15673
Disassembly and assembly of differential assembly ................15685
Undercarriage and frame ................15707
Removal and installation of center hinge pin ................15707
Removal and installation of counterweight assembly ................15716
Hydraulic system ................15720
Removal and installation of hydraulic tank assembly ................15720
Removal and installation of control valve assembly ................15724
Disassembly and assembly of control valve assembly ................15728
Removal and installation of hydraulic pump assembly ................15731
Removal and installation of HST motor1 assembly ................15736
Removal and installation of HST motor2 assembly ................15738
Disassembly and assembly of hydraulic cylinder assembly ................15740
Work equipment ................15747
Removal and installation of work equipment assembly ................15747
Cab and its attachments ................15753
Removal and installation of operator's cab and floor frame assembly ................15753
Removal and installation of operator's cab glass (adhered glass) ................15758
Removal and installation of operator's seat assembly ................15766
Removal and installation of seat belt ................15768
Removal and installation of air conditioner unit assembly ................15769
Removal and installation of air conditioner compressor ................15774
Removal and installation of air conditioner condenser ................15776
Electrical system ................15778
Removal and installation of machine monitor assembly ................15778
Removal and installation of engine controller assembly ................15780
Removal and installation of HST controller assembly ................15782
Removal and installation of air conditioner controller assembly ................15784
Removal and installation of monitor controller assembly ................15785
Removal and installation of mass air flow and temperature sensor ................15787
Removal and installation of KOMTRAX terminal assembly ................15788
60 Maintenance standard ................15789
Table of contents ................15790
Engine and cooling system ................15791
Engine related parts ................15791
Cooling fan motor ................15792
Power train ................15794
Damper ................15794
Transfer ................15795
Drive shaft ................15802
Axle ................15803
Differential ................15805
Limited slip differential ................15809
Final drive ................15811
Steering system ................15813
Steering column ................15813
Priority valve ................15814
Emergency steering valve ................15815
Steering cylinder ................15816
Brake system ................15818
Brake accumulator charge valve ................15818
Slack adjuster ................15819
Brake ................15820
Parking brake ................15822
Parking brake solenoid valve ................15823
Undercarriage and frame ................15824
Axle mount ................15824
Center hinge pin ................15826
Hydraulic system ................15829
Hydraulic tank ................15829
Double type gear pump ................15830
Steering and work equipment pump ................15831
Control valve ................15835
Self-pressure reducing valve ................15848
Work equipment PPC valve ................15850
Work equipment lock solenoid valve ................15852
Work equipment ................15853
Work equipment linkage ................15853
Bucket ................15857
Work equipment cylinder ................15859
Cab and its attachments ................15860
Cab mount ................15860
Electrical system ................15861
Bucket positioner ................15861
Fork positioner ................15862
Remote boom positioner ................15863
80 Appendix ................15865
Table of contents ................15866
Air conditioner components ................15867
Precautions for refrigerant ................15867
Air conditioner component ................15868
Configuration and function of refrigeration cycle ................15870
Outline of refrigeration cycle ................15871
Air conditioner unit ................15873
Dual pressure switch ................15878
Air conditioner controller ................15879
Compressor ................15880
Condenser ................15881
Receiver drier ................15882
Sunlight sensor ................15884
Outer temperature sensor (outside air temperature sensor) ................15885
Procedure for testing and troubleshooting ................15886
Circuit diagram and arrangement of connector pins ................15888
System diagram ................15891
Parts and connectors layout ................15894
Testing with self-diagnosis function ................15899
How to open the electrical system abnormality record screen in service mode of the machine monitor ................15900
Testing temperature control system ................15902
Testing vent (mode) changeover ................15904
Testing FRESH/RECIRC air changeover ................15906
Testing evaporator temperature sensor ................15908
Testing relays ................15910
Troubleshooting chart 1 ................15912
Troubleshooting chart 2 ................15913
Information in troubleshooting table ................15915
Failure code list related to air conditioner ................15916
Failure code [879AKA] A/C Inner Sensor Open Circuit ................15917
Failure code [879AKB] A/C Inner Sensor Short Circuit ................15919
Failure code [879BKA] A/C Outer Sensor Open Circuit ................15921
Failure code [879BKB] A/C Outer Sensor Short Circuit ................15923
Failure code [879CKA] Ventilating Sensor Open Circuit ................15925
Failure code [879CKB] Ventilating Sensor Short Circuit ................15927
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................15929
Failure code [879EMC] Ventilation Damper Abnormality ................15931
Failure code [879FMC] Air Mix Damper Abnormality ................15934
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ................15937
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ................15940
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................15943
A-4 Troubleshooting for FRESH/RECIRC air changeover ................15946
Troubleshooting with gauge pressure ................15948
Connection of service tool ................15951
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ................15953
Handling of compressor oil ................15955
90 Diagrams and drawings ................15957
Table of contents ................15958
Hydraulic circuit diagram ................15959
Symbols in hydraulic circuit diagram ................15959
Hydraulic circuit diagram ................15963
Electric circuit diagram ................15964
Symbols in electric circuit diagram ................15964
Electrical circuit diagram of machine body ................15968
Electrical circuit diagram of floor ................15972
INDEX................15981
SEN06202-01 - Wheel Loader WA320-7 Shop Manual................15993
SEN06202-03 - Wheel Loader WA320-7 Shop Manual................18045
Cover................18045
00 Index and foreword ................18047
Index ................18048
Foreword, safety and general information ................18063
Important safety notice ................18063
How to read the shop manual ................18070
Explanation of terms for maintenance standard ................18072
Handling equipment of fuel system devices ................18074
Handling of intake system parts ................18075
Handling of hydraulic equipment ................18076
Method of disconnecting and connecting of push-pull type coupler ................18078
Handling of electrical equipment ................18081
How to read electric wire code ................18089
Precautions when performing operation ................18092
Practical use of KOMTRAX ................18097
Standard tightening torque table ................18098
List of abbreviation ................18104
Conversion table ................18109
01 Specification ................18115
Table of contents ................18116
Specifications ................18117
Specification drawing ................18117
Specifications ................18121
Weight table ................18131
Table of fuel, coolant, and lubricants ................18135
10 Structure and function ................18137
Table of contents ................18138
Engine and cooling system ................18140
Engine related parts ................18140
KVGT ................18142
EGR system piping drawing ................18149
EGR system circuit diagram ................18151
EGR valve ................18153
EGR cooler ................18155
KCCV layout drawing ................18156
KCCV ventilator ................18158
KDPF ................18160
Cooling system ................18164
Cooling fan motor ................18166
Power train ................18176
Power train system ................18176
Layout of power train parts ................18178
Damper ................18179
HST pump ................18180
HST motor1 ................18193
HST motor2 ................18195
Transfer ................18200
Clutch solenoid valve ................18207
Drive shaft ................18209
Axle ................18210
Differential ................18212
Torque proportional differential ................18216
Limited slip differential ................18218
Final drive ................18223
Steering system ................18225
Layout of steering devices ................18225
Steering column ................18226
Priority valve ................18227
Cushion valve ................18231
Emergency steering valve ................18232
Orbitrol valve ................18235
Brake system ................18241
Layout of brake parts ................18241
Brake accumulator charge valve ................18243
Brake valve ................18248
Brake accumulator ................18252
Slack adjuster ................18253
Brake ................18255
Parking brake control ................18258
Parking brake ................18259
Parking brake solenoid valve ................18260
Undercarriage and frame ................18262
Axle mount ................18262
Center hinge pin ................18264
Tire ................18265
Hydraulic system ................18267
Hydraulic component layout ................18267
Work equipment control ................18269
Hydraulic tank ................18270
Double type gear pump ................18273
Steering and work equipment pump ................18274
Control valve ................18286
CLSS ................18296
Hydraulic circuit diagram and names of valves ................18300
Self-pressure reducing valve ................18313
Work equipment PPC valve ................18318
Work equipment lock solenoid valve ................18326
PPC circuit accumulator ................18327
ECSS accumulator ................18328
Work equipment ................18329
Work equipment linkage ................18329
Bucket ................18330
Cab and its attachments ................18331
ROPS cab ................18331
Cab mount ................18333
Electrical system ................18334
Engine control system ................18334
Preheating system ................18337
Engine output limit function ................18339
Automatic warm-up function ................18340
Parking brake control system ................18341
System operating lamp function ................18345
Battery disconnect switch function ................18346
HST controller system ................18348
Machine monitor system ................18388
Rearview monitor system ................18409
KOMTRAX system ................18412
System component parts ................18415
Sensor ................18438
20 Standard value tables ................18459
Table of contents ................18460
Standard service value table ................18461
Standard value table for engine ................18461
Standard value table for machine ................18463
Standard value table for electrical system ................18475
30 Testing and adjusting ................18485
Table of contents ................18486
Related information on testing and adjusting ................18488
Tools for testing and adjusting ................18488
Sketch of tools for testing and adjusting ................18494
Engine and cooling system ................18495
Testing engine speed ................18495
Testing boost pressure ................18496
Testing exhaust gas temperature ................18498
Testing exhaust gas color ................18499
Testing and adjusting valve clearance ................18501
Testing compression pressure ................18504
Testing blowby pressure ................18508
Testing engine oil pressure ................18509
Testing EGR valve and KVGT oil pressures ................18510
Testing fuel pressure ................18511
Testing fuel discharge, return and leakage ................18516
Bleeding air from fuel system ................18521
Testing fuel circuit for leakage ................18523
Handling cylinder cutout mode operation ................18524
Handling no-injection cranking operation ................18525
Testing of KDPF and muffler stack for looseness and damage ................18526
Testing of installed condition of cylinder heads and manifolds ................18527
Testing engine piping for damage and looseness ................18528
Testing and adjusting air conditioner compressor belt tension ................18529
Replacing alternator belt ................18530
Power train ................18531
Testing oil leakage from axle final drive ................18531
Testing drive shaft for looseness, backlash, and damage ................18532
Testing accelerator pedal ................18533
Testing and adjusting HST oil pressure ................18534
Testing transfer clutch control pressure ................18537
Steering system ................18538
Testing directional lever ................18538
Testing steering wheel ................18539
Testing work equipment control lever ................18541
Testing and adjusting steering circuit oil pressure ................18543
Bleeding air from steering cylinder circuit ................18545
Brake system ................18546
Testing brake pedal ................18546
Testing braking performance ................18547
Testing and adjusting of accumulator charge pressure ................18548
Testing wheel brake oil pressure ................18550
Testing lowering of wheel brake pressure ................18551
Testing wear of wheel brake disc ................18553
Bleeding air from wheel brake circuit ................18554
Releasing remaining pressure in brake accumulator circuit ................18555
Testing parking brake performance ................18556
Testing wear of parking brake disc ................18557
Testing parking brake release pressure ................18558
Method of releasing parking brake manually ................18559
Hydraulic system ................18560
Testing cooling fan speed ................18560
Testing cooling fan pump circuit oil pressure ................18561
Bleeding air from hydraulic fan circuit ................18563
Testing and adjusting work equipment PPC oil pressure ................18564
Testing and adjusting work equipment oil pressure ................18566
Bleeding air from work equipment circuit ................18570
Releasing remaining pressure from work equipment circuit ................18571
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ................18573
Work equipment ................18577
Testing and adjusting bucket positioner and bucket proximity switch ................18577
Testing and adjusting boom position detection lever ................18579
Electrical system ................18580
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................18580
Special functions of machine monitor ................18581
Adjusting rearview camera angle ................18660
Handling voltage circuit of engine controller ................18661
Handling battery disconnect switch ................18662
Testing diodes ................18663
Pm clinic ................18664
Pm Clinic service ................18664
Check sheet ................18665
40 Troubleshooting ................18671
Table of contents ................18672
Related information on troubleshooting ................18681
Troubleshooting points ................18681
Sequence of events in troubleshooting ................18683
Checks before troubleshooting ................18685
Inspection procedure before troubleshooting ................18687
Preparation for troubleshooting of electrical system ................18704
Classification and procedures for troubleshooting ................18710
Symptom and troubleshooting numbers ................18713
Information in troubleshooting table ................18716
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ................18718
Connector list and layout ................18721
Connector contact identification ................18735
T-branch box and T-branch adapter table ................18774
Fuse location table ................18779
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................18782
Precautions when performing troubleshooting of machine monitor ................18785
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ................18787
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................18792
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ................18793
Failure codes table ................18794
Troubleshooting by failure code (Display of code) ................18806
Failure code [2F00MA] Failure of Parking Brake Circuit ................18806
Failure code [2F00MB] Malfunction of Parking Brake ................18809
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ................18811
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................18813
Failure code [6091NX] HST Oil Filter Clogging ................18815
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ................18817
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. ................18819
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ................18821
Failure code [879AKA] A/C Inner Sensor Open Circuit ................18823
Failure code [879AKB] A/C Inner Sensor Short Circuit ................18824
Failure code [879BKA] A/C Outer Sensor Open Circuit ................18825
Failure code [879BKB] A/C Outer Sensor Short Circuit ................18826
Failure code [879CKA] Ventilating Sensor Open Circuit ................18827
Failure code [879CKB] Ventilating Sensor Short Circuit ................18828
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................18829
Failure code [879EMC] Ventilation Damper Abnormality ................18830
Failure code [879FMC] Air Mix Damper Abnormality ................18831
Failure code [989L00] Engine Controller Lock Caution 1 ................18832
Failure code [989M00] Engine Controller Lock Caution 2 ................18833
Failure code [989N00] Engine Controller Lock Caution 3 ................18834
Failure code [A1U0N3] HC Desorb Request 1 ................18835
Failure code [A1U0N4] HC Desorb Request 2 ................18837
Failure code [AA10NX] Air Cleaner Clogging ................18839
Failure code [AB00KE] Charge Voltage Low ................18841
Failure code [AB00KY] Hot Short of Alternator R Terminal ................18842
Failure code [B@BAZG] Eng Oil Press Low ................18843
Failure code [B@BAZK] Engine Oil Level Low ................18844
Failure code [B@BCNS] Eng Water Overheat ................18846
Failure code [B@BCZK] Eng Water Level Low ................18847
Failure code [B@CRNS] HST Oil Temp. Overheat ................18849
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................18850
Failure code [CA122] Chg Air Press Sensor High Error ................18851
Failure code [CA123] Chg Air Press Sensor Low Error ................18853
Failure code [CA131] Throttle Sensor High Error ................18855
Failure code [CA132] Throttle Sensor Low Error ................18857
Failure code [CA144] Coolant Temp Sens High Error ................18859
Failure code [CA145] Coolant Temp Sens Low Error ................18861
Failure code [CA153] Chg Air Temp Sensor High Error ................18863
Failure code [CA154] Chg Air Temp Sensor Low Error ................18865
Failure code [CA187] Sensor 2 Supply Volt Low Error ................18867
Failure code [CA221] Ambient Press Sensor High Error ................18869
Failure code [CA222] Ambient Press Sensor Low Error ................18871
Failure code [CA227] Sensor 2 Supply Volt High Error ................18873
Failure code [CA234] Eng Overspeed ................18874
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................18875
Failure code [CA239] Ne Speed Sens Supply Volt High Error ................18876
Failure code [CA271] IMV/PCV1 Short Error ................18877
Failure code [CA272] IMV/PCV1 Open Error ................18879
Failure code [CA295] Ambient Press Sens In Range Error ................18881
Failure code [CA322] Inj #1(L#1) Open/Short Error ................18882
Failure code [CA323] Inj #5(L#5) Open/Short Error ................18884
Failure code [CA324] Inj #3(L#3) Open/Short Error ................18886
Failure code [CA325] Inj #6(L#6) Open/Short Error ................18888
Failure code [CA331] Inj #2(L#2) Open/Short Error ................18890
Failure code [CA332] Inj #4(L#4) Open/Short Error ................18892
Failure code [CA343] ECM Critical Internal Failure ................18894
Failure code [CA351] Injectors Drive Circuit Error ................18895
Failure code [CA352] Sensor 1 Supply Volt Low Error ................18896
Failure code [CA356] Mass Air Flow Sensor High Error ................18898
Failure code [CA357] Mass Air Flow Sensor Low Error ................18900
Failure code [CA386] Sensor 1 Supply Volt High Error ................18902
Failure code [CA428] Water in Fuel Sensor High Error ................18903
Failure code [CA429] Water in Fuel Sensor Low Error ................18905
Failure code [CA431] Idle Validation Sw Error ................18907
Failure code [CA432] Idle Validation Process Error ................18910
Failure code [CA435] Eng Oil Press Sw Error ................18913
Failure code [CA441] Battery Voltage Low Error ................18914
Failure code [CA442] Battery Voltage High Error ................18916
Failure code [CA449] Rail Press Very High Error ................18917
Failure code [CA451] Rail Press Sensor High Error ................18918
Failure code [CA452] Rail Press Sensor Low Error ................18920
Failure code [CA488] Chg Air Temp High Torque Derate ................18922
Failure code [CA515] Rail Press Sens Sup Volt High Error ................18923
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................18925
Failure code [CA553] Rail Press High Error ................18927
Failure code [CA555] Crankcase Press High Error 1 ................18928
Failure code [CA556] Crankcase Press High Error 2 ................18929
Failure code [CA559] Rail Press Low Error ................18930
Failure code [CA595] Turbo Speed High Error 2 ................18932
Failure code [CA687] Turbo Speed Low Error ................18933
Failure code [CA689] Eng Ne Speed Sensor Error ................18935
Failure code [CA691] Intake Air Temp Sens High Error ................18937
Failure code [CA692] Intake Air Temp Sens Low Error ................18939
Failure code [CA697] ECM Internal Temp Sensor High Error ................18941
Failure code [CA698] ECM Int Temp Sensor Low Error ................18942
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................18943
Failure code [CA778] Eng Bkup Speed Sensor Error ................18945
Failure code [CA1117] Persistent Data Lost Error ................18950
Failure code [CA1664] KDOC Malfunction ................18951
Failure code [CA1691] Regeneration Ineffective ................18954
Failure code [CA1695] Sensor 5 Supply Volt High Error ................18957
Failure code [CA1696] Sensor 5 Supply Volt Low Error ................18958
Failure code [CA1843] Crankcase Press Sens High Error ................18960
Failure code [CA1844] Crankcase Press Sens Low Error ................18962
Failure code [CA1879] KDPF Delta P Sensor High Error ................18964
Failure code [CA1881] KDPF Delta P Sensor Low Error ................18966
Failure code [CA1883] KDPF Delta P Sens In Range Error ................18968
Failure code [CA1921] KDPF Soot Load High Error 1 ................18972
Failure code [CA1922] KDPF Soot Load High Error 2 ................18975
Failure code [CA1942] Crankcase Press Sens In Range Error ................18980
Failure code [CA1993] KDPF Delta Pressure Low Error ................18981
Failure code [CA2185] Throt Sensor Sup Volt High Error ................18984
Failure code [CA2186] Throt Sensor Sup Volt Low Error ................18986
Failure code [CA2249] Rail Press Very Low Error ................18988
Failure code [CA2271] EGR Valve Pos Sens High Error ................18989
Failure code [CA2272] EGR Valve Pos Sens Low Error ................18991
Failure code [CA2288] Turbo Speed High Error 1 ................18994
Failure code [CA2311] IMV Solenoid Error ................18995
Failure code [CA2349] EGR Valve Solenoid Open Error ................18996
Failure code [CA2353] EGR Valve Solenoid Short Error ................18998
Failure code [CA2357] EGR Valve Servo Error ................19000
Failure code [CA2373] Exhaust Manifold Press Sens High error ................19001
Failure code [CA2374] Exhaust Manifold Press Sens Low error ................19003
Failure code [CA2375] EGR Orifice Temp Sens High Error ................19005
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................19007
Failure code [CA2381] KVGT Pos Sens High Error ................19009
Failure code [CA2382] KVGT Pos Sens Low Error ................19011
Failure code [CA2383] KVGT Solenoid Open Error ................19014
Failure code [CA2386] KVGT Solenoid Short Error ................19016
Failure code [CA2387] KVGT Servo Error ................19018
Failure code [CA2554] Exh Manifold Press Sens In Range Error ................19019
Failure code [CA2555] Grid Htr Relay Volt Low Error ................19020
Failure code [CA2556] Grid Htr Relay Volt High Error ................19022
Failure code [CA2637] KDOC Face Plugging ................19024
Failure code [CA2639] Manual Stationary Regeneration Request ................19026
Failure code [CA2961] EGR Orifice Temp High Error 1 ................19029
Failure code [CA2973] Chg Air Press Sensor In Range Error ................19030
Failure code [CA3133] KDPF Outlet Press Sens High Error ................19031
Failure code [CA3134] KDPF Outlet Press Sens Low Error ................19033
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ................19035
Failure code [CA3251] KDOC Inlet Temp High Error ................19039
Failure code [CA3253] KDOC Temp Error - Non Regeneration ................19042
Failure code [CA3254] KDOC Outlet Temp High Error 1 ................19046
Failure code [CA3255] KDPF Temp Error - Non Regeneration ................19049
Failure code [CA3256] KDPF Outlet Temp High Error 1 ................19053
Failure code [CA3311] KDOC Outlet Temp High Error 2 ................19056
Failure code [CA3312] KDPF Outlet Temp High Error 2 ................19060
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................19064
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................19067
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................19070
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................19074
Failure code [CA3317] KDOC Outlet Temp Sens High Error ................19077
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ................19080
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................19084
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ................19087
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ................19090
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ................19094
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ................19096
Failure code [CA3741] Rail Press Valve Trip Error ................19098
Failure code [D110L4] Disconnection of Battery Relay Signal ................19099
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................19101
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ................19103
Failure code [D191KA] Disconnection of Neutral Output Relay ................19105
Failure code [D191KB] Ground Fault of Neutral Output Relay ................19107
Failure code [D191KY] Hot Short of Neutral Output Relay ................19109
Failure code [D192KA] Disconnection of ECSS Solenoid ................19111
Failure code [D192KB] Ground Fault of ECSS Solenoid ................19113
Failure code [D192KY] Hot Short of ECSS Solenoid ................19114
Failure code [D19JKZ] Personal Code Relay Abnormality ................19115
Failure code [D1B0KA] Disconnection of HST Safety Relay ................19117
Failure code [D1B0KB] Ground Fault of HST Safety Relay ................19119
Failure code [D1B0KY] Hot Short of HST Safety Relay ................19121
Failure code [D1B0MC] Malfunction of HST Safety Relay ................19123
Failure code [D1E6KA] Disconnection of Parking Brake Relay ................19124
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................19126
Failure code [D1E6KY] Hot Short of Parking Brake Relay ................19128
Failure code [D5ZHKA] Failure of Key SW C Signal ................19130
Failure code [D5ZHKB] Key SW C Signal Short Circuit ................19132
Failure code [D5ZHL6] Disconnection of Key SW C ................19134
Failure code [D811MC] KOMTRAX Error ................19135
Failure code [D862KA] GPS Antenna Open Circuit ................19136
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ................19137
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ................19139
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ................19141
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ................19142
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ................19144
Failure code [DAF0MB] Monitor ROM Abnormality ................19145
Failure code [DAF0MC] Monitor Error ................19146
Failure code [DAF3KK] Controller Power Source Low (MON) ................19147
Failure code [DAF8KB] Camera Power Supply Short Circuit ................19149
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ................19150
Failure code [DAFGMC] GPS Module Error ................19151
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ................19152
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ................19154
Failure code [DAFQKR] CAN2 Discon (Monitor) ................19156
Failure code [DAJ0KK] Controller Power Source Low (HST) ................19157
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ................19160
Failure code [DAJ0MC] HST Con Error ................19161
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ................19162
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ................19164
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ................19167
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay ................19169
Failure code [DAJ5KX] Failure of 5V Power Source 0 ................19171
Failure code [DAJ6KX] Failure of 5V Power Source 1 ................19173
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) ................19175
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ................19176
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ................19178
Failure code [DAJQKR] CAN2 Discon ( HST Con) ................19180
Failure code [DAJRKR] CAN1 Discon ( HST Con) ................19181
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ................19182
Failure code [DAZ9KQ] A/C Model Selection Abnormality ................19183
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ................19184
Failure code [DB2QKR] CAN2 Discon (Engine Con) ................19185
Failure code [DB2RKR] CAN1 Discon (Engine Con) ................19190
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ................19194
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................19196
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................19198
Failure code [DDB6L4] Parking Brake Signal Malfunction ................19200
Failure code [DDD7KA] Failure of Variable Speed Control ................19203
Failure code [DDD7KY] Hot Short of Variable Speed Control ................19205
Failure code [DDK3KA] FNR SW Input Signal Disconnection ................19207
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ................19209
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ................19211
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ................19214
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ................19216
Failure code [DF10KA] Disconnection of Speed Range Input ................19218
Failure code [DF10KB] Ground Fault of Speed Range Input ................19221
Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ................19224
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ................19226
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ................19228
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ................19230
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ................19232
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) ................19234
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ................19236
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) ................19238
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ................19240
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ................19242
Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ................19244
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. ................19246
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ................19248
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ................19250
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ................19252
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ................19254
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ................19256
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit ................19258
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ................19260
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ................19262
Failure code [DHT8ZG] Steering Oil Pressure Low ................19264
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ................19265
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................19267
Failure code [DK55KA] Failure of FNR Lever Potentio ................19269
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ................19272
Failure code [DK55L5] Failure of FNR Lever Potentio ................19274
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................19275
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ................19278
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ................19281
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................19284
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ................19287
Failure code [DK70KA] Failure of inching sensor Circuit ................19290
Failure code [DK70KY] Hot Short of inching sensor Circuit ................19293
Failure code [DKA0KA] Failure of Boom Angle Sensor ................19295
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ................19297
Failure code [DKA0L0] Boom Angle Sensor Dislocation ................19299
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................19301
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ................19303
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ................19304
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ................19306
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ................19308
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ................19311
Failure code [DPQ1KR] LIN Discon (Switch Panel) ................19313
Failure code [DPQ2KR] LIN Discon (LED Unit) ................19316
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ................19319
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ................19322
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ................19324
Failure code [DV00KB] Ground Fault of Buzzer Output ................19326
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ................19328
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ................19330
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ................19332
Failure code [DW4BKA] Disconnection of Parking Brake Valve ................19334
Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................19336
Failure code [DW4BKY] Hot Short of Parking Brake Valve ................19338
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ................19339
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................19341
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ................19343
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ................19344
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ................19346
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................19348
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ................19349
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ................19351
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................19353
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ................19355
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ................19357
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ................19359
Failure code [DX19KA] Disconnection of Motor 1 Solenoid ................19360
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ................19362
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ................19364
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ................19366
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ................19368
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ................19370
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ................19372
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ................19374
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. ................19376
Failure code [DXH7KA] Disconnection of Reverse Solenoid ................19378
Failure code [DXH7KB] Ground Fault of Reverse Solenoid ................19380
Failure code [DXH7KY] Hot Short of Reverse Solenoid ................19382
Failure code [DXH8KA] Disconnection of Forward Solenoid ................19384
Failure code [DXH8KB] Ground Fault of Forward Solenoid ................19386
Failure code [DXH8KY] Hot Short of Forward Solenoid ................19388
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ................19390
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ................19392
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................19394
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ................19395
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ................19397
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................19399
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ................19400
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ................19403
Failure code [J141N1] Steering Pump Over Run ................19405
Failure code [LA00L3] Failure of Fan Reverse ................19406
Failure code [M100N1] HST Pump Over Run ................19407
Failure code [M400N1] HST Motor 1 Over Run ................19408
Troubleshooting of electrical system (E-mode) ................19409
E-1 Engine does not start ................19409
E-2 Manual preheating system does not work ................19416
E-3 Automatic preheating system does not work ................19419
E-4 While preheating is working, preheating monitor does not light up ................19421
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................19423
E-6 LCD unit on machine monitor displays nothing ................19426
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................19428
E-8 LCD on machine monitor does not display properly ................19430
E-9 Meter unit display on machine monitor is abnormal ................19432
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................19435
E-11 Caution LED on machine monitor is abnormal ................19438
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ................19440
E-13 Two switches operation of switch panel on machine monitor does not function ................19442
E-14 Switch panel buzzer of machine monitor is abnormal ................19445
E-15 Rearview monitor does not light up or backlight flickers ................19447
E-16 Rearview monitor images are not displayed clearly ................19450
E-17 Rearview monitor brightness cannot be adjusted ................19453
E-18 Night lighting lamp of rearview monitor is abnormal ................19456
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................19458
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ................19459
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ................19463
E-22 Air cleaner clogging indicator lamp does not light ................19465
E-23 Radiator coolant level caution lamp does not light ................19467
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light ................19469
E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel speed or traction force does not lower), or while not depressed, inching function operates ................19470
E-26 Fuel level gauge does not indicate correct level ................19472
E-27 Seat belt caution lamp indication is abnormal ................19474
E-28 Horn does not sound ................19475
E-29 Horn does not stop sounding ................19478
E-30 Alarm buzzer does not sound ................19480
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................19482
E-32 When emergency HST pump drive switch is operated, emergency HST pump does not work or when emergency HST pump drive switch is not operated, emergency HST pump works ................19483
E-33 Setting does not change while operating traction control switch ................19485
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake is released and FR drive is operated ................19487
E-35 Remote positioner does not work or cannot be released ................19490
E-36 Bucket positioner does not work or cannot be released ................19492
E-37 Direction selector (FNR) switch mode is not selected or not released ................19495
E-38 PZ auto tilt-in does not work ................19497
E-39 Tracktion level does not display MAX when max traction switch is turned ON ................19500
E-40 ECSS function cannot be selected or cannot be released ................19502
E-41 None of headlamp, clearance lamp, and tail lamp lights ................19504
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ................19506
E-43 Both High and Low beams of headlamp do not light up or go out ................19510
E-44 Low beam of headlamp does not light up or go out ................19514
E-45 High beam of headlamp does not light up or go out ................19516
E-46 Front working lamp does not light up or go out ................19518
E-47 Rear working lamp does not light up or go out ................19522
E-48 All of turn signal lamps and hazard lamps do not flash or go out ................19526
E-49 Turn signal lamps do not flash or go out ................19529
E-50 Hazard lamp does not flash or go out ................19532
E-51 Brake lamp does not light or stays lighted ................19535
E-52 Backup lamp does not light up or does not go out ................19538
E-53 Backup buzzer does not sound or continues to sound ................19541
E-54 Front wiper does not operate ................19543
E-55 Rear wiper does not operate ................19546
E-56 Window washer does not operate ................19548
E-57 KOMTRAX system does not operate normally ................19551
Troubleshooting of hydraulic and mechanical system (H-mode) ................19553
Information described in troubleshooting table (H-mode) ................19553
System chart of hydraulic and mechanical systems ................19554
Failure mode and cause table ................19556
H-1 Machine does not travel forward or backward ................19562
H-2 Machine does not travel forward (Machine travels backward normally) ................19565
H-3 Machine does not travel backward (Machine travels forward normally) ................19566
H-4 Machine does not travel forward or backward fast ................19567
H-5 Machine does not travel forward fast (Machine travel backward fast) ................19571
H-6 Machine does not travel backward fast (Machine travel forward fast) ................19572
H-7 Machine lacks power neither when traveling forward nor backward ................19573
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ................19576
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ................19577
H-10 Engine stalls during travel or engine speed drops significantly ................19578
H-11 Steering wheel is too heavy to turn ................19579
H-12 Steering wheel is heavy to turn ................19581
H-13 Machine sways or large shocks are made while machine turns ................19582
H-14 Machine unintentionally turns when machine travels ................19583
H-15 Wheel brakes do not work or are weak ................19584
H-16 Wheel brakes are not released or drag ................19585
H-17 Parking brake does not work or it is weak ................19586
H-18 Parking brake is not released or drags. ................19587
H-19 Boom does not rise ................19588
H-20 Boom moves slow or boom lacks lifting force ................19590
H-21 Rising boom slows down at certain height ................19592
H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................19593
H-23 Hydraulic drift of boom is large ................19594
H-24 Boom moves up and down during operation ................19595
H-25 Bucket does not tilt back ................19596
H-26 Bucket moves slow or lacks tilt force ................19598
H-27 Bucket decelerates during tilt-back operation ................19600
H-28 Bucket cylinder does not hold bucket on ground ................19601
H-29 Hydraulic drift of bucket is large ................19602
H-30 Bucket tilts back and forth during carrying load ................19603
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ................19604
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ................19605
H-33 Large shocks are made when work equipment starts to move and stops ................19606
H-34 When certain work equipment is relieved hydraulically, other work equipment moves ................19607
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ................19608
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ................19609
H-37 Unusual noise is heard from around fan ................19611
Troubleshooting of engine (S-mode) ................19612
Information described in troubleshooting table (S mode) ................19612
S-1 Engine does not crank when starting switch is turned to START position ................19613
S-2 Engine cranks but no exhaust smoke comes out ................19614
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ................19615
S-4 Engine startability is poor ................19616
S-5 Engine does not pick up smoothly ................19618
S-6 Engine stops during operation ................19620
S-7 Engine runs rough or is unstable ................19622
S-8 Engine lacks power ................19623
S-9 KDPF gets clogged in a short time ................19625
S-10 Engine oil consumption is excessive ................19627
S-11 Engine oil becomes contaminated early ................19628
S-12 Fuel consumption is excessive ................19629
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ................19630
S-14 Oil pressure drops ................19631
S-15 Fuel mixes into engine oil ................19632
S-16 Water mixes into engine oil (milky) ................19633
S-17 Coolant temperature rises too high (overheating) ................19634
S-18 Unusual noise is heard ................19635
S-19 Vibration is excessive ................19636
S-20 Air cannot be bled from fuel circuit ................19638
S-21 Active regeneration is executed frequently ................19639
S-22 Active regeneration takes time ................19640
S-23 White smoke is exhausted during active regeneration ................19641
50 Disassembly and assembly ................19643
Table of contents ................19644
Related information on disassembly and assembly ................19646
How to read this manual ................19646
Coating materials list ................19648
Special tools list ................19652
Sketches of special tools ................19657
Engine and cooling system ................19670
Removal and installation of supply pump assembly ................19670
Removal and installation of injector assembly ................19673
Removal and installation of cylinder head assembly ................19682
Removal and installation of engine hood assembly ................19695
Removal and installation of radiator core assembly ................19697
Removal and installation of aftercooler ................19699
Removal and installation of hydraulic oil cooler ................19700
Removal and installation of engine assembly ................19701
Removal and installation of engine front oil seal ................19709
Removal and installation of engine rear oil seal ................19712
Removal and installation of cooling fan and fan motor assembly ................19715
Removal and installation of KDPF assembly ................19717
Disassembly and assembly of KDPF assembly ................19720
Removal and installation of KCCV assembly ................19729
Removal and installation of air cleaner assembly ................19730
Removal and installation of KVGT assembly ................19731
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ................19734
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ................19736
Removal and installation of alternator belt ................19738
Removal and installation of fuel tank assembly ................19739
Power train ................19742
Removal and installation of transfer assembly ................19742
Disassembly and assembly of transfer assembly ................19746
Removal and installation of front axle assembly ................19777
Removal and installation of rear axle assembly ................19779
Disassembly and assembly of axle housing assembly ................19782
Disassembly and assembly of differential assembly ................19794
Undercarriage and frame ................19816
Removal and installation of center hinge pin ................19816
Removal and installation of counterweight assembly ................19825
Hydraulic system ................19829
Removal and installation of hydraulic tank assembly ................19829
Removal and installation of control valve assembly ................19833
Disassembly and assembly of control valve assembly ................19837
Removal and installation of hydraulic pump assembly ................19840
Removal and installation of HST motor1 assembly ................19845
Removal and installation of HST motor2 assembly ................19847
Disassembly and assembly of hydraulic cylinder assembly ................19849
Work equipment ................19856
Removal and installation of work equipment assembly ................19856
Cab and its attachments ................19862
Removal and installation of operator's cab and floor frame assembly ................19862
Removal and installation of operator's cab glass (adhered glass) ................19867
Removal and installation of operator's seat assembly ................19875
Removal and installation of seat belt ................19877
Removal and installation of air conditioner unit assembly ................19878
Removal and installation of air conditioner compressor ................19883
Removal and installation of air conditioner condenser ................19885
Electrical system ................19887
Removal and installation of machine monitor assembly ................19887
Removal and installation of engine controller assembly ................19889
Removal and installation of HST controller assembly ................19891
Removal and installation of air conditioner controller assembly ................19893
Removal and installation of monitor controller assembly ................19894
Removal and installation of mass air flow and temperature sensor ................19896
Removal and installation of KOMTRAX terminal assembly ................19897
60 Maintenance standard ................19899
Table of contents ................19900
Engine and cooling system ................19901
Engine related parts ................19901
Cooling fan motor ................19902
Power train ................19904
Damper ................19904
Transfer ................19905
Drive shaft ................19912
Axle ................19913
Differential ................19915
Limited slip differential ................19919
Final drive ................19921
Steering system ................19923
Steering column ................19923
Priority valve ................19924
Emergency steering valve ................19925
Steering cylinder ................19926
Brake system ................19928
Brake accumulator charge valve ................19928
Slack adjuster ................19929
Brake ................19930
Parking brake ................19932
Parking brake solenoid valve ................19933
Undercarriage and frame ................19934
Axle mount ................19934
Center hinge pin ................19936
Hydraulic system ................19939
Hydraulic tank ................19939
Double type gear pump ................19940
Steering and work equipment pump ................19941
Control valve ................19945
Self-pressure reducing valve ................19958
Work equipment PPC valve ................19960
Work equipment lock solenoid valve ................19962
Work equipment ................19963
Work equipment linkage ................19963
Bucket ................19967
Work equipment cylinder ................19969
Cab and its attachments ................19970
Cab mount ................19970
Electrical system ................19971
Bucket positioner ................19971
Fork positioner ................19972
Remote boom positioner ................19973
80 Appendix ................19975
Table of contents ................19976
Air conditioner components ................19977
Precautions for refrigerant ................19977
Air conditioner component ................19978
Configuration and function of refrigeration cycle ................19980
Outline of refrigeration cycle ................19981
Air conditioner unit ................19983
Dual pressure switch ................19988
Air conditioner controller ................19989
Compressor ................19990
Condenser ................19991
Receiver drier ................19992
Sunlight sensor ................19994
Outer temperature sensor (outside air temperature sensor) ................19995
Procedure for testing and troubleshooting ................19996
Circuit diagram and arrangement of connector pins ................19998
System diagram ................20001
Parts and connectors layout ................20004
Testing with self-diagnosis function ................20009
How to open the electrical system abnormality record screen in service mode of the machine monitor ................20010
Testing temperature control system ................20012
Testing vent (mode) changeover ................20014
Testing FRESH/RECIRC air changeover ................20016
Testing evaporator temperature sensor ................20018
Testing relays ................20020
Troubleshooting chart 1 ................20022
Troubleshooting chart 2 ................20023
Information in troubleshooting table ................20025
Failure code list related to air conditioner ................20026
Failure code [879AKA] A/C Inner Sensor Open Circuit ................20027
Failure code [879AKB] A/C Inner Sensor Short Circuit ................20029
Failure code [879BKA] A/C Outer Sensor Open Circuit ................20031
Failure code [879BKB] A/C Outer Sensor Short Circuit ................20033
Failure code [879CKA] Ventilating Sensor Open Circuit ................20035
Failure code [879CKB] Ventilating Sensor Short Circuit ................20037
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................20039
Failure code [879EMC] Ventilation Damper Abnormality ................20041
Failure code [879FMC] Air Mix Damper Abnormality ................20044
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ................20047
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ................20050
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................20053
A-4 Troubleshooting for FRESH/RECIRC air changeover ................20056
Troubleshooting with gauge pressure ................20058
Connection of service tool ................20061
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ................20063
Handling of compressor oil ................20065
90 Diagrams and drawings ................20067
Table of contents ................20068
Hydraulic circuit diagram ................20069
Symbols in hydraulic circuit diagram ................20069
Hydraulic circuit diagram ................20073
Electric circuit diagram ................20074
Symbols in electric circuit diagram ................20074
Electrical circuit diagram of machine body ................20078
Electrical circuit diagram of floor ................20083
INDEX................20091
SEN06597-05 - Wheel Loader WA320-8 Shop Manual................20103
COVER................20103
00 INDEX AND FOREWORD................20105
INDEX................20106
ABBREVIATION LIST................20125
FOREWORD, SAFETY, BASIC INFORMATION................20131
HOW TO READ THE SHOP MANUAL................20131
SAFETY NOTICE FOR OPERATION................20133
PRECAUTIONS TO PREVENT FIRE................20141
ACTIONS IF FIRE OCCURS................20143
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS................20144
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................20145
PRECAUTIONS FOR DEF................20146
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING................20146
PRECAUTIONS FOR ADDING................20146
PRECAUTIONS FOR STORING................20146
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE................20146
THE OTHER PRECAUTIONS................20146
STORE AdBlue/DEF................20147
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT................20148
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................20151
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................20157
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT................20159
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................20160
PRACTICAL USE OF KOMTRAX................20161
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................20162
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER................20162
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER................20163
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER................20164
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS................20166
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR................20170
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR................20171
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL................20173
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH................20174
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE................20176
HOW TO READ ELECTRICAL WIRE CODE................20177
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................20181
STANDARD TIGHTENING TORQUE TABLE................20184
CONVERSION TABLE................20191
01 SPECIFICATIONS................20197
CONTENTS................20198
ABBREVIATION LIST................20199
SPECIFICATIONS................20205
SPECIFICATION DRAWING................20205
SPECIFICATION DRAWING: WA320-8................20205
SPECIFICATIONS................20207
SPECIFICATIONS: WA320-8................20207
WEIGHT TABLE................20212
WEIGHT TABLE: WA320-8................20212
TABLE OF FUEL, COOLANT, AND LUBRICANTS................20214
10 STRUCTURE AND FUNCTION................20217
CONTENTS................20218
ABBREVIATION LIST................20222
UREA SCR SYSTEM................20228
LAYOUT DRAWING OF UREA SCR SYSTEM................20228
UREA SCR SYSTEM DIAGRAM................20230
FUNCTION OF UREA SCR SYSTEM................20231
FUNCTION OF AdBlue/DEF SYSTEM................20231
INDUCEMENT STRATEGY................20234
COMPONENT PARTS OF UREA SCR SYSTEM................20249
AdBlue/DEF MIXING TUBE................20249
SCR ASSEMBLY................20250
AdBlue/DEF TANK................20252
AdBlue/DEF PUMP................20254
AdBlue/DEF INJECTOR................20255
AdBlue/DEF HOSE................20256
AdBlue/DEF TANK HEATING VALVE................20257
BOOT-UP SYSTEM................20258
LAYOUT DRAWING OF BOOT-UP SYSTEM................20258
SYSTEM OPERATING LAMP SYSTEM................20260
SYSTEM OPERATING LAMP SYSTEM DIAGRAM................20260
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM................20260
BATTERY DISCONNECT SWITCH................20261
FUNCTION OF BATTERY DISCONNECT SWITCH................20261
PREHEATING SYSTEM................20262
PREHEATING SYSTEM DIAGRAM................20262
FUNCTION OF AUTOMATIC PREHEATING SYSTEM................20262
OPERATION OF AUTOMATIC PREHEATING SYSTEM................20262
FUNCTION OF MANUAL PREHEATING SYSTEM................20263
OPERATION OF MANUAL PREHEATING SYSTEM................20263
ENGINE SYSTEM................20264
LAYOUT DRAWING OF ENGINE SYSTEM................20264
FUNCTION OF ENGINE SYSTEM................20265
ENGINE CONTROL SYSTEM................20266
ENGINE CONTROL SYSTEM DIAGRAM................20266
FUNCTION OF ENGINE CONTROL SYSTEM................20268
OPERATION OF ENGINE CONTROL SYSTEM................20271
AUTOMATIC IDLE STOP SYSTEM................20273
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM................20273
COMPONENT PARTS OF ENGINE SYSTEM................20274
DAMPER................20274
VGT................20275
EGR SYSTEM................20279
EGR VALVE................20281
EGR COOLER................20283
KCCV SYSTEM................20285
KCCV VENTILATOR................20287
KDPF................20289
COOLING SYSTEM................20293
LAYOUT DRAWING OF COOLING SYSTEM................20293
SPECIFICATIONS OF COOLING SYSTEM................20294
COOLING FAN CONTROL SYSTEM................20295
COOLING FAN CONTROL SYSTEM DIAGRAM................20295
FUNCTION OF COOLING FAN CONTROL SYSTEM................20295
COMPONENT PARTS OF COOLING SYSTEM................20300
COOLING FAN MOTOR................20300
CONTROL SYSTEM................20313
LAYOUT DRAWING OF CONTROL SYSTEM................20313
MACHINE MONITOR SYSTEM................20315
MACHINE MONITOR SYSTEM DIAGRAM................20315
FUNCTION OF MACHINE MONITOR SYSTEM................20315
REARVIEW MONITOR SYSTEM................20317
REARVIEW MONITOR SYSTEM DIAGRAM................20317
FUNCTION OF REARVIEW MONITOR SYSTEM................20317
KOMTRAX SYSTEM................20318
KOMTRAX SYSTEM DIAGRAM................20318
FUNCTION OF KOMTRAX SYSTEM................20318
COMPONENT PARTS OF CONTROL SYSTEM................20319
MACHINE MONITOR................20319
SWITCH PANEL................20337
REARVIEW MONITOR................20338
REARVIEW CAMERA................20340
KOMTRAX TERMINAL................20341
MONITOR CONTROLLER................20343
HST CONTROLLER................20348
CAN TERMINATING RESISTOR................20352
ENGINE CONTROLLER................20353
ACCELERATOR PEDAL................20360
HYDRAULIC SYSTEM................20362
LAYOUT DRAWING OF HYDRAULIC SYSTEM................20362
CLSS................20363
STRUCTURE OF CLSS................20363
FUNCTION OF CLSS................20364
COMPONENT PARTS OF HYDRAULIC SYSTEM................20366
HYDRAULIC TANK................20366
HYDRAULIC OIL FILTER................20369
STEERING AND WORK EQUIPMENT PUMP................20370
BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP................20383
CONTROL VALVE................20384
POWER TRAIN SYSTEM................20414
LAYOUT DRAWING OF POWER TRAIN SYSTEM................20414
OPERATION OF POWER TRAIN SYSTEM................20416
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION................20417
HST CONTROL SYSTEM................20419
HST CONTROL SYSTEM DIAGRAM................20419
ENGINE OVERRUN PREVENTION FUNCTION................20420
NEUTRALIZER FUNCTION................20420
HST CHARGE SYSTEM................20421
SYSTEM DIAGRAM OF HST CHARGE SYSTEM................20421
FUNCTION OF HST CHARGE SYSTEM................20421
HST PUMP CONTROL SYSTEM................20422
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM................20422
DIRECTIONAL SELECTION FUNCTION................20422
ABSORBING TORQUE CONTROL FUNCTION................20422
INCHING CONTROL FUNCTION................20423
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED)................20423
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION................20424
GEAR SHIFT FUNCTION................20424
GEAR SHIFT DISPLAY FUNCTION................20426
TRAVEL SPEED ADJUSTMENT FUNCTION................20426
TRANSFER CLUTCH CONTROL FUNCTION................20427
HST SYSTEM PROTECTION FUNCTION................20428
TRANSFER PROTECTION FUNCTION................20428
DIRECTION PROTECTION FUNCTION................20428
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1................20428
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2................20429
TRAVEL SPEED LIMITATION FUNCTION................20430
MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL................20431
FUNCTION OF MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL................20431
KOMATSU TRACTION CONTROL SYSTEM (KTCS)................20434
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM................20434
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)................20434
COMPONENT PARTS OF POWER TRAIN SYSTEM................20439
DRIVE SHAFT................20439
HST PUMP................20441
HST CHARGE PUMP................20453
HST MOTOR................20455
TRANSFER................20461
AXLE................20469
TORQUE PROPORTIONING DIFFERENTIAL................20471
LIMITED SLIP DIFFERENTIAL................20476
FINAL DRIVE................20480
COMBINATION SWITCH................20482
WORK EQUIPMENT SYSTEM................20486
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM................20486
WORK EQUIPMENT CONTROL SYSTEM................20488
WORK EQUIPMENT LEVER OPERATION FUNCTION................20488
PZ AUTO TILT-IN COMPENSATION CONTROL FUNCTION................20488
WORK EQUIPMENT LOCK SYSTEM................20489
WORK EQUIPMENT LOCK SYSTEM DIAGRAM................20489
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM................20489
BUCKET POSITIONER SYSTEM................20491
BUCKET POSITIONER SYSTEM DIAGRAM................20491
FUNCTION OF BUCKET POSITIONER SYSTEM................20491
OPERATION OF BUCKET POSITIONER SYSTEM................20493
FORK POSITIONER SYSTEM................20495
FORK POSITIONER SYSTEM DIAGRAM................20495
FUNCTION OF FORK POSITIONER SYSTEM................20495
OPERATION OF FORK POSITIONER SYSTEM................20496
REMOTE POSITIONER SYSTEM................20499
REMOTE BOOM POSITIONER SYSTEM DIAGRAM................20499
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM................20499
ECSS................20502
ECSS DIAGRAM................20502
FUNCTION OF ECSS................20502
OPERATION OF ECSS................20502
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM................20504
SELF-PRESSURE REDUCING VALVE................20504
WORK EQUIPMENT LOCK SOLENOID VALVE................20509
PILOT CIRCUIT ACCUMULATOR................20510
ECSS CIRCUIT ACCUMULATOR................20511
MULTIFUNCTION MONO-LEVER................20512
MULTIFUNCTION MONO-LEVER PPC VALVE................20514
STEERING SYSTEM................20519
LAYOUT DRAWING OF STEERING SYSTEM................20519
STEERING COLUMN................20520
STRUCTURE OF STEERING COLUMN................20520
COMPONENT PARTS OF STEERING SYSTEM................20521
PRIORITY VALVE................20521
ORBITROL VALVE................20524
CUSHION VALVE................20529
SECONDARY STEERING VALVE................20531
BRAKE SYSTEM................20534
LAYOUT DRAWING OF BRAKE SYSTEM................20534
PARKING BRAKE CONTROL SYSTEM................20536
PARKING BRAKE CONTROL SYSTEM DIAGRAM................20536
OPERATION OF PARKING BRAKE CONTROL SYSTEM................20536
COMPONENT PARTS OF BRAKE SYSTEM................20540
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE................20540
PARKING BRAKE SOLENOID VALVE................20544
BRAKE CIRCUIT ACCUMULATOR................20546
BRAKE VALVE................20548
SLACK ADJUSTER................20551
BRAKE................20553
PARKING BRAKE................20556
AUTO-GREASING SYSTEM................20558
LAYOUT DRAWING OF AUTO-GREASING SYSTEM................20558
SPECIFICATIONS OF AUTO-GREASING SYSTEM................20559
FUNCTION OF AUTO-GREASING SYSTEM................20561
COMPONENT PARTS OF AUTO-GREASING SYSTEM................20562
AUTO-GREASING PUMP................20562
UNDERCARRIAGE AND FRAME................20563
FRAME, AXLE MOUNT AND CENTER HINGE PIN................20563
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN................20563
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN................20564
TIRE................20566
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE................20566
STRUCTURE OF RADIAL TIRE................20566
FUNCTION OF RADIAL TIRE................20566
STRUCTURE OF BIAS TIRE................20567
FUNCTION OF BIAS TIRE................20567
WORK EQUIPMENT................20568
STRUCTURE OF WORK EQUIPMENT................20568
STRUCTURE OF BUCKET................20569
CAB AND ITS ATTACHMENTS................20570
ROPS CAB................20570
STRUCTURE OF ROPS CAB................20570
FUNCTION OF ROPS CAB................20570
CAB MOUNT................20571
STRUCTURE OF CAB MOUNT................20571
FUNCTION OF CAB MOUNT................20571
20 STANDARD VALUE TABLE................20573
CONTENTS................20574
ABBREVIATION LIST................20575
STANDARD VALUE TABLE FOR ENGINE................20581
STANDARD VALUE TABLE FOR ENGINE: WA320-8................20581
STANDARD VALUE TABLE FOR MACHINE................20585
STANDARD VALUE TABLE FOR MACHINE: WA320-8................20585
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE................20599
30 TESTING AND ADJUSTING................20603
CONTENTS................20604
ABBREVIATION LIST................20608
RELATED INFORMATION ON TESTING AND ADJUSTING................20614
TOOLS FOR TESTING AND ADJUSTING................20614
SKETCH OF TOOLS FOR TESTING AND ADJUSTING................20623
ENGINE AND COOLING SYSTEM................20624
TEST ENGINE SPEED................20624
METHOD FOR TESTING ENGINE SPEED................20624
TEST BOOST PRESSURE................20627
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR................20627
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL................20628
TESTING EXHAUST GAS TEMPERATURE................20630
METHOD FOR TESTING EXHAUST GAS TEMPERATURE................20630
TEST EXHAUST GAS COLOR................20632
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................20632
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER................20634
TEST AND ADJUST VALVE CLEARANCE................20636
METHOD FOR TESTING VALVE CLEARANCE................20636
METHOD FOR ADJUSTING VALVE CLEARANCE................20637
TEST COMPRESSION PRESSURE................20638
METHOD FOR TESTING COMPRESSION PRESSURE................20638
TEST BLOWBY PRESSURE................20643
METHOD FOR TESTING BLOWBY PRESSURE................20643
TEST ENGINE OIL PRESSURE................20646
METHOD FOR TESTING ENGINE OIL PRESSURE................20646
TEST EGR VALVE AND VGT OIL PRESSURE................20648
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE................20648
TEST FUEL PRESSURE................20650
METHOD FOR TESTING FUEL PRESSURE................20651
TEST FUEL DISCHARGE, RETURN AND LEAKAGE................20656
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE................20657
BLEED AIR FROM FUEL SYSTEM................20663
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM................20663
TEST FUEL CIRCUIT FOR LEAKAGE................20665
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................20665
HANDLE CYLINDER CUT-OUT MODE OPERATION................20667
HANDLE NO-INJECTION CRANKING OPERATION................20668
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE................20669
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE................20669
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS................20670
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS................20670
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS................20671
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS................20671
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION................20672
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT................20672
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT................20672
TEST ALTERNATOR BELT................20674
METHOD FOR TESTING ALTERNATOR BELT................20674
TEST AUTOMATIC TENSIONER................20676
METHOD FOR TESTING AUTOMATIC TENSIONER................20676
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................20679
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................20679
TEST SCR RELATED FUNCTIONS................20680
TEST AdBlue/DEF PUMP RAISED PRESSURE................20684
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR................20687
TEST AdBlue/DEF LINE HEATER RELAY 1................20693
TEST AdBlue/DEF LINE HEATER RELAY 2................20697
TEST AdBlue/DEF PUMP HEATER RELAY................20701
TEST AdBlue/DEF TANK HEATER VALVE................20705
TEST SCR NOx REMOVAL EFFICIENCY................20709
CLEAN AdBlue/DEF TANK................20713
METHOD FOR CLEANING AdBlue/DEF TANK................20713
POWER TRAIN................20717
TEST AND ADJUST HST OIL PRESSURE................20717
METHOD FOR TESTING HST OIL PRESSURE................20717
METHOD FOR ADJUSTING HST OIL PRESSURE................20719
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH................20721
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH................20721
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE................20723
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE................20723
STEERING SYSTEM................20724
TEST STEERING WHEEL................20724
METHOD FOR TESTING STEERING WHEEL................20724
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE................20726
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE ON MACHINE MONITOR................20726
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE BY TESTING TOOL................20727
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE................20727
BLEED AIR FROM STEERING CYLINDER CIRCUIT................20729
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT................20729
BRAKE SYSTEM................20730
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT................20730
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT................20730
TEST WHEEL BRAKE OIL PRESSURE................20731
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE................20731
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE................20733
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE................20733
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE................20734
TEST BRAKING PERFORMANCE................20735
METHOD FOR TESTING BRAKING PERFORMANCE................20735
TEST BRAKE PEDAL................20736
METHOD FOR TESTING BRAKE PEDAL................20736
BLEED AIR FROM BRAKE CIRCUIT................20737
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT................20737
TEST LOWERING OF WHEEL BRAKE PRESSURE................20738
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE................20739
TEST WEAR OF WHEEL BRAKE DISC................20741
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC................20741
TEST PARKING BRAKE OIL PRESSURE................20743
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE................20743
TEST PARKING BRAKE PERFORMANCE................20745
METHOD FOR TESTING PARKING BRAKE PERFORMANCE................20745
RELEASE PARKING BRAKE MANUALLY................20746
METHOD FOR RELEASING PARKING BRAKE MANUALLY................20746
TEST WEAR AMOUNT OF PARKING BRAKE DISC................20747
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC................20747
HYDRAULIC SYSTEM................20748
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................20748
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................20748
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE................20750
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE................20750
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE................20754
TEST AND ADJUST WORK EQUIPMENT PPC OIL PRESSURE................20756
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE................20756
METHOD FOR ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE................20758
BLEED AIR FROM WORK EQUIPMENT CIRCUIT................20760
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................20760
TEST COOLING FAN SPEED................20762
METHOD FOR TESTING COOLING FAN SPEED................20762
TEST COOLING FAN CIRCUIT OIL PRESSURE................20763
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE................20763
BLEED AIR FROM COOLING FAN CIRCUIT................20766
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT................20766
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS................20768
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE................20768
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS................20770
WORK EQUIPMENT................20774
TEST AND ADJUST BUCKET POSITIONER................20774
METHOD FOR TESTING BUCKET POSITIONER................20774
METHOD FOR ADJUSTING BUCKET POSITIONER................20774
TEST AND ADJUST BOOM POTENTIOMETER LEVER................20776
METHOD FOR TESTING BOOM POTENTIOMETER LEVER................20776
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER................20776
CAB AND ITS ATTACHMENTS................20777
TEST DIRECTIONAL LEVER................20777
METHOD FOR TESTING DIRECTIONAL LEVER................20777
TEST MULTIFUNCTION MONO-LEVER................20778
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER................20778
TEST ACCELERATOR PEDAL................20780
METHOD FOR TESTING ACCELERATOR PEDAL................20780
ELECTRICAL SYSTEM................20782
SET AND ADJUST EACH EQUIPMENT................20782
SET AND OPERATE MACHINE MONITOR................20786
OPERATOR MODE................20790
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................20790
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN................20790
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)................20791
CHECKING FUNCTION OF SERVICE METER AND ODOMETER................20792
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD................20792
SERVICE MODE................20796
METHOD FOR OPERATING SERVICE MODE................20796
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION................20799
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION................20805
ABNORMALITY RECORD MENU................20818
METHOD FOR CONFIRMING MAINTENANCE RECORD................20823
METHOD FOR OPERATING MAINTENANCE MODE SETTING................20826
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING................20832
DEFAULT MENU................20833
DIAGNOSTIC TESTS MENU................20847
ADJUSTMENT MENU................20857
METHOD FOR PERFORMING NO-INJECTION CRANKING................20891
KOMTRAX SETTINGS MENU................20893
METHOD FOR DISPLAYING SERVICE MESSAGE................20895
METHOD FOR STARTING UP KOMTRAX TERMINAL................20897
ADJUST REARVIEW CAMERA ANGLE................20902
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE................20902
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER................20904
HANDLE BATTERY DISCONNECT SWITCH................20905
TEST DIODES................20906
METHOD FOR TESTING DIODE USING DIGITAL TESTER................20906
METHOD FOR TESTING DIODE USING ANALOG TESTER................20906
AUTO-GREASING DEVICE................20907
BLEED THE AIR OF AUTO-GREASING SYSTEM................20907
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM................20907
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES................20910
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES................20911
Pm CLINIC................20913
Pm CLINIC SERVICE................20913
Pm CLINIC CHECK SHEET: WA320-8................20915
40 TROUBLESHOOTING................20923
CONTENTS................20924
ABBREVIATION LIST................20936
RELATED INFORMATION ON TROUBLESHOOTING................20942
GENERAL TROUBLESHOOTING POINTS................20942
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................20943
SEQUENCE OF EVENTS IN TROUBLESHOOTING................20955
CHECKS BEFORE TROUBLESHOOTING................20957
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING................20959
WALK-AROUND CHECK................20959
TESTING IN ACCORDANCE WITH TESTING PROCEDURE................20961
CHECK FUEL LEVEL AND TYPE................20961
FUEL - CHECK FOR FOREIGN MATERIAL................20961
CHECK AdBule/DEF LEVEL AND TYPE................20962
CHECK FUEL PREFILTER................20962
CHECK MAIN FILTER................20964
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE................20965
CHECK COOLANT LEVEL (RESERVOIR TANK)................20966
CHECK CLOGGING OF AIR CLEANER................20967
OUTER ELEMENT - CLEAN................20968
REPLACE ELEMENT................20969
CHECK HYDRAULIC OIL LEVEL................20971
CHECK HYDRAULIC OIL STRAINER................20971
CHECK HYDRAULIC FILTER................20974
CHECK THE OIL LEVEL IN THE TRANSFER CASE................20974
CHECK OIL LEVEL IN FRONT AXLE CASE................20976
CHECK OIL LEVEL IN REAR AXLE CASE................20977
BLEED AIR FROM FUEL SYSTEM................20977
BLEED AIR FROM HYDRAULIC SYSTEM................20977
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod................20978
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION................20983
PROCEDURE FOR TESTING AND TROUBLESHOOTING................20991
SYMPTOM AND TROUBLESHOOTING NUMBERS................20993
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE................20997
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM................20999
CONNECTORS LIST AND LAYOUT................21002
CONNECTOR CONTACT IDENTIFICATION................21023
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE................21063
FUSE LOCATION TABLE................21069
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)................21072
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR................21076
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT................21078
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])................21084
FAILURE CODES TABLE................21086
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................21105
FAILURE CODE [2F00MA]................21105
FAILURE CODE [2F00MB]................21108
FAILURE CODE [2G42ZG]................21110
FAILURE CODE [2G43ZG]................21112
FAILURE CODE [6091NX]................21114
FAILURE CODE [7RHYKA]................21116
FAILURE CODE [7RHYKB]................21118
FAILURE CODE [7RHYKY]................21120
FAILURE CODE [879AKA]................21122
FAILURE CODE [879AKB]................21124
FAILURE CODE [879BKA]................21126
FAILURE CODE [879BKB]................21128
FAILURE CODE [879CKA]................21130
FAILURE CODE [879CKB]................21132
FAILURE CODE [879DKZ]................21134
FAILURE CODE [879EMC]................21136
FAILURE CODE [879FMC]................21137
FAILURE CODE [989FN1]................21138
FAILURE CODE [989L00]................21139
FAILURE CODE [989M00]................21140
FAILURE CODE [989N00]................21141
FAILURE CODE [A1U0N3]................21142
FAILURE CODE [A1U0N4]................21144
FAILURE CODE [AA10NX]................21146
FAILURE CODE [AB00KE]................21148
FAILURE CODE [AB00KY]................21150
FAILURE CODE [AQ10N3]................21152
FAILURE CODE [AS00N3]................21154
FAILURE CODE [AS00R2]................21156
FAILURE CODE [AS00R3]................21157
FAILURE CODE [AS00R4]................21158
FAILURE CODE [AS00R5]................21159
FAILURE CODE [AS00R6]................21160
FAILURE CODE [AS00ZK]................21161
FAILURE CODE [AS10KM]................21162
FAILURE CODE [AS10NR]................21163
FAILURE CODE [AS10NT]................21164
FAILURE CODE [B@BAZG]................21165
FAILURE CODE [B@BAZK]................21166
FAILURE CODE [B@BCNS]................21168
FAILURE CODE [B@BCZK]................21169
FAILURE CODE [B@C6NS]................21171
FAILURE CODE [B@CRNS]................21173
FAILURE CODE [CA115]................21174
FAILURE CODE [CA122]................21175
FAILURE CODE [CA123]................21177
FAILURE CODE [CA131]................21179
FAILURE CODE [CA132]................21181
FAILURE CODE [CA144]................21184
FAILURE CODE [CA145]................21186
FAILURE CODE [CA153]................21188
FAILURE CODE [CA154]................21191
FAILURE CODE [CA187]................21193
FAILURE CODE [CA221]................21195
FAILURE CODE [CA222]................21197
FAILURE CODE [CA227]................21199
FAILURE CODE [CA234]................21200
FAILURE CODE [CA238]................21201
FAILURE CODE [CA239]................21203
FAILURE CODE [CA249]................21205
FAILURE CODE [CA256]................21207
FAILURE CODE [CA271]................21209
FAILURE CODE [CA272]................21211
FAILURE CODE [CA322]................21213
FAILURE CODE [CA323]................21215
FAILURE CODE [CA324]................21217
FAILURE CODE [CA325]................21219
FAILURE CODE [CA331]................21221
FAILURE CODE [CA332]................21223
FAILURE CODE [CA343]................21225
FAILURE CODE [CA351]................21226
FAILURE CODE [CA352]................21227
FAILURE CODE [CA356]................21230
FAILURE CODE [CA357]................21232
FAILURE CODE [CA386]................21235
FAILURE CODE [CA428]................21236
FAILURE CODE [CA429]................21238
FAILURE CODE [CA431]................21240
FAILURE CODE [CA432]................21243
FAILURE CODE [CA435]................21247
FAILURE CODE [CA441]................21249
FAILURE CODE [CA442]................21251
FAILURE CODE [CA449]................21252
FAILURE CODE [CA451]................21253
FAILURE CODE [CA452]................21255
FAILURE CODE [CA488]................21257
FAILURE CODE [CA515]................21258
FAILURE CODE [CA516]................21260
FAILURE CODE [CA553]................21262
FAILURE CODE [CA555]................21263
FAILURE CODE [CA556]................21264
FAILURE CODE [CA559]................21265
FAILURE CODE [CA595]................21268
FAILURE CODE [CA687]................21269
FAILURE CODE [CA689]................21271
FAILURE CODE [CA691]................21274
FAILURE CODE [CA692]................21276
FAILURE CODE [CA697]................21278
FAILURE CODE [CA698]................21279
FAILURE CODE [CA731]................21280
FAILURE CODE [CA778]................21282
FAILURE CODE [CA1117]................21287
FAILURE CODE [CA1664]................21288
FAILURE CODE [CA1669]................21290
FAILURE CODE [CA1673]................21291
FAILURE CODE [CA1677]................21292
FAILURE CODE [CA1678]................21293
FAILURE CODE [CA1682]................21294
FAILURE CODE [CA1683]................21296
FAILURE CODE [CA1684]................21298
FAILURE CODE [CA1686]................21300
FAILURE CODE [CA1691]................21301
FAILURE CODE [CA1694]................21304
FAILURE CODE [CA1695]................21307
FAILURE CODE [CA1696]................21308
FAILURE CODE [CA1712]................21310
FAILURE CODE [CA1713]................21313
FAILURE CODE [CA1714]................21315
FAILURE CODE [CA1715]................21316
FAILURE CODE [CA1776]................21317
FAILURE CODE [CA1777]................21320
FAILURE CODE [CA1843]................21323
FAILURE CODE [CA1844]................21325
FAILURE CODE [CA1879]................21328
FAILURE CODE [CA1881]................21331
FAILURE CODE [CA1883]................21333
FAILURE CODE [CA1885]................21337
FAILURE CODE [CA1887]................21339
FAILURE CODE [CA1921]................21341
FAILURE CODE [CA1922]................21344
FAILURE CODE [CA1942]................21349
FAILURE CODE [CA1993]................21350
FAILURE CODE [CA2185]................21353
FAILURE CODE [CA2186]................21355
FAILURE CODE [CA2249]................21357
FAILURE CODE [CA2271]................21358
FAILURE CODE [CA2272]................21361
FAILURE CODE [CA2288]................21364
FAILURE CODE [CA2311]................21365
FAILURE CODE [CA2349]................21366
FAILURE CODE [CA2353]................21369
FAILURE CODE [CA2357]................21371
FAILURE CODE [CA2381]................21372
FAILURE CODE [CA2382]................21375
FAILURE CODE [CA2383]................21378
FAILURE CODE [CA2386]................21381
FAILURE CODE [CA2387]................21383
FAILURE CODE [CA2555]................21384
FAILURE CODE [CA2556]................21387
FAILURE CODE [CA2637]................21389
FAILURE CODE [CA2639]................21391
FAILURE CODE [CA2771]................21394
FAILURE CODE [CA2777]................21400
FAILURE CODE [CA2976]................21403
FAILURE CODE [CA3133]................21405
FAILURE CODE [CA3134]................21408
FAILURE CODE [CA3135]................21410
FAILURE CODE [CA3142]................21414
FAILURE CODE [CA3143]................21415
FAILURE CODE [CA3144]................21416
FAILURE CODE [CA3146]................21419
FAILURE CODE [CA3147]................21420
FAILURE CODE [CA3148]................21421
FAILURE CODE [CA3151]................21423
FAILURE CODE [CA3165]................21429
FAILURE CODE [CA3229]................21431
FAILURE CODE [CA3231]................21433
FAILURE CODE [CA3232]................21435
FAILURE CODE [CA3235]................21439
FAILURE CODE [CA3239]................21441
FAILURE CODE [CA3241]................21444
FAILURE CODE [CA3242]................21447
FAILURE CODE [CA3251]................21450
FAILURE CODE [CA3253]................21452
FAILURE CODE [CA3254]................21455
FAILURE CODE [CA3255]................21458
FAILURE CODE [CA3256]................21462
FAILURE CODE [CA3311]................21464
FAILURE CODE [CA3312]................21466
FAILURE CODE [CA3313]................21469
FAILURE CODE [CA3314]................21470
FAILURE CODE [CA3315]................21471
FAILURE CODE [CA3316]................21474
FAILURE CODE [CA3317]................21475
FAILURE CODE [CA3318]................21476
FAILURE CODE [CA3319]................21479
FAILURE CODE [CA3321]................21480
FAILURE CODE [CA3322]................21482
FAILURE CODE [CA3419]................21485
FAILURE CODE [CA3421]................21487
FAILURE CODE [CA3497]................21489
FAILURE CODE [CA3498]................21490
FAILURE CODE [CA3543]................21491
FAILURE CODE [CA3545]................21498
FAILURE CODE [CA3547]................21500
FAILURE CODE [CA3558]................21501
FAILURE CODE [CA3559]................21503
FAILURE CODE [CA3562]................21505
FAILURE CODE [CA3563]................21507
FAILURE CODE [CA3567]................21510
FAILURE CODE [CA3568]................21514
FAILURE CODE [CA3571]................21518
FAILURE CODE [CA3572]................21520
FAILURE CODE [CA3574]................21522
FAILURE CODE [CA3575]................21524
FAILURE CODE [CA3577]................21526
FAILURE CODE [CA3578]................21528
FAILURE CODE [CA3582]................21530
FAILURE CODE [CA3583]................21536
FAILURE CODE [CA3596]................21538
FAILURE CODE [CA3649]................21540
FAILURE CODE [CA3681]................21542
FAILURE CODE [CA3682]................21547
FAILURE CODE [CA3713]................21553
FAILURE CODE [CA3717]................21556
FAILURE CODE [CA3718]................21557
FAILURE CODE [CA3725]................21558
FAILURE CODE [CA3741]................21561
FAILURE CODE [CA3748]................21562
FAILURE CODE [CA3751]................21565
FAILURE CODE [CA3755]................21567
FAILURE CODE [CA3866]................21569
FAILURE CODE [CA3867]................21572
FAILURE CODE [CA3868]................21575
FAILURE CODE [CA3899]................21579
FAILURE CODE [CA3911]................21581
FAILURE CODE [CA3912]................21585
FAILURE CODE [CA3932]................21587
FAILURE CODE [CA3933]................21589
FAILURE CODE [CA3934]................21591
FAILURE CODE [CA3935]................21594
FAILURE CODE [CA3936]................21596
FAILURE CODE [CA4151]................21598
FAILURE CODE [CA4152]................21602
FAILURE CODE [CA4155]................21606
FAILURE CODE [CA4156]................21609
FAILURE CODE [CA4157]................21612
FAILURE CODE [CA4158]................21614
FAILURE CODE [CA4159]................21615
FAILURE CODE [CA4161]................21616
FAILURE CODE [CA4162]................21619
FAILURE CODE [CA4163]................21622
FAILURE CODE [CA4164]................21624
FAILURE CODE [CA4165]................21626
FAILURE CODE [CA4166]................21628
FAILURE CODE [CA4168]................21630
FAILURE CODE [CA4169]................21633
FAILURE CODE [CA4171]................21635
FAILURE CODE [CA4249]................21638
FAILURE CODE [CA4251]................21640
FAILURE CODE [CA4259]................21642
FAILURE CODE [CA4261]................21645
FAILURE CODE [CA4277]................21648
FAILURE CODE [CA4281]................21651
FAILURE CODE [CA4459]................21654
FAILURE CODE [CA4461]................21657
FAILURE CODE [CA4658]................21660
FAILURE CODE [CA4731]................21664
FAILURE CODE [CA4732]................21665
FAILURE CODE [CA4739]................21666
FAILURE CODE [CA4768]................21667
FAILURE CODE [CA4769]................21669
FAILURE CODE [CA4842]................21672
FAILURE CODE [CA4952]................21675
FAILURE CODE [CA5115]................21677
FAILURE CODE [CA5179]................21680
FAILURE CODE [CA5181]................21682
FAILURE CODE [CA5383]................21684
FAILURE CODE [D110L4]................21686
FAILURE CODE [D160KA]................21688
FAILURE CODE [D160KY]................21690
FAILURE CODE [D191KA]................21691
FAILURE CODE [D191KB]................21693
FAILURE CODE [D191KY]................21695
FAILURE CODE [D192KA]................21696
FAILURE CODE [D192KB]................21697
FAILURE CODE [D192KY]................21698
FAILURE CODE [D19JKZ]................21699
FAILURE CODE [D1B0KA]................21701
FAILURE CODE [D1B0KB]................21703
FAILURE CODE [D1B0KY]................21705
FAILURE CODE [D1B0MC]................21707
FAILURE CODE [D1E6KA]................21709
FAILURE CODE [D1E6KB]................21711
FAILURE CODE [D1E6KY]................21713
FAILURE CODE [D5ZHKA]................21715
FAILURE CODE [D5ZHKB]................21717
FAILURE CODE [D5ZHL6]................21719
FAILURE CODE [D811MC]................21720
FAILURE CODE [D862KA]................21721
FAILURE CODE [D8ALKA]................21722
FAILURE CODE [D8ALKB]................21724
FAILURE CODE [D8AQK4]................21726
FAILURE CODE [D8AQKR]................21730
FAILURE CODE [DAF0KT]................21734
FAILURE CODE [DAF0MB]................21735
FAILURE CODE [DAF0MC]................21736
FAILURE CODE [DAF3KK]................21737
FAILURE CODE [DAF8KB]................21739
FAILURE CODE [DAFDKB]................21740
FAILURE CODE [DAFGMC]................21742
FAILURE CODE [DAFLKA]................21743
FAILURE CODE [DAFLKB]................21745
FAILURE CODE [DAFQKR]................21747
FAILURE CODE [DAJ0KK]................21752
FAILURE CODE [DAJ0KT]................21755
FAILURE CODE [DAJ0MC]................21756
FAILURE CODE [DAJ1KA]................21757
FAILURE CODE [DAJ2KK]................21759
FAILURE CODE [DAJ4KB]................21762
FAILURE CODE [DAJ4KZ]................21764
FAILURE CODE [DAJ5KX]................21766
FAILURE CODE [DAJ6KX]................21768
FAILURE CODE [DAJ9KQ]................21770
FAILURE CODE [DAJLKA]................21771
FAILURE CODE [DAJLKB]................21773
FAILURE CODE [DAJQKR]................21775
FAILURE CODE [DAJRKR]................21780
FAILURE CODE [DAJRMA]................21785
FAILURE CODE [DAZ9KQ]................21786
FAILURE CODE [DAZQKR]................21787
FAILURE CODE [DB2QKR]................21791
FAILURE CODE [DB2RKR]................21797
FAILURE CODE [DD1ALD]................21802
FAILURE CODE [DDAAL6]................21804
FAILURE CODE [DDB2L4]................21806
FAILURE CODE [DDB6L4]................21808
FAILURE CODE [DDD7KA]................21810
FAILURE CODE [DDD7KY]................21812
FAILURE CODE [DDK3KA]................21814
FAILURE CODE [DDK3KB]................21817
FAILURE CODE [DDK6KA]................21820
FAILURE CODE [DDK6KB]................21823
FAILURE CODE [DDNRLD]................21826
FAILURE CODE [DF10KA]................21828
FAILURE CODE [DF10KB]................21831
FAILURE CODE [DGH1KX]................21834
FAILURE CODE [DGR2KB]................21836
FAILURE CODE [DGR2KZ]................21838
FAILURE CODE [DHA4KA]................21840
FAILURE CODE [DHHBKA]................21842
FAILURE CODE [DHHBKY]................21844
FAILURE CODE [DHHCKA]................21846
FAILURE CODE [DHHCKY]................21848
FAILURE CODE [DHPCKA]................21850
FAILURE CODE [DHPCKY]................21852
FAILURE CODE [DHPEKA]................21854
FAILURE CODE [DHPEKY]................21856
FAILURE CODE [DHS8KA]................21858
FAILURE CODE [DHS8KY]................21860
FAILURE CODE [DHS9KA]................21862
FAILURE CODE [DHS9KY]................21864
FAILURE CODE [DHSDKA]................21866
FAILURE CODE [DHSDKY]................21868
FAILURE CODE [DHSNKA]................21870
FAILURE CODE [DHSNKY]................21872
FAILURE CODE [DHT8ZG]................21874
FAILURE CODE [DHTCL6]................21875
FAILURE CODE [DJF1KA]................21877
FAILURE CODE [DK55KA]................21878
FAILURE CODE [DK55KY]................21880
FAILURE CODE [DK55L5]................21882
FAILURE CODE [DK5DKA]................21883
FAILURE CODE [DK5DKY]................21886
FAILURE CODE [DK5DL8]................21889
FAILURE CODE [DK5EKA]................21893
FAILURE CODE [DK5EKY]................21896
FAILURE CODE [DK70KA]................21899
FAILURE CODE [DK70KY]................21901
FAILURE CODE [DKA0KA]................21903
FAILURE CODE [DKA0KY]................21906
FAILURE CODE [DKA0L0]................21908
FAILURE CODE [DLM3KA]................21910
FAILURE CODE [DLM3LC]................21911
FAILURE CODE [DLT3KX]................21913
FAILURE CODE [DLT4KX]................21915
FAILURE CODE [DLT4L0]................21917
FAILURE CODE [DLT4LC]................21918
FAILURE CODE [DPQ1KR]................21920
FAILURE CODE [DPQ2KR]................21923
FAILURE CODE [DPQ3KR]................21926
FAILURE CODE [DSJ0KR]................21930
FAILURE CODE [DT22KB]................21935
FAILURE CODE [DV00KB]................21937
FAILURE CODE [DW26KA]................21938
FAILURE CODE [DW26KB]................21940
FAILURE CODE [DW26KY]................21942
FAILURE CODE [DW4BKA]................21944
FAILURE CODE [DW4BKB]................21946
FAILURE CODE [DW4BKY]................21948
FAILURE CODE [DW4RKA]................21949
FAILURE CODE [DW4RKB]................21951
FAILURE CODE [DW4RKY]................21953
FAILURE CODE [DWM1KA]................21955
FAILURE CODE [DWM1KB]................21956
FAILURE CODE [DWM1KY]................21958
FAILURE CODE [DWN6KA]................21959
FAILURE CODE [DWN6KB]................21961
FAILURE CODE [DWN6KY]................21963
FAILURE CODE [DWN8KA]................21964
FAILURE CODE [DWN8KB]................21965
FAILURE CODE [DWN8KY]................21966
FAILURE CODE [DX19KA]................21967
FAILURE CODE [DX19KB]................21969
FAILURE CODE [DX19KY]................21971
FAILURE CODE [DX20KA]................21973
FAILURE CODE [DX20KB]................21975
FAILURE CODE [DX20KY]................21977
FAILURE CODE [DXAWKA]................21978
FAILURE CODE [DXAWKB]................21981
FAILURE CODE [DXAWKY]................21984
FAILURE CODE [DXH7KA]................21987
FAILURE CODE [DXH7KB]................21989
FAILURE CODE [DXH7KY]................21991
FAILURE CODE [DXH8KA]................21993
FAILURE CODE [DXH8KB]................21995
FAILURE CODE [DXH8KY]................21997
FAILURE CODE [DXHJKA]................21999
FAILURE CODE [DXHJKB]................22001
FAILURE CODE [DXHJKY]................22003
FAILURE CODE [DXHKKA]................22004
FAILURE CODE [DXHKKB]................22006
FAILURE CODE [DXHKKY]................22008
FAILURE CODE [H2K0KA]................22009
FAILURE CODE [H2K0KY]................22011
FAILURE CODE [J141N1]................22013
FAILURE CODE [LA00L3]................22014
FAILURE CODE [M100N1]................22015
FAILURE CODE [M400N1]................22016
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)................22017
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)................22017
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK................22025
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK................22028
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP................22031
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING................22033
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING................22036
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)................22038
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY................22040
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL................22042
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL................22045
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL................22049
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY................22051
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION................22054
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL................22057
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY................22060
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS................22061
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY................22064
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED................22068
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL................22072
E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP................22074
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP................22076
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION................22077
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP................22081
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP................22082
E-25 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP................22083
E-26 WHEN THE INCHING PEDAL IS DEPRESSED, INCHING FUNCTION DOES NOT WORK OR WHILE THE PEDAL HAS NOT BEEN DEPRESSED, INCHING FUNCTION OPERATES................22084
E-27 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL................22086
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL................22088
E-29 ALARM BUZZER DOES NOT SOUND................22089
E-30 ALARM BUZZER DOES NOT STOP SOUNDING................22090
E-31 WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS OPERATED, IT DOES NOT WORK OR WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS NOT OPERATED, IT WORKS................22091
E-32 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH................22094
E-33 THE REMOTE POSITIONER DOES NOT WORK OR CANNOT BE RELEASED................22096
E-34 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED................22098
E-35 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED................22101
E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED................22105
E-37 PZ AUTO TILT-IN DOES NOT WORK................22107
E-38 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX. TRACTION SWITCH IS TURNED ON................22110
E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED................22112
E-40 HORN DOES NOT SOUND................22114
E-41 HORN DOES NOT STOP SOUNDING................22117
E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS................22119
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT................22121
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)................22125
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT................22129
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)................22133
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT................22137
E-48 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)................22139
E-49 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT................22141
E-50 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)................22143
E-51 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT................22145
E-52 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT................22150
E-53 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT................22154
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT................22157
E-55 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)................22160
E-56 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT................22163
E-57 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)................22167
E-58 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED................22171
E-59 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED (FOR EUROPEAN UNION)................22175
E-60 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT................22179
E-61 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT (FOR EUROPEAN UNION)................22183
E-62 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND................22187
E-63 FRONT WIPER DOES NOT OPERATE................22189
E-64 REAR WIPER DOES NOT OPERATE................22193
E-65 WINDOW WASHER DOES NOT OPERATE................22196
E-66 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY................22199
E-67 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP................22200
E-68 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP................22201
E-69 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP................22202
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)................22203
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)................22203
FAILURE MODE AND CAUSE TABLE................22204
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE................22218
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)................22221
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)................22222
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW................22223
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)................22227
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)................22228
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS................22229
H-8 MACHINE DOES NOT TURN................22231
H-9 STEERING WHEEL IS HEAVY TO OPERATE................22233
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS................22235
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS................22236
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK................22237
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG................22239
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK................22240
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS................22241
H-16 BOOM DOES NOT RISE................22243
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE................22246
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT................22249
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND................22250
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE................22252
H-21 BOOM MOVES UP AND DOWN DURING OPERATION................22253
H-22 BUCKET DOES NOT TILT BACK................22254
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE................22257
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION................22260
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND................22261
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE................22263
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)................22264
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE................22265
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS................22266
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS................22267
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES................22269
H-32 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES................22270
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)................22271
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN................22274
TROUBLESHOOTING OF ENGINE (S-MODE)................22275
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)................22275
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION................22276
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT................22277
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)................22278
S-4 ENGINE STARTABILITY IS POOR................22280
S-5 ENGINE DOES NOT PICK UP SMOOTHLY................22282
S-6 ENGINE STOPS DURING OPERATION................22284
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE................22286
S-8 ENGINE LACKS POWER................22287
S-9 KDPF GETS CLOGGED IN A SHORT TIME................22289
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE................22291
S-11 OIL BECOMES CONTAMINATED QUICKLY................22292
S-12 FUEL CONSUMPTION IS EXCESSIVE................22293
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)................22294
S-14 OIL PRESSURE DROPS................22295
S-15 FUEL MIXES INTO ENGINE OIL................22297
S-16 WATER MIXES INTO ENGINE OIL (MILKY)................22298
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)................22299
S-18 UNUSUAL NOISE IS HEARD................22300
S-19 VIBRATION IS EXCESSIVE................22301
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT................22302
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY................22303
S-22 ACTIVE REGENERATION TAKES TIME................22305
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION................22306
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE................22307
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)................22309
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM................22310
OUTLINE OF FAILURE DISPLAY................22310
TROUBLESHOOTING FOR FCS................22311
TROUBLESHOOTING FOR AUTO-GREASING PUMP................22312
REPLACEMENT OF PUMP ELEMENT................22315
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM................22316
REPLACEMENT OF AUTO-GREASING CONTROLLER................22318
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING................22319
50 DISASSEMBLY AND ASSEMBLY................22321
CONTENTS................22322
ABBREVIATION LIST................22326
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY................22332
HOW TO READ THIS MANUAL................22332
COATING MATERIALS LIST................22334
SPECIAL TOOLS LIST................22339
SKETCHES OF SPECIAL TOOLS................22361
ENGINE AND COOLING SYSTEM................22375
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY................22375
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY................22376
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY................22380
REMOVE AND INSTALL INJECTOR ASSEMBLY................22387
METHOD FOR REMOVING INJECTOR ASSEMBLY................22387
METHOD FOR INSTALLING INJECTOR ASSEMBLY................22395
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY................22405
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY................22406
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................22417
REMOVE AND INSTALL EGR VALVE ASSEMBLY................22432
METHOD FOR REMOVING EGR VALVE ASSEMBLY................22432
METHOD FOR INSTALLING EGR VALVE ASSEMBLY................22436
REMOVE AND INSTALL EGR COOLER ASSEMBLY................22440
METHOD FOR REMOVING EGR COOLER ASSEMBLY................22440
METHOD FOR INSTALLING EGR COOLER ASSEMBLY................22443
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY................22448
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY................22448
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY................22450
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT................22454
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT................22454
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT................22455
REMOVE AND INSTALL ALTERNATOR BELT................22457
METHOD FOR REMOVING ALTERNATOR BELT................22457
METHOD FOR INSTALLING ALTERNATOR BELT................22460
REMOVE AND INSTALL ALTERNATOR ASSEMBLY................22463
METHOD FOR REMOVING ALTERNATOR ASSEMBLY................22463
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY................22465
REMOVE AND INSTALL AUTOMATIC TENSIONER................22470
METHOD FOR REMOVING AUTOMATIC TENSIONER................22470
METHOD FOR INSTALLING AUTOMATIC TENSIONER................22470
REMOVE AND INSTALL RADIATOR ASSEMBLY................22471
METHOD FOR REMOVING RADIATOR ASSEMBLY................22471
METHOD FOR INSTALLING RADIATOR ASSEMBLY................22474
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY................22477
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY................22477
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY................22480
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................22484
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY................22484
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY................22485
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................22487
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY................22487
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY................22488
REMOVE AND INSTALL ENGINE ASSEMBLY................22490
METHOD FOR REMOVING ENGINE ASSEMBLY................22491
METHOD FOR INSTALLING ENGINE ASSEMBLY................22510
REMOVE AND INSTALL ENGINE FRONT OIL SEAL................22530
METHOD FOR REMOVING ENGINE FRONT OIL SEAL................22530
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL................22532
REMOVE AND INSTALL ENGINE REAR OIL SEAL................22535
METHOD FOR REMOVING ENGINE REAR OIL SEAL................22535
METHOD FOR INSTALLING ENGINE REAR OIL SEAL................22537
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY................22541
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY................22541
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY................22548
REMOVE AND INSTALL FUEL TANK ASSEMBLY................22555
METHOD FOR REMOVING FUEL TANK ASSEMBLY................22555
METHOD FOR INSTALLING FUEL TANK ASSEMBLY................22559
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY................22563
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................22564
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY................22570
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................22575
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................22575
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................22577
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR................22580
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR................22580
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................22581
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER................22583
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................22583
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER................22584
REMOVE AND INSTALL KDPF ASSEMBLY................22585
METHOD FOR REMOVING KDPF ASSEMBLY................22587
METHOD FOR INSTALLING KDPF ASSEMBLY................22596
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY................22609
METHOD FOR DISASSEMBLING KDPF ASSEMBLY................22609
METHOD FOR ASSEMBLING KDPF ASSEMBLY................22614
REMOVE AND INSTALL SCR ASSEMBLY................22619
METHOD FOR REMOVING SCR ASSEMBLY................22620
METHOD FOR INSTALLING SCR ASSEMBLY................22630
REMOVE AND INSTALL KDPF, SCR ASSEMBLY................22644
METHOD FOR REMOVING KDPF, SCR ASSEMBLY................22645
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY................22655
REMOVE AND INSTALL KCCV ASSEMBLY................22670
METHOD FOR REMOVING KCCV ASSEMBLY................22670
METHOD FOR INSTALLING KCCV ASSEMBLY................22672
REMOVE AND INSTALL VGT ASSEMBLY................22675
METHOD FOR REMOVING VGT ASSEMBLY................22675
METHOD FOR INSTALLING VGT ASSEMBLY................22682
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE................22691
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE................22692
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................22697
REMOVE AND INSTALL AdBlue/DEF INJECTOR................22704
METHOD FOR REMOVING AdBlue/DEF INJECTOR................22704
METHOD FOR INSTALLING AdBlue/DEF INJECTOR................22707
REMOVE AND INSTALL AdBlue/DEF PUMP................22712
METHOD FOR REMOVING AdBlue/DEF PUMP................22712
METHOD FOR INSTALLING AdBlue/DEF PUMP................22714
REMOVE AND INSTALL AdBlue/DEF HOSE................22717
METHOD FOR REMOVING AdBlue/DEF HOSE................22717
METHOD FOR INSTALLING AdBlue/DEF HOSE................22725
REMOVE AND INSTALL AIR CLEANER ASSEMBLY................22733
METHOD FOR REMOVING AIR CLEANER ASSEMBLY................22733
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY................22736
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY................22739
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY................22740
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY................22742
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY................22744
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY................22744
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY................22746
POWER TRAIN................22749
REMOVE AND INSTALL HST PUMP ASSEMBLY................22749
METHOD FOR REMOVING HST PUMP ASSEMBLY................22750
METHOD FOR INSTALLING HST PUMP ASSEMBLY................22756
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY................22765
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY................22765
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY................22768
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY................22771
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY................22772
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY................22780
REMOVE AND INSTALL TRANSFER ASSEMBLY................22790
METHOD FOR REMOVING TRANSFER ASSEMBLY................22791
METHOD FOR INSTALLING TRANSFER ASSEMBLY................22795
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY................22802
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY................22804
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY................22824
REMOVE AND INSTALL FRONT AXLE ASSEMBLY................22849
METHOD FOR REMOVING FRONT AXLE ASSEMBLY................22849
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY................22851
REMOVE AND INSTALL REAR AXLE ASSEMBLY................22854
METHOD FOR REMOVING REAR AXLE ASSEMBLY................22854
METHOD FOR INSTALLING REAR AXLE ASSEMBLY................22858
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY................22862
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY................22863
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY................22871
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY................22881
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY................22882
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY................22895
UNDERCARRIAGE AND FRAME................22915
REMOVE AND INSTALL CENTER HINGE PIN................22915
METHOD FOR REMOVING CENTER HINGE PIN................22916
METHOD FOR INSTALLING CENTER HINGE PIN................22922
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY................22933
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY................22933
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................22939
HYDRAULIC SYSTEM................22944
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY................22944
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY................22944
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY................22955
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY................22965
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY................22965
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................22971
WORK EQUIPMENT................22977
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY................22977
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY................22978
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY................22982
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY................22993
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY................22994
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY................22998
CAB AND ITS ATTACHMENTS................23006
REMOVE AND INSTALL OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY................23006
METHOD FOR REMOVING OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY................23007
METHOD FOR INSTALLING OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY................23015
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)................23023
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)................23023
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)................23024
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................23033
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY................23033
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY................23039
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY................23046
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY................23046
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY................23046
REMOVE AND INSTALL SEAT BELT................23048
METHOD FOR REMOVING SEAT BELT................23048
METHOD FOR INSTALLING SEAT BELT................23048
ELECTRICAL SYSTEM................23050
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY................23050
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY................23050
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY................23054
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY................23061
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY................23061
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY................23063
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY................23065
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY................23065
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY................23066
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY................23068
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY................23068
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY................23071
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY................23073
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................23073
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY................23076
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR................23079
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR................23079
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR................23080
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR................23081
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR................23081
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR................23082
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR................23084
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR................23084
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR................23086
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR................23089
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR................23089
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR................23092
REMOVE AND INSTALL SCR TEMPERATURE SENSOR................23094
METHOD FOR REMOVING SCR TEMPERATURE SENSOR................23094
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................23095
REMOVE AND INSTALL AMMONIA SENSOR................23097
METHOD FOR REMOVING AMMONIA SENSOR................23097
METHOD FOR INSTALLING AMMONIA SENSOR................23099
REMOVE AND INSTALL SCR OUTLET NOx SENSOR................23102
METHOD FOR REMOVING SCR OUTLET NOx SENSOR................23102
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR................23104
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY................23107
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY................23107
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY................23108
60 MAINTENANCE STANDARD................23109
CONTENTS................23110
ABBREVIATION LIST................23111
ENGINE AND COOLING SYSTEM................23117
MAINTENANCE STANDARD OF ENGINE MOUNT................23117
MAINTENANCE STANDARD OF DAMPER................23118
MAINTENANCE STANDARD OF COOLING FAN MOTOR................23119
POWER TRAIN................23121
MAINTENANCE STANDARD OF DRIVE SHAFT................23121
MAINTENANCE STANDARD OF TRANSFER................23122
MAINTENANCE STANDARD OF TRANSFER MOUNT................23130
MAINTENANCE STANDARD OF FRONT AXLE................23131
MAINTENANCE STANDARD OF REAR AXLE................23132
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL................23133
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL................23135
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL................23137
MAINTENANCE STANDARD OF FINAL DRIVE................23139
STEERING SYSTEM................23141
MAINTENANCE STANDARD OF STEERING COLUMN................23141
MAINTENANCE STANDARD OF PRIORITY VALVE................23142
MAINTENANCE STANDARD OF STEERING CYLINDER................23143
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE................23146
BRAKE SYSTEM................23147
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE................23147
MAINTENANCE STANDARD OF SLACK ADJUSTER................23148
MAINTENANCE STANDARD OF FRONT BRAKE................23149
MAINTENANCE STANDARD OF REAR BRAKE................23150
MAINTENANCE STANDARD OF PARKING BRAKE................23151
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE................23153
UNDERCARRIAGE AND FRAME................23154
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN................23154
HYDRAULIC SYSTEM................23159
MAINTENANCE STANDARD OF HYDRAULIC TANK................23159
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP................23160
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP................23161
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND WORK EQUIPMENT PUMP................23164
MAINTENANCE STANDARD OF CONTROL VALVE................23165
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE................23177
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE................23179
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE................23181
WORK EQUIPMENT................23182
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................23182
MAINTENANCE STANDARD OF BUCKET................23186
MAINTENANCE STANDARD OF LIFT CYLINDER................23188
MAINTENANCE STANDARD OF BUCKET CYLINDER................23189
CAB AND ITS ATTACHMENTS................23190
MAINTENANCE STANDARD OF CAB MOUNT................23190
80 APPENDIX................23191
CONTENTS................23192
ABBREVIATION LIST................23194
AIR CONDITIONER SYSTEM................23200
PRECAUTIONS FOR REFRIGERANT................23200
AIR CONDITIONER COMPONENT................23201
SPECIFICATIONS OF AIR CONDITIONER................23203
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE................23204
OUTLINE OF REFRIGERATION CYCLE................23205
COMPONENT PARTS OF AIR CONDITIONER SYSTEM................23207
AIR CONDITIONER UNIT................23207
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT................23207
FUNCTION OF AIR CONDITIONER UNIT................23208
COMPONENT PARTS OF AIR CONDITIONER UNIT................23209
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT................23209
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT................23209
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT................23210
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT................23210
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT................23210
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT................23210
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT................23210
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT................23210
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT................23211
FUNCTION OF DUAL PRESSURE SWITCH................23211
AIR CONDITIONER CONTROLLER................23212
STRUCTURE OF AIR CONDITIONER CONTROLLER................23212
COMPRESSOR................23213
STRUCTURE OF COMPRESSOR................23213
SPECIFICATIONS OF COMPRESSOR................23213
FUNCTION OF COMPRESSOR................23213
CONDENSER................23214
STRUCTURE OF CONDENSER................23214
SPECIFICATIONS OF CONDENSER................23214
FUNCTION OF CONDENSER................23214
RECEIVER DRIER................23215
STRUCTURE OF RECEIVER DRIER................23215
SPECIFICATIONS OF RECEIVER DRIER................23215
FUNCTION OF RECEIVER DRIER................23215
SENSORS FOR AIR CONDITIONER SYSTEM................23216
FUNCTION OF SUNLIGHT SENSOR................23216
FUNCTION OF AMBIENT TEMPERATURE SENSOR................23216
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER................23217
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER................23219
AIR CONDITIONER SYSTEM DIAGRAM................23222
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER................23223
FUNCTION OF AIR CONDITIONER CONTROLLER................23224
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS................23225
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................23231
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR................23232
CHECK TEMPERATURE CONTROL FUNCTION................23233
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION................23233
TEST VENT (MODE) CHANGEOVER................23235
METHOD FOR TESTING VENT (MODE) CHANGEOVER................23235
TESTING FRESH/RECIRC AIR CHANGEOVER................23237
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER................23237
TEST EVAPORATOR TEMPERATURE SENSOR................23239
TEST RELAYS................23241
METHOD FOR TESTING RELAYS................23241
AIR CONDITIONER TROUBLESHOOTING CHART 1................23243
AIR CONDITIONER TROUBLESHOOTING CHART 2................23244
FAILURE CODE [879AKA]................23247
FAILURE CODE [879AKB]................23249
FAILURE CODE [879BKA]................23251
FAILURE CODE [879BKB]................23253
FAILURE CODE [879CKA]................23255
FAILURE CODE [879CKB]................23257
FAILURE CODE [879DKZ]................23259
FAILURE CODE [879EMC]................23261
FAILURE CODE [879FMC]................23262
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)................23263
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)................23266
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)................23269
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER................23273
TROUBLESHOOTING USING GAUGE PRESSURE................23275
CONNECTION OF SERVICE TOOL................23278
METHOD FOR CONNECTING SERVICE TOOL................23279
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS................23280
HANDLE COMPRESSOR OIL................23282
90 CIRCUIT DIAGRAMS................23285
CONTENTS................23286
ABBREVIATION LIST................23287
HYDRAULIC CIRCUIT DIAGRAM................23293
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM................23293
HYDRAULIC CIRCUIT DIAGRAM (1/2)................23297
HYDRAULIC CIRCUIT DIAGRAM (2/2)................23298
HYDRAULIC AUTO-GREASING DIAGRAM................23299
ELECTRICAL CIRCUIT DIAGRAM................23300
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM................23300
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/7)................23304
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/7)................23305
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/7)................23306
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/7)................23307
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/7)................23308
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/7)................23309
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/7)................23310
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9)................23311
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9)................23312
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9)................23313
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9)................23314
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9)................23315
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9)................23316
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9)................23317
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9)................23318
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9)................23319
INDEX................23320
TEN00088-00 - Wheel Loader GALEO WA320L-5 Operation & Maintenance Manual................23340
COVER................23340
FOREWORD................23341
FOREWORD................23342
SAFETY INFORMATION................23345
INTRODUCTION................23347
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................23347
NECESSARY INFORMATION................23348
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................23348
ENGINE SERIAL NO. PLATE ................23348
POSITION OF SERVIVE METER................23349
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................23349
CONTENTS................23350
SAFETY................23353
SAFETY................23354
SAFETY LABELS................23357
LOCATION OF SAFETY LABELS................23357
SAFETY LABELS................23358
GENERAL PRECAUTIONS................23363
SAFETY RULES................23363
IF ABNORMALITIES ARE FOUND................23363
CLOTHING AND PERSONAL PROTECTIVE ITEMS................23363
FIRE EXTINGUISHER AND FIRST AID KIT................23363
SAFETY FEATURES................23363
KEEP MACHINE CLEAN................23364
INSIDE OPERATOR'S COMPARTMENT................23364
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT................23364
HANDRAILS AND STEPS................23365
MOUNTING AND DISMOUNTING................23366
NO PEOPLE ON ATTACHMENTS................23366
DO NOT GET CAUGHT IN ARTICULATED PORTION................23366
PREVENTION OF BURNS................23366
FIRE PREVENTION................23367
ACTION IF FIRE OCCURS................23368
WINDOW WASHER LIQUID................23368
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................23368
PRECAUTIONS FOR ATTACHMENTS, OPTIONS................23368
UNAUTHORIZED MODIFICATION................23368
SAFETY AT WORKSITE................23369
WORKING ON LOOSE GROUND................23369
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................23369
ENSURE GOOD VISIBILITY................23370
VENTILATION FOR ENCLOSED AREAS................23370
CHECKING SIGNALMAN'S SIGNALS AND SIGNS................23370
EMERGENCY EXIT FROM OPERATOR'S CAB................23370
BE CAREFUL ABOUT ASBESTOS DUST................23371
PRECAUTIONS FOR OPERATION................23372
STARTING ENGINE................23372
CHECKS BEFORE STARTING ENGINE................23372
PRECAUTIONS WHEN STARTING................23372
PRECAUTIONS IN COLD AREAS................23373
OPERATION................23374
CHECKS BEFORE OPERATION................23374
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................23374
PRECAUTIONS WHEN TRAVELING................23375
TRAVELING ON SLOPES................23376
PROHIBITED OPERATIONS................23377
PRECAUTIONS WHEN OPERATING................23377
METHODS OF USING BRAKE................23378
OPERATE CAREFULLY ON SNOW................23378
PARKING MACHINE................23379
TRANSPORTATION................23380
LOADING AND UNLOADING................23380
SHIPPING................23380
BATTERY................23381
BATTERY HAZARD PREVENTION................23381
STARTING WITH BOOSTER CABLES................23382
TOWING................23383
WHEN TOWING ................23383
PRECAUTIONS FOR MAINTENACE................23384
WARNING TAG................23384
KEEP WORK PLACE CLEAN AND TIDY................23384
APPOINT LEADER WHEN WORKING WITH OTHERS................23384
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................23385
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING................23386
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.SWITCH OFF................23386
PROPER TOOLS................23387
ACCUMULATOR................23387
PERSONNEL................23387
ATTACHMENTS................23387
WORK UNDER THE MACHINE................23388
NOISE................23388
PRECAUTIONS WHEN USING HAMMER................23388
REPAIR WELDING................23388
REMOVING BATTERY TERMINAL................23388
PRECAUTIONS WITH HIGH-PRESSURE OIL................23389
HANDLING HIGH-PRESSURE HOSES................23389
WASTE MATERIALS................23389
MAINTENANCE OF AIR CONDITIONER................23389
COMPRESSED AIR................23390
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................23390
PRECAUTIONS WITH TIRES................23391
HANDLING TIRES................23391
PRECAUTIONS WHEN STORING TIRES................23391
OPERATION................23392
GENERAL VIEW................23393
GENERAL VIEW OF MACHINE................23393
GENERAL VIEW OF CONTROLS AND GAUGES................23394
EXPLANATION OF COMPONENTS................23396
MACHINE MONITOR................23396
SWITCHES................23423
CONTROL LEVERS, PEDALS................23431
STEERING TILT LOCK LEVER................23435
CAP AND COVER WITH LOCK................23435
FRAME LOCK BAR................23436
TOWING PIN................23437
GREASE PUMP................23437
CAB DOOR INNER LOCK................23437
CAB DOOR OPEN LOCK................23438
CAB WINDOW OPEN LOCK CANCEL KNOB................23438
FUSE................23438
SLOW BLOW FUSE................23440
POWER OUTLET................23440
STORAGE BOX................23440
AM/FM RADIO-CASSETTE STEREO................23441
AIR CONDITIONER................23449
HANDLING CAB WIPER................23454
OPERATION................23455
CHECK BEFORE STARTING ENGINE, ADJUST................23455
STARTING ENGINE................23470
OPERATIONS AND CHECKS AFTER STARTING ENGINE................23474
STOPPING ENGINE................23476
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................23477
TURNING................23481
OPERATION OF WORK EQUIPMENT................23483
WORK POSSIBLE USING WHEEL LOADER................23485
PRECAUTIONS FOR OPERATION................23492
ADJUSTING WORK EQUIPMENT POSTURE................23494
PARKING MACHINE................23496
CHECKS AFTER COMPLETION OF OPERATION................23498
LOCKING................23498
HANDLING THE TIRES................23499
TRANSPORTATION................23501
TRANSPORTATION PROCEDURE................23501
LOADING, UNLOADING WORK WITH TRAILERS................23501
LIFTING MACHINE................23505
COLD WEATHER OPERATION................23507
PRECAUTIONS FOR LOW TEMPERATURE................23507
PRECAUTIONS AFTER COMPLETION OF WORK................23508
AFTER COLD WEATHER................23508
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER................23509
LONG-TERM STORAGE................23510
BEFORE STORAGE................23510
DURING STORAGE................23510
AFTER STORAGE................23510
TROUBLESHOOTING................23511
WHEN MACHINE RUNS OUT OF FUEL................23511
METHOD OF TOWING MACHINE................23511
IF BATTERY IS DISCHARGED................23513
OTHER TROUBLE................23516
MAINTENANCE................23521
GUIDES TO MAINTENANCE................23522
OUTLINES OF SERVICE................23524
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC................23524
OUTLINE OF ELECTRIC SYSTEM................23527
WEAR PARTS................23528
WEAR PARTS LIST................23528
RECOMMENDED FUEL, COOLANT, AND LUBRICANT................23529
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................23530
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL................23531
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................23532
TORQUE LIST................23532
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................23533
MAINTENANCE SCHEDULE CHART................23534
MAINTENANCE SCHEDULE CHART................23534
SERVICE PROCEDURE................23536
INITIAL 250 HOURS SERVICE................23536
WHEN REQUIRED................23537
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT................23537
CLEAN INSIDE OF COOLING SYSTEM................23540
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL................23543
CHECK AXLE OIL LEVEL, ADD OIL................23544
CLEAN AXLE CASE BREATHER................23545
CLEAN AIR CONDITIONER CONDENSER................23546
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID................23546
CLEAN RADIATOR FINS AND COOLER FINS................23547
CLEAN TRANSFER OIL COOLER FINS................23547
CHECK ELECTRICAL INTAKE AIR HEATER................23547
TURN, REPLACE BOLT-ON CUTTING EDGE................23548
REPLACE BUCKET TEETH................23549
CHECK AIR CONDITIONER................23550
REPLACE SLOW BLOW FUSE................23551
CHECKING FUNCTION OF ACCUMULATOR................23552
SELECTION AND INSPECTION OF TIRES................23553
CHECK BEFORE STARTING................23555
EVERY 50 HOURS SERVICE................23556
DRAIN WATER, SEDIMENT FROM FUEL TANK................23556
EVERY 100 HOURS SERVICE................23557
LUBRICATE REAR AXLE PIVOT PIN................23557
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................23557
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................23558
EVERY 250 HOURS SERVICE................23559
CHECK BATTERY ELECTROLYTE LEVEL................23559
CHECK PARKING BRAKE................23561
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................23561
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN................23562
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER................23563
CHECKING FUNCTION OF ACCUMULATOR................23563
LUBRICATING................23564
EVERY 500 HOURS SERVICE................23566
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE................23566
REPLACE FUEL FILTER CARTRIDGE................23567
CLEAN WATER SEPARATOR STRAINER................23568
EVERY 1000 HOURS SERVICE................23569
CHANGE OIL IN TRANSFER CASE................23569
CLEAN TRANSFER CASE BREATHER................23570
REPLACE HST OIL FILTER ELEMENT................23571
LUBRICATING................23572
CHECK TIGHTENING PARTS OF TURBOCHARGER................23572
CHECK PLAY OF TURBOCHARGER ROTOR................23572
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT ................23572
EVERY 2000 HOURS SERVICE................23573
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT................23573
REPLACE HYDRAULIC TANK BREATHER ELEMENT................23574
CHANGE AXLE OIL................23575
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER................23575
CLEAN BRAKE CIRCUIT STRAINER................23576
CHECK BRAKE DISC WEAR................23577
CHECKING FUNCTION OF ACCUMULATOR................23578
CHECK ALTERNATOR, STARTING MOTOR................23578
CHECK ENGINE VALVE CLEARANCE, ADJUST................23578
CLEAN AND CHECK TURBOCHARGER................23578
CHECK VIBRATION DAMPER................23578
EVERY 4000 HOURS SERVICE................23579
LUBRICATING................23579
CHECK WATER PUMP................23579
SPECIFICATIONS................23580
SPECIFICATIONS................23581
ATTACHMENTS, OPTIONS................23582
SELECTING BUCKET AND TIRES................23583
MACHINE MONITOR WITH LOAD METER................23584
EXPLANATION OF COMPONENTS................23585
MACHINE MONITOR................23587
HANDLING MULTI-FUNCTION LEVER................23642
EXPLANATION OF COMPONENTS................23642
OPERATION................23645
INDEX................23647
TEN00235-05 - Wheel Loader WA320-6 Operation & Maintenance Manual................23650
COVER................23650
FOREWORD................23651
BEFORE READING THIS MANUAL................23652
SAFETY INFORMATION................23653
INTRODUCTION................23654
USE OF MACHINE................23654
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................23654
VISIBILITY FROM OPERATOR'S SEAT................23654
NECESSARY INFORMATION................23655
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................23655
EPA REGULATIONS, ENGINE NUMBER PLATE................23655
POSITION OF SERVICE METER................23656
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................23656
CONTENTS................23657
SAFETY................23661
SAFETY................23662
SAFETY LABELS................23665
LOCATION OF SAFETY LABELS................23665
SAFETY LABELS................23666
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE................23672
PRECAUTIONS BEFORE STARTING OPERATION................23672
PREPARATIONS FOR SAFE OPERATION................23672
FIRE PREVENTION................23674
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE................23675
DO NOT GET CAUGHT IN ARTICULATING PORTION................23678
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES................23678
UNAUTHORIZED MODIFICATION................23678
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS................23678
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING................23679
PRECAUTIONS FOR OPERATION................23680
PRECAUTIONS FOR JOBSITE................23680
STARTING ENGINE................23682
OPERATION................23684
TRANSPORTATION................23691
TOWING................23692
PRECAUTIONS FOR MAINTENANCE................23693
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................23693
PRECAUTIONS FOR INSPECTION AND MAINTENANCE................23698
TIRES................23703
OPERATION................23705
GENERAL VIEW................23706
GENERAL VIEW OF MACHINE................23706
GENERAL VIEW OF CONTROLS AND GAUGES................23707
EXPLANATION OF COMPONENTS................23709
MACHINE MONITOR................23709
SWITCHES................23747
CONTROL LEVERS, PEDALS................23761
STEERING TILT LOCK LEVER................23766
CAP AND COVER WITH LOCK................23766
FRAME LOCK BAR................23767
TOWING PIN................23768
GREASE PUMP................23768
OPENING, CLOSING CAB DOORS, WINDOWS................23769
FUSE................23773
SLOW BLOW FUSE................23775
POWER OUTLET................23776
STORAGE BOX................23776
AM/FM RADIO-CASSETTE STEREO................23777
AIR CONDITIONER................23785
HANDLING CAB WIPER................23792
OPERATION................23793
CHECK BEFORE STARTING ENGINE, ADJUST................23793
STARTING ENGINE................23811
CHECKS AFTER STARTING ENGINE................23815
OPERATIONS AND CHECKS AFTER STARTING ENGINE................23816
STOPPING ENGINE................23819
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................23820
TURNING................23826
OPERATION OF WORK EQUIPMENT................23828
WORK POSSIBLE USING WHEEL LOADER................23830
PRECAUTIONS FOR OPERATION................23835
ADJUSTING WORK EQUIPMENT POSTURE................23837
PARKING MACHINE................23839
CHECKS AFTER COMPLETION OF OPERATION................23841
LOCKING................23841
HANDLING THE TIRES................23842
TRANSPORTATION................23844
TRANSPORTATION PROCEDURE................23844
LOADING, UNLOADING WORK WITH TRAILERS................23844
LIFTING MACHINE................23848
COLD WEATHER OPERATION................23850
PRECAUTIONS FOR LOW TEMPERATURE................23850
PRECAUTIONS AFTER COMPLETION OF WORK................23851
AFTER COLD WEATHER................23851
LONG-TERM STORAGE................23852
BEFORE STORAGE................23852
DURING STORAGE................23852
AFTER STORAGE................23852
TROUBLESHOOTING................23853
WHEN MACHINE RUNS OUT OF FUEL................23853
METHOD OF TOWING MACHINE................23853
IF BATTERY IS DISCHARGED................23855
OTHER TROUBLE................23858
MAINTENANCE................23863
GUIDES TO MAINTENANCE................23864
OUTLINES OF SERVICE................23866
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC................23866
OUTLINE OF ELECTRIC SYSTEM................23869
WEAR PARTS................23870
WEAR PARTS LIST................23870
RECOMMENDED FUEL, COOLANT, AND LUBRICANT................23871
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................23872
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL................23873
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................23874
TORQUE LIST................23874
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................23875
MAINTENANCE SCHEDULE CHART................23876
MAINTENANCE SCHEDULE CHART................23876
SERVICE PROCEDURE................23878
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)................23878
INITIAL 250 HOURS SERVICE................23878
INITIAL 1000 HOURS SERVICE................23878
WHEN REQUIRED................23879
CHECK BEFORE STARTING................23905
EVERY 50 HOURS SERVICE................23906
EVERY 100 HOURS SERVICE................23907
EVERY 250 HOURS SERVICE................23910
EVERY 500 HOURS SERVICE................23916
EVERY 1000 HOURS SERVICE................23920
EVERY 2000 HOURS SERVICE................23926
EVERY 4000 HOURS SERVICE................23932
EVERY 8000 HOURS SERVICE................23934
SPECIFICATIONS................23935
SPECIFICATIONS................23936
ATTACHMENTS, OPTIONS................23939
SELECTING BUCKET AND TIRES................23940
HANDLING HYDRAULIC QUICK COUPLER................23941
REMOVING ATTACHMENT................23941
INSTALLING ATTACHMENT................23943
METHOD OF USING 2 LEVERS................23945
EXPLANATION OF COMPONENTS................23945
HANDLING MACHINES EQUIPPED WITH KOMTRAX................23947
BASIC PRECAUTIONS................23947
INDEX................23949
TEN00456-01 - Wheel Loader WA320-6 Operation & Maintenance Manual................23953
COVER................23953
FOREWORD................23954
BEFORE READING THIS MANUAL................23955
SAFETY INFORMATION................23956
INTRODUCTION................23957
USE OF MACHINE................23957
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................23957
VISIBILITY FROM OPERATOR'S SEAT................23957
NECESSARY INFORMATION................23958
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................23958
EPA REGULATIONS, ENGINE NUMBER PLATE................23958
POSITION OF SERVICE METER................23959
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................23959
CONTENTS................23960
SAFETY................23964
SAFETY................23965
SAFETY LABELS................23968
LOCATION OF SAFETY LABELS................23968
SAFETY LABELS................23969
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE................23975
PRECAUTIONS BEFORE STARTING OPERATION................23975
PREPARATIONS FOR SAFE OPERATION................23975
FIRE PREVENTION................23977
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE................23978
DO NOT GET CAUGHT IN ARTICULATING PORTION................23981
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES................23981
UNAUTHORIZED MODIFICATION................23981
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS................23981
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING................23982
PRECAUTIONS FOR OPERATION................23983
PRECAUTIONS FOR JOBSITE................23983
STARTING ENGINE................23985
OPERATION................23987
TRANSPORTATION................23994
TOWING................23995
PRECAUTIONS FOR MAINTENANCE................23996
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................23996
PRECAUTIONS FOR INSPECTION AND MAINTENANCE................24001
TIRES................24006
OPERATION................24008
GENERAL VIEW................24009
GENERAL VIEW OF MACHINE................24009
GENERAL VIEW OF CONTROLS AND GAUGES................24010
EXPLANATION OF COMPONENTS................24012
MACHINE MONITOR................24012
SWITCHES................24050
CONTROL LEVERS, PEDALS................24064
CAP AND COVER WITH LOCK................24069
FRAME LOCK BAR................24070
TOWING PIN................24071
GREASE PUMP................24071
OPENING, CLOSING CAB DOORS, WINDOWS................24072
FUSE................24076
SLOW BLOW FUSE................24078
POWER OUTLET................24079
STORAGE BOX................24079
AM/FM RADIO-CASSETTE STEREO................24080
AIR CONDITIONER................24088
HANDLING CAB WIPER................24095
OPERATION................24096
CHECK BEFORE STARTING ENGINE, ADJUST................24096
STARTING ENGINE................24114
CHECKS AFTER STARTING ENGINE................24118
OPERATIONS AND CHECKS AFTER STARTING ENGINE................24119
STOPPING ENGINE................24122
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................24123
TURNING................24129
OPERATION OF WORK EQUIPMENT................24131
WORK POSSIBLE USING WHEEL LOADER................24133
PRECAUTIONS FOR OPERATION................24138
ADJUSTING WORK EQUIPMENT POSTURE................24140
PARKING MACHINE................24142
CHECKS AFTER COMPLETION OF OPERATION................24144
LOCKING................24144
HANDLING THE TIRES................24145
TRANSPORTATION................24147
TRANSPORTATION PROCEDURE................24147
LOADING, UNLOADING WORK WITH TRAILERS................24147
LIFTING MACHINE................24151
COLD WEATHER OPERATION................24153
PRECAUTIONS FOR LOW TEMPERATURE................24153
PRECAUTIONS AFTER COMPLETION OF WORK................24154
AFTER COLD WEATHER................24154
LONG-TERM STORAGE................24155
BEFORE STORAGE................24155
DURING STORAGE................24155
AFTER STORAGE................24155
TROUBLESHOOTING................24156
WHEN MACHINE RUNS OUT OF FUEL................24156
METHOD OF TOWING MACHINE................24156
IF BATTERY IS DISCHARGED................24158
OTHER TROUBLE................24161
MAINTENANCE................24166
GUIDES TO MAINTENANCE................24167
OUTLINES OF SERVICE................24169
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC................24169
OUTLINE OF ELECTRIC SYSTEM................24172
WEAR PARTS................24173
WEAR PARTS LIST................24173
RECOMMENDED FUEL, COOLANT, AND LUBRICANT................24174
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................24175
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL................24176
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................24177
TORQUE LIST................24177
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................24178
MAINTENANCE SCHEDULE CHART................24179
MAINTENANCE SCHEDULE CHART................24179
SERVICE PROCEDURE................24181
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)................24181
INITIAL 250 HOURS SERVICE................24181
INITIAL 1000 HOURS SERVICE................24181
WHEN REQUIRED................24182
CHECK BEFORE STARTING................24208
EVERY 50 HOURS SERVICE................24209
EVERY 100 HOURS SERVICE................24210
EVERY 250 HOURS SERVICE................24213
EVERY 500 HOURS SERVICE................24219
EVERY 1000 HOURS SERVICE................24223
EVERY 2000 HOURS SERVICE................24229
EVERY 4000 HOURS SERVICE................24235
EVERY 8000 HOURS SERVICE................24237
SPECIFICATIONS................24238
SPECIFICATIONS................24239
ATTACHMENTS, OPTIONS................24242
SELECTING BUCKET AND TIRES................24243
HANDLING HYDRAULIC QUICK COUPLER................24244
REMOVING ATTACHMENT................24244
INSTALLING ATTACHMENT................24246
METHOD OF USING 2 LEVERS................24248
EXPLANATION OF COMPONENTS................24248
HANDLING MACHINES EQUIPPED WITH KOMTRAX................24250
BASIC PRECAUTIONS................24250
INDEX................24252
TEN00612-00 - Wheel Loader WA320-7 Operation & Maintenance Manual................24256
COVER................24256
FOREWORD ................24257
BEFORE READING THIS MANUAL ................24258
SAFETY INFORMATION ................24259
INTRODUCTION ................24260
USE OF MACHINE ................24260
DIRECTIONS OF MACHINE ................24260
VISIBILITY FROM OPERATOR'S SEAT ................24260
PRODUCT INFORMATION ................24261
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ................24261
EPA REGULATIONS, ENGINE NUMBER PLATE ................24261
SERVICE METER LOCATION ................24262
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ................24262
CONTENTS ................24263
SAFETY ................24267
SAFETY ................24268
SAFETY LABELS ................24270
LOCATION OF SAFETY LABELS ................24270
SAFETY LABELS ................24271
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ................24278
PRECAUTIONS BEFORE STARTING OPERATION ................24278
PREPARATIONS FOR SAFE OPERATION ................24279
FIRE PREVENTION ................24281
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ................24283
DO NOT GET CAUGHT IN WORK EQUIPMENT ................24286
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ................24286
UNAUTHORIZED MODIFICATION ................24286
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ................24287
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ................24287
PRECAUTIONS FOR OPERATION ................24288
PRECAUTIONS FOR JOBSITE ................24288
STARTING ENGINE ................24291
OPERATION ................24294
TRANSPORTATION ................24300
TOWING ................24301
PRECAUTIONS FOR MAINTENANCE ................24302
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................24302
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ................24307
TIRES ................24312
OPERATION ................24313
GENERAL VIEW ................24314
GENERAL VIEW OF MACHINE ................24314
GENERAL VIEW OF CONTROLS AND GAUGES ................24316
EXPLANATION OF COMPONENTS ................24321
MACHINE MONITOR ................24321
SWITCHES ................24388
CONTROL LEVERS AND PEDALS ................24403
CAPS AND COVERS WITH LOCK ................24407
ASHTRAY ................24410
FRAME LOCK BAR ................24411
TOWING PIN ................24412
GREASE PUMP HOLDER ................24413
BATTERY DISCONNECT SWITCH ................24414
SYSTEM OPERATING LAMP ................24416
BACKUP ALARM ................24417
OPEN AND CLOSE CAB DOOR ................24418
FUSE ................24422
SLOW-BLOW FUSE ................24424
AUXILIARY ELECTRIC POWER ................24425
HANDLING RADIO ................24426
HANDLING AUTO AIR CONDITIONER ................24431
HANDLING FRONT WIPER ................24442
HANDLING REAR VIEW MONITOR ................24443
HANDLING Komatsu Diesel Particulate Filter (KDPF) ................24444
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ................24452
HANDLING MACHINES EQUIPPED WITH KOMTRAX ................24453
MACHINE OPERATIONS AND CONTROLS ................24455
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ................24455
STARTING ENGINE ................24480
CHECKS AFTER STARTING ENGINE ................24485
STOPPING ENGINE ................24488
MACHINE OPERATION ................24489
STEERING MACHINE ................24498
WORK EQUIPMENT CONTROLS AND OPERATIONS ................24500
HANDLING HYDRAULIC TYPE QUICK COUPLER ................24502
RECOMMENDED APPLICATIONS ................24507
RULES FOR OPERATION ................24513
ADJUST WORK EQUIPMENT POSTURE ................24515
PARKING MACHINE ................24522
CHECK AFTER FINISHING WORK ................24524
LOCKING ................24525
HANDLING TIRES ................24526
TRANSPORTATION ................24528
TRANSPORTATION PROCEDURE ................24528
LOADING AND UNLOADING WITH TRAILER ................24529
LIFTING MACHINE ................24533
COLD WEATHER OPERATION ................24535
COLD WEATHER OPERATION INFORMATION ................24535
AFTER DAILY WORK COMPLETION ................24536
IN COLD AREAS ................24536
AFTER COLD WEATHER SEASON ................24536
LONG-TERM STORAGE ................24537
BEFORE STORAGE ................24537
DURING STORAGE ................24537
AFTER STORAGE ................24538
STARTING MACHINE AFTER LONG-TERM STORAGE ................24538
TROUBLES AND ACTIONS ................24539
RUNNING OUT OF FUEL ................24539
TOWING MACHINE ................24540
DISCHARGED BATTERY ................24544
OTHER TROUBLE ................24548
MAINTENANCE ................24553
RULES FOR MAINTENANCE ................24554
SERVICE METER READING ................24554
KOMATSU GENUINE REPLACEMENT PARTS ................24554
KOMATSU GENUINE LUBRICANTS ................24554
ALWAYS USE CLEAN WASHER FLUID ................24554
FRESH AND CLEAN LUBRICANTS ................24554
CHECK DRAINED OIL AND USED FILTER ................24554
CAUTION FOR REFILLING OIL OR FUEL ................24554
WELDING INSTRUCTIONS ................24554
DO NOT DROP THINGS INSIDE MACHINE ................24554
PRECAUTIONS FOR KDPF ................24554
DUSTY JOBSITES ................24554
AVOID MIXING OIL ................24555
LOCKING INSPECTION COVERS ................24555
BLEEDING AIR FROM HYDRAULIC CIRCUIT ................24555
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ................24555
CHECKS AFTER INSPECTION AND MAINTENANCE ................24555
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ................24555
CLOSE ENGINE SIDE COVER SECURELY ................24555
OUTLINE OF MAINTENANCE ................24556
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ................24556
HANDLING ELECTRICAL COMPONENTS ................24560
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ................24561
TIGHTENING TORQUE LIST ................24561
MAINTENANCE SCHEDULE ................24562
MAINTENANCE SCHEDULE TABLE ................24562
MAINTENANCE PROCEDURE ................24564
EVERY 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ................24564
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ................24564
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ................24564
WHEN REQUIRED ................24565
CHECKS BEFORE STARTING ................24594
EVERY 50 HOURS MAINTENANCE ................24595
EVERY 100 HOURS MAINTENANCE ................24596
EVERY 250 HOURS MAINTENANCE ................24598
EVERY 500 HOURS MAINTENANCE ................24605
EVERY 1000 HOURS MAINTENANCE ................24610
EVERY 2000 HOURS MAINTENANCE ................24616
EVERY 4000 HOURS MAINTENANCE ................24627
EVERY 4500 HOURS MAINTENANCE ................24629
EVERY 8000 HOURS MAINTENANCE ................24630
SPECIFICATIONS ................24631
SPECIFICATIONS ................24632
ATTACHMENTS AND OPTIONS ................24635
TIRE AND BUCKET SELECTION ................24636
HANDLING FORK ................24637
EXPLANATION OF COMPONENTS ................24637
MACHINE OPERATIONS AND CONTROLS ................24639
PCS (Proportional Control Switch) ................24642
DISPLAY OF LIQUID CRYSTAL UNIT ................24643
SETTING METHOD OF PCS ................24645
REPLACEMENT PARTS ................24647
SAFETY CRITICAL PARTS ................24648
SAFETY CRITICAL PARTS LIST ................24648
CONSUMABLE PARTS ................24649
CONSUMABLE PARTS LIST ................24649
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................24650
LUBRICATION CHART ................24650
LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE AND RECOMMENDED GENUINE LUBRICANTS ................24652
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ................24654
INDEX ................24655
VEAM240100 - Wheel Loader WA320-5 Operation & Maintenance Manual................24659
FOREWORD................24661
FOREWORD................24662
SAFETY INFORMATION................24664
INTRODUCTION................24666
INTENDED USE................24666
DIRECTIONS OF MACHINE................24666
NECESSARY INFORMATION................24667
PIN/MACHINE SERIAL NO. PLATE AND POSITION................24667
ENGINE SERIAL NO. PLATE AND POSITION................24667
ROPS/FOPS-CAB SERIAL NO. PLATE................24668
AXLE SERIAL NO. PLATE................24668
TRANSMISSION SERIAL NO. PLATE................24668
SEAT OPERATOR SERIAL NO. PLATE................24668
POSITION OF SERVICE METER................24669
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................24669
CONTENTS................24670
DIMENSIONS, WEIGHTS AND OPERATING DATA................24677
WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA................24677
CE-CONFORMING EQUIPMENT................24678
CE-CONFORMING EQUIPMENT................24678
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900................24679
SAFETY................24683
SAFETY LABELS................24685
LOCATION OF SAFETY LABELS................24685
PRESENTATION OF SAFETY LABELS................24686
GENERAL PRECAUTIONS................24689
PRECAUTIONS FOR OPERATION................24699
STARTING ENGINE................24699
OPERATION................24701
TRANSPORTATION................24707
BATTERY................24708
TOWING................24710
PRECAUTIONS FOR MAINTENANCE................24711
PRECAUTIONS WITH TIRES................24718
OPERATION................24719
GENERAL VIEW................24720
GENERAL VIEW OF MACHINE................24720
GENERAL VIEW OF CONTROLS AND GAUGES................24721
EXPLANATION OF COMPONENTS................24723
MACHINE MONITOR................24723
MONITOR SYSTEM................24724
TYPES OF WARNING................24725
CENTRAL WARNING LAMP................24725
CHARACTER DISPLAY PORTION................24726
EMERGENCY STOP ITEM................24732
CAUTION ITEMS................24734
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED................24736
INSPECTION AND MAINTENANCE ITEM................24737
PILOT DISPLAY PORTION................24740
METER DISPLAY PORTION................24743
OTHER FUNCTIONS OF MACHINE MONITOR................24745
SWITCHES................24748
CONTROL LEVERS, PEDALS................24757
STEERING TILT LOCK LEVER................24761
CAP AND COVER WITH LOCK................24761
SAFETY BAR................24762
TOWING PIN................24763
GREASE PUMP................24763
CAB DOOR INNER LOCK................24763
CAB DOOR OPEN LOCK................24764
CAB WINDOW OPEN LOCK CANCEL KNOB................24764
FUSE................24764
FUSE CAPACITY AND NAME OF CIRCUIT................24765
SLOW BLOW FUSE................24766
POWER OUTLET................24766
STORAGE BOX................24766
AIR CONDITIONER................24767
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................24767
METHOD OF OPERATION................24770
PRECAUTIONS WHEN USING................24771
HANDLING CAB WIPER................24771
PREVENTING DAMAGE TO WIPER ARM BRACKET................24771
OPERATION................24772
CHECK BEFORE STARTING ENGINE, ADJUST................24772
WALK-AROUND CHECK................24772
CHECK BEFORE STARTING................24775
ADJUSTMENT................24781
OPERATIONS AND CHECKS BEFORE STARTING ENGINE................24784
STARTING ENGINE................24786
NORMAL STARTING................24786
STARTING IN COLD WEATHER................24788
OPERATIONS AND CHECKS AFTER STARTING ENGINE................24790
BREAKING-IN THE MACHINE................24790
NORMAL OPERATION................24791
STOPPING ENGINE................24792
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................24793
MOVING THE MACHINE................24793
CHANGING DIRECTION................24795
STOPPING THE MACHINE................24797
TURNING................24798
EMERGENCY STEERING................24799
OPERATION OF WORK EQUIPMENT................24800
WORK POSSIBLE USING WHEEL LOADER................24802
DIGGING OPERATIONS................24802
LEVELING OPERATIONS................24805
PUSHING OPERATION................24805
LOAD AND CARRY OPERATIONS................24805
LOADING OPERATIONS................24805
PRECAUTIONS FOR OPERATION................24808
PERMISSIBLE WATER DEPTH................24808
IF WHEEL BRAKE DOES NOT WORK................24808
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES................24808
ADJUSTING WORK EQUIPMENT POSTURE................24810
ADJUSTING BOOM KICKOUT................24810
ADJUSTING BUCKET POSITIONER................24811
BUCKET LEVEL INDICATOR................24811
PARKING MACHINE................24812
CHECK AFTER STOPPING ENGINE................24813
CHECKS AFTER COMPLETION OF OPERATION................24813
LOCKING................24814
HANDLING THE TIRES................24815
PRECAUTIONS WHEN HANDLING TIRES................24815
TIRE PRESSURE................24815
PRECAUTIONS FOR USING LOAD AND CARRY METHOD................24816
TRANSPORTATION................24817
TRANSPORTATION PROCEDURE................24817
LOADING, UNLOADING WORK WITH TRAILERS................24817
LOADING................24817
SECURING MACHINE................24818
UNLOADING................24819
LIFTING MACHINE................24820
LOCATION OF LIFTING POSITION MARK................24821
WEIGHT TABLE................24821
LIFTING PROCEDURE................24822
COLD WEATHER OPERATION................24823
PRECAUTIONS FOR LOW TEMPERATURE................24823
FUEL AND LUBRICANTS................24823
COOLANT................24823
BATTERY................24824
PRECAUTIONS AFTER COMPLETION OF WORK................24824
AFTER COLD WEATHER................24825
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER................24825
LONG-TERM STORAGE................24826
BEFORE STORAGE................24826
DURING STORAGE................24826
AFTER STORAGE................24826
TROUBLESHOOTING................24827
WHEN MACHINE RUNS OUT OF FUEL................24827
TOWING THE MACHINE................24827
WHEN ENGINE CAN BE USED................24828
WHEN ENGINE CANNOT BE USED................24828
IF BATTERY IS DISCHARGED................24829
REMOVAL AND INSTALLATION OF BATTERY................24829
PRECAUTIONS FOR CHARGING BATTERY................24830
STARTING ENGINE WITH BOOSTER CABLE................24831
OTHER TROUBLE................24833
ELECTRICAL SYSTEM................24833
CHASSIS................24834
ENGINE................24836
MAINTENANCE................24839
GUIDES TO MAINTENANCE................24840
OUTLINES OF SERVICE................24842
HANDLING OIL, FUEL, COOLANT, GREASE AND CARRYING OUT KOWA (Komatsu Oil Wear Analysis)................24842
OIL................24842
FUEL................24842
COOLANT................24843
GREASE................24843
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)................24843
STORING OIL AND FUEL................24844
FILTERS................24844
BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS................24845
OUTLINE OF ELECTRIC SYSTEM................24845
WEAR PARTS................24846
WEAR PARTS LIST................24846
FUEL, COOLANT AND LUBRICANTS................24847
LUBRICATION CHART................24847
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS................24848
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................24851
TORQUE LIST................24851
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................24852
MAINTENANCE SCHEDULE CHART................24853
MAINTENANCE SCHEDULE CHART................24853
SERVICE PROCEDURE................24855
INITIAL 50 HOURS SERVICE................24855
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN................24855
INITIAL 250 HOURS SERVICE................24855
WHEN REQUIRED................24856
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT................24856
DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN................24858
CLEAN INSIDE OF COOLING SYSTEM................24859
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL................24862
CHECK AXLE OIL LEVEL, ADD OIL................24863
CLEAN AXLE CASE BREATHER................24864
CLEAN AIR CONDITIONER CONDENSER................24865
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID................24865
CLEAN RADIATOR FINS AND COOLER FINS................24866
CLEAN TRANSFER OIL COOLER FINS................24867
CHECK ELECTRICAL INTAKE AIR HEATER................24867
REPLACE BOLT ON CUTTING EDGE................24868
REPLACE BUCKET TEETH................24869
CHECK AIR CONDITIONER................24870
REPLACE SLOW BLOW FUSE................24871
SELECTION AND INSPECTION OF TIRES................24872
CHECK BEFORE STARTING................24874
EVERY 50 HOURS SERVICE................24875
DRAIN WATER, SEDIMENT FROM FUEL TANK................24875
EVERY 100 HOURS SERVICE................24876
LUBRICATE REAR AXLE PIVOT PIN................24876
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................24876
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................24877
EVERY 250 HOURS SERVICE................24878
CHECK BATTERY ELECTROLYTE LEVEL................24878
CHECK PARKING BRAKE................24880
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................24880
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN................24881
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER................24882
LUBRICATING................24882
EVERY 500 HOURS SERVICE................24884
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE................24884
REPLACE FUEL FILTER CARTRIDGE................24885
CLEAN WATER SEPARATOR STRAINER................24886
EVERY 1000 HOURS SERVICE................24887
CHANGE OIL IN TRANSFER CASE................24887
CLEAN TRANSFER CASE BREATHER................24888
REPLACE HST OIL FILTER ELEMENT................24889
LUBRICATING................24890
CHECK TIGHTENING PARTS OF TURBOCHARGER................24890
CHECK PLAY OF TURBOCHARGER ROTOR................24890
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT................24890
EVERY 2000 HOURS SERVICE................24891
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT................24891
REPLACE HYDRAULIC TANK BREATHER ELEMENT................24892
CLEANING THE STRAINER OF THE BRAKE FILTER................24893
CHANGE AXLE OIL................24894
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER................24895
CHECK ALTERNATOR, STARTING MOTOR................24895
CHECK ENGINE VALVE CLEARANCE, ADJUST................24895
CHECK BRAKE DISC WEAR................24895
CLEAN AND CHECK TURBOCHARGER................24896
CHECK ACCUMULATOR GAS PRESSURE................24896
CHECK VIBRATION DAMPER................24896
EVERY 4000 HOURS SERVICE................24897
LUBRICATING................24897
CHECK WATER PUMP................24897
TECHNICAL DATA................24899
TECHNICAL DATA................24900
NOISE EMISSION LEVELS................24902
VIBRATION LEVELS................24902
Operating condition:................24902
Guide to Reduce Vibration Levels on Machine................24902
ATTACHMENTS, OPTIONS................24905
SELECTING BUCKET AND TIRES................24906
MACHINE MONITOR WITH LOAD METER................24907
EXPLANATION OF COMPONENTS................24907
MACHINE MONITOR................24907
MONITOR PANEL MODE SELECTOR SWITCH 1................24908
MONITOR PANEL MODE SELECTOR SWITCH 2................24908
LOAD METER CANCEL SWITCH................24908
LOAD METER SUB TOTAL SWITCH................24909
MACHINE MONITOR................24910
MONITOR SYSTEM................24910
TYPES OF WARNING................24911
CENTRAL WARNING LAMP................24911
CHARACTER DISPLAY PORTION................24912
EMERGENCY STOP ITEM................24918
CAUTION ITEMS................24921
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED................24923
INSPECTION AND MAINTENANCE ITEM................24924
PILOT DISPLAY PORTION................24927
METER DISPLAY PORTION................24930
LOAD METER................24932
OTHER FUNCTIONS OF MACHINE MONITOR................24955
HANDLING MULTI-FUNCTION LEVER................24962
EXPLANATION OF COMPONENTS................24962
WORK EQUIPMENT LEVER................24962
DIRECTIONAL SELECTOR SWITCH................24963
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH................24963
DIRECTIONAL SELECTOR PILOT LAMP................24964
OPERATION................24965
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE................24965
CENTRAL LUBRICATION SYSTEM................24967
OPERATING THE CENTRAL LUBRICATION SYSTEM................24967
DISPLAY AND CONTROL UNIT................24967
LED-DISPLAY................24968
PUSHBUTTONS................24968
CHANGING THE LUBRICATION INTERVAL TIMES................24969
INDEX................24971
INDEX................24973
A................24973
C................24973
D................24973
E................24973
F................24973
G................24973
H................24973
I................24973
L................24973
M................24973
N................24973
O................24973
P................24973
R................24974
S................24974
T................24974
U................24974
W................24974
NOTES................24975
NOTES................24976
VEBM450104 - Wheel Loader WA320-3 Shop Manual................24978
Contents................24979
01 General................24986
Dimensions and weights................24988
Specification................24989
Weight table................24992
General view of controls and gauges................24993
Dimensions and weights................24994
Specification................24995
List of lubricant and water................24998
Ountlines of service................25000
General view of controls and gauges................25003
Torque list................25005
10 Structure and function................25006
Power train................25008
Power train system................25009
Toque converter, transmission piping................25011
Transmission hydrqulic system diagram................25012
Torque converter................25014
Torque cnverter oil filter................25016
Transmission................25018
Clutch................25020
Transmission control valve................25030
Transmission solenoid valve................25033
Pilot reducing valve................25034
Main relief valve................25035
Torque converter outlet port valve................25036
Priority valve................25037
Quick return valve................25038
Directional selector valve................25042
H-L selector valve and range selector valve................25043
Emergency manual spool................25045
Modulation valve................25046
Pilot oil filter................25049
Accumulation valve................25050
Drive shaft................25052
Axle................25053
Differential................25055
Final drive................25060
Axle mount, center hinge pin................25061
Steering piping................25064
Steering column, orbit roll................25065
Priority valve................25066
Steering valve (orbit roll)................25070
Cushion valve................25078
2-way restrictor valve................25079
Emergency steering................25080
Brake piping................25090
Brake hydraulic circuit diagram................25091
Brake valve................25092
Accumulation charge valve................25097
Accumulation (for brake)................25101
Brake pressure regulation valve................25111
Accumutator for PPC valve................25113
Brake accumulator unit................25114
Brake................25116
Parking brake control................25118
Parking brake................25119
Parking brake valve................25120
Hydraulic piping................25122
Work equipment hydraulic circuit diagram................25123
Work equipment lever linkage................25133
Hydraulic tank................25134
Oil filter bypass valve................25135
PPC valve................25136
Operation of PPC relief valve................25141
Accumulator (for PPC valve)................25145
Main control valve up to H20343................25146
Relief valve up to H20343................25150
Safety valve with suction up to H20343................25151
Suction valve up to H20343 ................25152
Main control valve from H20344 up to H20710................25153
Safety valve with suction: H20344 and up................25155
Anticavitation valve: H20344 and up................25156
Main control valve:H20711 and up................25157
Operation of cut-off valve up to H20343................25159
Work equipment valve operation................25161
Hydraulic safety system up to H20710................25167
Work equipment linkage................25170
Bucket................25172
Bucket positioner and boom kick-out................25173
Machine monitor system................25180
Main monitor................25181
Maintenance monitor................25185
Transmission auto-shift control function................25187
Transmission controler................25192
E.C.S.S. (ALS-electronic)................25194
Sensors................25204
Engine starting circuit................25209
Etherstart (option)................25210
Engine start/stop/preheating circuit................25211
Ribbon heater: H20561 and up................25213
Electric transmission control................25214
Kick-down/hold switch................25217
Kick-down electric circuit diagram (normal)................25218
Transmission cut-off switch................25223
Transmission cut-off function................25224
Electric parking brake control................25228
Air-conditioner................25230
Wiring diagrams................25284
20 Testing and adjusting................25332
Standard value table for engine................25333
Standard value table for chassis................25335
Standard value table for electrical system................25339
Test certificate WA320-3................25350
Tools for testing and adjusting................25354
Measuring compression pressure................25360
Measuring blow-by pressure................25362
Testing and adjusting fuel injection timing................25364
Measuring exhaust color................25366
Measuring intake air pressure (boost pressure)................25367
Measuring engine oil pressure................25368
Testing the fan belt tension................25369
Measuring acceerator pedal................25370
Basic adjustment of accelerator pedal................25372
Measuring operating force, travel of speed lever................25374
Measuring stall speed................25375
Measuring torque converter, transmission, parking brake pressure................25377
Method of operating emergency manuel spool................25379
Measuring clearance between tire and wheel................25381
Testing and adjusting steering wheel................25382
Measuring steering oil pressure................25384
Measuring operating force, travel of brake pedal................25386
Measuring brake performance................25387
Testing brake oil pressure................25388
Testing for brake disc wear................25389
Bleeding air from brake system................25390
Measuring parking brake performance................25391
Manual release note for parking brake................25392
Testing wear of parking brake disc................25393
Measuring work equipment control lever................25394
Measuring work equipment hydraulic pressure................25396
Measuring PPC valve pressure................25398
Measuring work equipment................25402
Testing and adjusting bucket positioner................25404
Testing and adjusting boom kick-out................25405
Adjusting main monitor (speedometer module)................25407
Gas side test and topping up gas pressure................25408
Hydraulic accumulator................25410
30 Disassembly and assembly................25626
Method of using manual................25628
Precautions when carrying out operation................25629
Special tool list................25631
Sketches of special tools................25633
SDtarting motor................25635
Alternator................25636
Engine oil cooler................25637
Fuel injection pump................25640
Water pump................25646
Turbocharger................25647
Thermostat................25651
Cylinder head................25655
Radiator................25673
Engine................25679
Torque converter charging pump................25684
Torque converter, transmission................25685
Torque converter................25701
Transmission................25705
Transmission clutch pack................25729
Transmission control valve................25747
Transmission accumulator valve................25756
Transmission modulating valve................25758
Drife shaft................25760
Front axle................25764
Rear axle................25767
Differential................25772
Axle housing................25787
Center hinge pin................25802
Priority valve................25811
Steering valve................25813
Steering cylinder................25823
Right brake valve (tandem)................25825
Left brake valve (single)................25827
Parking brake disc................25829
Hydraulic tank................25832
Hydraulic filter................25834
Hydraulic, steerring pump................25835
Main control valve................25842
PPC valve................25850
Bucket cylinder................25854
Boom cylinder................25856
Hydraulic cylinder................25858
Work equipment................25864
Counterweight................25869
Fuel tank................25870
Cab................25873
Main monitor................25875
Maintenance monitor................25877
Air conditioner unit................25878
Air conditrioner condenser................25884
Dry receiver................25886
Air conditioner compressor................25887
40 Maintenance standard................25890
Engine mount, transmission mount................25891
Torque converter charging pump................25892
Torque converter................25893
Transmission................25894
Transmission control valve................25903
Modulation valve assembly................25907
Accumulation valve................25908
Drive shaft................25909
Differential................25910
Final drive................25913
Axle mount................25915
Center hinge pin................25917
Steering column................25919
Priority valve................25920
Steering cylinder mount................25921
Brake................25922
Brake valve................25924
Parking brake................25927
Hydraulic pump................25928
Main control valve................25929
PPC valve................25933
Hydraulic cylinder................25934
Work equipment linkage................25935
Bucket................25937
Bucket positioner and boom kick-out................25938
Komatsu Wheel Loaders WA320 and WA320L Models Repair Service Manual
