Service manual Komatsu WA500-3, WA500-3LE A70001 & Up | CEBM001202

Komatsu WA500-3, WA500-3LE A70001 & Up CEBM001202 (Preview)

MAIN MENU
CONTENTS
01 GENERAL
– DIMENSIONS
– SPECIFICATIONS
– WEIGHT TABLE
– FUEL, COOLANT, AND LUBRICANTS
– ENGINE OIL SPECIFICATIONS
– TRANSMISSION, HYDRAULIC, AND BRAKE OIL
– AXLE OIL SPECIFICATIONS
– GREASE SPECIFICATIONS
– DIESEL FUEL SPECIFICATIONS
– COOLANT SPECIFICATIONS
10 STRUCTURE AND FUNCTION
– GENERAL
– RADIATOR AND OIL COOLER
– DAMPER
– TORQUE CONVERTER AND TRANSMISSION PIPING
– HYDRAULIC CIRCUIT FOR POWER TRAIN
– HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
– TORQUE CONVERTER AND PTO
– TRANSMISSION
– TRANSMISSION CONTROL VALVE
– ECMV (ELECTRONIC CONTROL MODULATION VALVE)
– MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
– LUBRICATING RELIEF VALVE
– TORQUE CONVERTER OIL FILTER
– PILOT FILTER
– TRANSFER
– DRIVE SHAFT
– CENTER SUPPORT
– AXLE
– DIFFERENTIAL
– FINAL DRIVE
– AXLE MOUNT
– CENTER HINGE PIN
– TIRE AND WHEEL
– STEERING PIPING
– ELECTRIC PARKING BRAKE CONTROL
– STEERING COLUMN
– STEERING VALVE
– ORBIT-ROLL VALVE
– STOP VALVE
– DIVERTER VALVE
– BRAKE CIRCUIT DIAGRAM
– BRAKE VALVE
– CHARGE VALVE
– ACCUMULATOR (FOR BRAKE)
– SLACK ADJUSTER
– BRAKE
– PARKING BRAKE CONTROL
– PARKING BRAKE
– PARKING BRAKE SOLENOID VALVE
– PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
– HYDRUALIC CIRCUIT SYSTEM
– WORK EQUIPMENT LEVER LINKAGE
– HYDRAULIC TANK
– ACCUMULATOR (FOR PPC VALVE)
– PPC VALVE
– PPC RELIEF VALVE
– CUT-OFF VALVE
– MAIN CONTROL VALVE
– WORK EQUIPMENT LINKAGE
– BUCKET
– BUCKET POSITIONER AND BOOM KICK-OUT
– PROXIMITY SWITCH
– CAB
– ROPS CANOPY
– AIR CONDITIONER
— AIR CONDITIONER PIPING
— BASIC INFORMATION ON AIR CONDITIONERS
— UNITS RELATED TO REFRIGERATION
— PRINCIPLE OF COOLING
— REFRIGERANTS
— SAFETY PRECAUTIONS
— REFRIGERATOR OIL (LUBE OIL)
– AIR CONDITIONING CONDENSER
— FUNCTION
— GENERAL DESCRIPTION
– AIR CONDITIONER COMPRESSOR
– RECEIVER WITH SIGHT GLASS (LIQUID TANK)
– AIR CONDITIONER UNIT
— OUTLINE
– ELECTRIC CIRCUIT DIAGRAM
– MACHINE MONITOR SYSTEM
– MAIN MONITOR
– MAINTENANCE MONITOR
– ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM
– TRANSMISSION CONTROLLER
– SENSORS
– ENGINE STARTING CIRCUIT
– ENGINE STOP CIRCUIT
– ETHER START CIRCUIT
– ELECTRIC TRANSMISSION CONTROL
– COMBINATION SWITCH
– KICK-DOWN/HOLD SWITCH
– KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS
– ELECTRIC PARKING BRAKE CONTROL
20 TESTING AND ADJUSTING
– STANDARD VALUE TABLE FOR ENGINE – IN CHASSIS
– STANDARD VALUE TABLE FOR CHASSIS
– STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
– SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING
– SKETCHES FOR SPECIAL TOOLS
– MEASURING ENGINE SPEED
— MEASURING INTAKE MANIFOLD PRESSURE
— MEASURING INTAKE AIR RESTRICTION
— MEASURING ENGINE LUBRICATING OIL PRESSURE
— MEASURING FUEL FILTER INLET RESTRICTION
— MEASURING BLOW-BY PRESSURE
— MEASURING EXHAUST BACK PRESSURE
— MEASURING COOLANT TEMPERATURE
— MEASURING AND ADJUSTING VALVE CLEARANCE
– ALTERNATOR DRIVE BELT
– AIR CONDITIONER BELT
– MEASURING EXHAUST TEMPERATURE
– EXHAUST GAS COLOR
– MEASURING ENGINE STALL SPEEDS
– MEASURING TORQUE CONVERTER STALL
– MEASURING HYDRAULIC STALL
– MEASURING FULL STALL
– ADJUSTING ENGINE SPEED SENSOR
– MEASURING SHIFT LEVERS
– MEASURING ACCELERATOR PEDAL
– MEASURING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE
– FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT
– MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
– TESTING AND ADJUSTING STEERING WHEEL
– STEERING OIL PRESSURE
– STEERING STOP VALVE
– MEASURING BRAKE PEDAL
– MEASURING BRAKE PERFORMANCE
– TESTING BRAKE OIL PRESSURE
– MEASURING BRAKE DISC WEAR
– PARKING BRAKE PERFORMANCE
– PARKING BRAKE OIL PRESSURE
– PARKING BRAKE DISC WEAR
– MANUAL RELEASE METHOD FOR PARKING BRAKE
– PPC OIL PRESSURE
– ADJUSTING PPC VALVE LINKAGE
– ACCUMULATOR CHARGE PRESSURE
– WORK EQUIPMENT HYDRAULIC PRESSURE
– RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
– ADJUSTING WORK EQUIPMENT LEVER LINKAGE
– BLEEDING AIR
– BUCKET POSITIONER
– BOOM POSITIONER
– TRANSMISSION CONTROLLER
– ADJUSTING MAIN MONITOR (SPEED MODULE)
– TROUBLESHOOTING
– POINTS TO REMEMBER WHEN TROUBLESHOOTING
– SEQUENCE OF EVENTS IN TROUBLESHOOTING
– POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
– CHECKS BEFORE TROUBLESHOOTING
– HANDLING CONNECTORS
— PRECAUTIONS WHEN TROUBLESHOOTING
— METHOD OF READING ROUBLESHOOTING TABLES
– PREVENTING RECURRENCE OF TROUBLE
– CONNECTOR TYPES AND MOUNTING LOCATIONS
– CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
– EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANIS
— TRANSMISSION CONTROL SYSTEM
— MAIN MONITOR SYSTEM
— MAINTENANCE MONITOR SYSTEM
— ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) CONTROL SYSTEM
— JOYSTICK STEERING CONTROL SYSTEM
— METHOD OF DISPLAYING ACTION AND FIALURE CODE
— CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION
— TRANSMISSION CONTROLLER LED DISPLAY
– METHOD OF USING JUDGEMENT TABLE
– METHOD OF USING JUDGEMENT CHARTS
– METHOD OF USING MATRIX TROUBLESHOOTING TABLES
– TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)
— JUDGMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
— ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEM ON MACHINE
— ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
— T-1 FAILURE CODE [10](SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP RELAY) IS DISPLAYED
— T-2 FAILURE CODE [12](SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED
— T-3 FAILURE CODE [13](SHORT CIRCUIT, DISCONNECTIONS, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED
— T-4 FAILURE CODE [14] (SHORT CIRUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED
— T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED
— T-6 FAILURE CODE [16](SHORT CIRUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED
— T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOUCE IN 4TH SOLENOID) IS DISPLAYED
— T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
— T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
— T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH
— T-11 FAILURE CODE [22](DISCONNECTIONS IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED
— T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
— T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED
— T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED
— T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMC FILL SWITCH SYSTEM) IS DISPLAYED
— T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
— T-23 HOLD SWITCH SYSTEM
— T-24 KICK-DOWN SWITCH SYSTEM
— T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM
— T-26 NEUTRALIZER RELAY SIGNAL SYSTEM
— T-27 BUZZER SIGNAL SYSTEM
— T-28 NETWORK SYSTEM
— T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM
— T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
— T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM
— T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM
— T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM
— T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM
— T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM
— T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM
— T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM
– TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
— TROUBLE DATA DISPLAY
— ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM
— M-1 MAIN MONITOR DOES NOT WORK
— M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP
— M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
— M-4 ABNORMALITY IN SHIFT INDICATOR
— A) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F
— B) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R
— C) DOES NOT DISPLAY N WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F
— D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R
— E) DOES NOT DISPLAY 1ST-4TH
— M-5 HIGH BEAM DOES NOT LIGHT UP
— M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
— A) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP
— B) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP
— M-7 ABNORMALITY IN PARKING DISPLAY
— A) PARKING LAMP DISPLAY DOES NOT LIGHT UP
— B) PARKING LAMP DISPLAY STAYS LIGHTED UP
— M-9 NIGHT LIGHTING DOES NOT LIGHT UP
— M-10 ABNORMALITY IN FRONT WORKING LAMP
— A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP
— B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
— C) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP
— M-11 ABNORMALITY IN REAR WORKING LAMP
— A) NEIGHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
— B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
— C) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP
— M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
— A) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE
— B) WHEN MONITOR SWITCH IS OFF MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED
— C) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED
— D) CUT-OFF FUNCTION IS ALWAYS ACTUATE REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)
— E) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED
— M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
— A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N
— B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP
— M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED
— A) ACTUATED CONTINUOUSLY
— B) NOT ACTUATED
— M-15 ABNORMALITY IN BUZZER
— A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS)(DURING SELF-CHECK)
— B) BUZZER ALWAYS SOUNDS
— M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY
— M-17 ABNORMALITY IN FAILURE DISPLAY MODE
— A) DOES NOT ENTER FAILURE DISPLAY MODE
— B) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE
— M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER
— M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY
— A) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP
— B) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP
— M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY
— M-21 ABNORMALITY IN AUTO-GREASING SYSTEM
— A) FORCED GREASING CANNOT BE CARRIED OUT
— B) MONITOR DISPLAY FLASHES RAPIDLY (2 TIME/SEC)
— C) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)
— D) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY
— E) MONITOR DISPLAY GOES OUT
— M-22 ABNORMALITY IN ECSS SYSTEM
— A) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED
— B) MONITOR DISPLAY LIGHT UP BUT ECSS FUNCIOTN DOES NOT WORK
— M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR ( ABNORMALITY IN NETWORK
– TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
— ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
— K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC, MAINTENANCE MONITOR DOES NOT
— A) NO LAMPS ON MAINTENANCE MONITOR DOES NOT WORK
— B) SOME LAMPS DO NOT LIGHT UP
— K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)
— K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNE ON (WITHIN 3 SECS), NO LAMPS ON MAINTENANCE MONITOR GO OUT
— K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH
— A) ENGINE OIL LEVEL DISPLAY FLASHES
— B) ENGINE WATER LEVEL DISPLAY FLASHES
— K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH
— A) ENGINE OIL PRESSURE DISPLAY FLASHES
— B) BATTERY CHARGE LEVEL DISPLAY FLASHES
— C) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE OIL PRESSURE IS CORRECT)
— D) AIR CLEANER DISPLAY FLASHES
— K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND
— K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS
— K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH
— A) CHECK LAMP
— B) CAUTION LAMP
— K-9 THERE IS NO ABNORMALITY IN MAINTENANCEMONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP
— A) CHECK LAMP
— B) CAUTION LAMP
— K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)
— K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF NIGHT LIGHTING STAYS LIGHTED UP
— K-12 SERVICE METER DOES NOT WORK
— K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED
— K-14 ABNORMALITY IN GAUGE ITEMS
— A) ABNORMALITY IN FUEL GAUGE
— B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
— C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
– TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
— ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING/STOP SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
— E-1 ENGINE DOES NOT START
— A) ENGINE DOES NOT START
— B) STARTING MOTOR TURNS
— E-2 ENGINE DOES NOT STOP
— E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING
— E-4 NOT USED
— E-5 PARKING BRAKE DOES NOT HAVE EFFECT
— A) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (ACTUATED)
— B) PARKING BRAKE HAS NOT EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKES)
— E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
— E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON
— E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)
— E-9 KICK-DOWN SWITCH DOES NOT WORK
— A) KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)
— B) KICK-DOWN IS NOT CANCELED
— E-10 BOOM KICK-OUT CANNOT BE USED
— E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION
— E-12 ABNORALITY IN LIGHTING UP OF FRONT WORKING LAMP
— E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP
— E-14 ABNORMALITY IN TRANSMISSION CUT-OFF
— E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
— E-16 ABNORMALITY IN BUZZER
– TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
— POWER TRAIN
— H-1 MACHINE DOES NOT START
— H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES, DOES NOT SHIFT GEAR
— H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE ARE SHIFTING GEAR
— H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OF SHIFTING GEAR
— H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
— STEERING SYSTEM
— H-6 STEERING WHEEL DOES NOT TURN
— H-7 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]
— H-8 TURNING, RESPONSE OF STEERING IS POOR
— H-9 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]
— H-10 STEERING IS HEAVY
— H-11 JOYSTICK STEERING IS HEAVY
— H-12 STEERING WHEEL SHAKES OR JERKS
— H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK)
— H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING
— BRAKE SYSTEM
— H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
— H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
— H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR
— H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)
— WORK EQUIPMENT
— H-19 NEITHER BOOM NOR BUCKET MOVE
— H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER
— H-21 BOOM DOES NOT MOVE
— H-22 NOT USED
— H-23 BOOM IS SLOW OR BOOM LACKS POWER
— H-24 NOT USED
— H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT
— H-27 NOT USED
— H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM
— H-29 BUCKET DOES NOT MOVE
— H-30 BUCKET IS SLOW OR LACKS POWER
— H-31 EXCESSIVE HYDRUALIC DRIFT OF BUCKET
— H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]
– TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE)
— JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
— D-1 ECSS DOES NOT WORK
— A) ERROR CODE [D0] IS DISPLAYED
— B) ERROR CODE [D1] IS DISPLAYED
— C) ERROR CODE [D2] IS DISPLAYED
— D) ERROR CODE [D3] IS DISPLAYED
— E) NO ABNORMALITY DISPLAY IS GIVEN
— D-2 ECSS CANNOT BE CANCELED
– TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)
— JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS
— ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
— ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
— J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION DISPLAY OUTPUT) IS DISPLAYED
— J-2 FAILURE CODE [57](SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
— J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
— J-4 FAILURE CODE [59](SHORT CIRUIT IN STEERING RIGHT SOLENOID (HOT END) IS DISPLAYED
— J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED
— J-6 FAILURE CODE [61](SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED
— J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IS JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED
— J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMTER SYSTEM) IS DISPLAYED (NOT USED)
— J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE
— J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM
— J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
— J-12 DISCONNECTION IN STEERING LEFT SOLENOID
– TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE)
— ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
— C-1 WHEN ENGINE IS RUNNING, ENGINE OIL LEVEL DISPLAY SHOWS ‘ABNORMAL”
— C-2 WHEN ENGINE IS RUNNING, BATTERY ELECTROLYTE LEVEL DISPLAY SHOWS ” ABNORMAL”
— C-3 ABNORMALITY IN ENGINE COOLANT LEVEL DISPLAY
— A) DISPLAY SHOWS “ABNORMAL”
— B) DISPLAY SHOWS “DISCONNECTION”
— C) DISPLAY SHOWS “SHORT CIRCUIT”
— C-4 ABNORMALITY IN BRAKE OIL PRESSURE DISPLAY
— A) WHEN ENGINE IS RUNNING, DISPLAY SHOWS “ABNORMAL”
— B) DISPLAY SHOWS “DISCONNECTION”
— C) DISPLAY SHOWS “SHORT CIRCUIT”
— C-5 ABNORMALITY IN ENGINE OIL PRESSURE DISPLAY
— A) WHEN ENGINE IS RUNNING, DISPLAY SHOWS “ABNORMAL”
— B) WHEN ENGINE IS STOPPED OR RUNNING, DISPLAY SHOWS “DISCONNECTION”
— C) ONLY WHEN ENGINE IS STOPPED, DISPLAY SHOWS “DISCONNECTION”
— D) DISPLAY SHOWS “SHORT CIRCUIT”
— C-6 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), BATTERY CHARGE DISPLAY SHOWS “ABNORMAL”
— C-7 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), AIR CLEANER DISPLAY SHOWS “ABNORMAL”
— C-8 CAUTION ITEM DISPLAY SHOWS “ABNORMAL”, BUT ALARM BUZZER DOES NOT SOUND
— C-9 MONITOR DISPLAY DOES NOT SHOW “ABNORMAL”, BUT ALARM BUZZER SOUNDS
— C-10 CAUTION ITEM DISPLAY SHOWS “ABNORMAL,” BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH
— A) CHECK LAMP
— B) CAUTION LAMP
— C-11 MONITOR DISPLAY DOES NOT SHOW ANY ABNORMALITY, BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP
— A) CHECK LAMP
— B) CAUTION LAMP
— C-12 SERVICE METER DOES NOT WORK
— C-13 SERVICE METER IS RUNNING WHEN ENGINE IS STOPPED
— C-14 ABNORMALITY IN FUEL GAUGE
— A) DISPLAY SHOWS “DISCONNECTION” OF LOW FUEL LEVEL
— B) DISPLAY ALWAYS SHOWS FULL AND DOES NOT GO DOWN
— C-15 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
— A) DISPLAY SHOWS “SHORT CIRCUIT”
— B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE
— C-16 ABNORMILITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
— A) DISPLAY SHOWS “SHORT CIRCUIT”
— B) DISPLAY ALWAYS SHOWS LOWEST LEVEL AND DOES NOT GO UP
— C-17 WHEN STARTING SWITCH IS TURNED TO ON, MONITOR IS NOT ACTUATED (KOMATSU IS NOT DISPLAYED)
— A) MAIN MONITOR CHECK LAMPS DO NOT LIGHT UP
— B) MAIN MONITOR CHECK LAMPS LIGHT UP
— C-18 DOES NOT SWITCH TO WORKING MEMORY (ENGINE RUNNING) MODE, OR SWITCHES TO CHECK BEFORE STARTING MODE WHEN ENGINE IS RUNNING
— C-19 ABNORMALITY IN MDC MONITOR DISPLAY
— A) DISPLAY COLOR IS NORMAL
— B) DISPLAY FLICKERS
— C-20 EVEN WHEN SWITCH IS OPERATED, NOTHING FUNCTIONS
— C-21 DOES NOT SWITCH TO TV/VIDEO MODE
— A) STAYS AT PARKING BRAKE APPLIED DISPLAY
— B) DISPLAY DOES NOT LIGHT UP
— C-22 ABNORMALITY IN MEMORY DATA
— A) LOAD METER DATA IS NOT SAVED TO MEMORY
— B) MAINTENANCE TIME IS NOT SAVED TO MEMORY
— C-23 ENGINE SPEED STAY AT 0 RPM
— C-24 PRESSURE SENSOR DISPLAY SHOWS “DISCONNECTION”
— A) SENSOR POWER SOURCE DISPLAY SHOWS “ABNORMAL”
— B) ONLY PRESSURE SENSOR DISPLAY SHOWS “DISCONNECTION”
— C-25 LOAD METER CANNOT WEIGH LOAD
— A) CANNOT CARRY OUT CALIBRATION
— B) CAN CARRY OUT CALIBRATION
— C-26 ABNORMALITY IS LEVER SWITCH
— A) SUB-TOTAL SWITCH DOES NOT WORK
— B) CANCEL SWITCH DOES NOT WORK
— C-27 PRINTER DOES NOT PRINT OUT
— C-28 ABNORMALITY IN ANTENNA SYSTEM
— C-29 ABNORMALITY IN SPEAKER SYSTEM
— A) ABNORMALITY IN RIGHT SPEAKER
— B) ABNORMALITY IN LEFT SPEAKER
– TROUBLESHOOTING AIR CONDITIONING
— AIR CONDITIONER/HEATER (DENSO)
— VISUAL AND AUDIBLE INSPECTION
— TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)
— TROUBLESHOOTING THE ELECTRICAL CIRCUIT
— COOLER CIRCUIT TROUBLESHOOTING
— WIRING DIAGRAM
30 DISASSEMBLY AND ASSEMBLY
– PRECAUTIONS WHEN CARRYING OUT OPERATIONS
– SPECIAL TOOL LIST
– SKETCHES OF SPECIAL TOOLS
– STARTING MOTOR ASSEMBLY
— REMOVAL
— INSTALLATION
– ALTERNATOR ASSEMBLY
— REMOVAL
— INSTALLATION
– ENGINE OIL COOLER
— REMOVAL
— INSTALLATION
– FUEL INJECTION PUMP ASSEMBLY
— REMOVAL
— INSTALLATION
– WATER PUMP ASSEMBLY
— REMOVAL
— INSTALLATION
– INJECTOR ASSEMBLY
— REMOVAL
— INSTALLATION
– TURBOCHARGER ASSEMBLY
— REMOVAL
— INSTALLATION
– AFTER COOLER ASSEMBLY
— REMOVAL
— INSTALLATION
– CYLINDER HEAD ASSEMBLY
— REMOVAL
— INSTALLATION
– RADIATOR ASSEMBLY
— REMOVAL
— INSTALLATION
– DAMPER ASSEMBLY
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– TORQUE CONVERTER AND TRANSMISSION
— REMOVAL
— INSTALLATION
— DISCONNECTION
— CONNECTION
– TORQUE CONVERTER ASSEMBLY
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION ASSEMBLY
— DISASSEMBLY
— ASSEMBLY
– TRANSFER ASSEMBLY
— DISASSEMBLY
— ASSEMBLY
– PARKING BRAKE ASSEMBLY
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY)
— REMOVAL
— INSTALLATION
– CENTER SUPPORT ASSEMBLY
— REMOVAL
— DISASSEMBLY
— ASSEMBLY
– DISASSEMBLY OF DRIVE SHAFT
– ASSEMBLY OF DRIVE SHAFT
– REMOVAL OF FRONT AXLE ASSEMBLY
– INSTALLATION OF FRONT AXLE ASSEMBLY
– REMOVAL OF FRONT DIFFERENTIAL ASSEMBLY
– INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY
– REMOVAL OF REAR AXLE ASSEMBLY
– INSTALLATION OF REAR AXLE ASSEMBLY
– REMOVAL OF REAR DIFFERENTIAL ASSEMBLY
– INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY
– DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
– FINE DISASSEMBLY OF PINION ASSEMBLY
– FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
– FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
– FINE ASSEMBLY OF PINION ASSEMBLY
– ASSEMBLY OF DIFFERENTIAL ASSEMBLY
– DISASSEMBLY OF FINAL DRIVE ASSEMBLY
– ASSEMBLY OF FINAL DRIVE ASSEMBLY
– REMOVAL OF ORBIT ROLL ASSEMBLY
– INSTALLATION OF ORBIT-ROLL ASSEMBLY
– DISASSEMBLY OF ORBIT-ROLL ASSEMBLY
– ASSEMBLY OF ORBIT-ROLL ASSEMBLY
– REMOVAL OF STEERING CYLINDER ASSEMBLY
– INSTALLATION OF STEERING CYLINDER ASSEMBLY
– DISASSEMBLY OF STEERING CYLINDER ASSEMBLY
– ASSEMBLY OF STEERING CYLINDER ASSEMBLY
– REMOVAL OF STEERING VALVE ASSEMBLY
– INSTALLATION OF STEERING VALVE ASSEMBLY
– REMOVAL OF BRAKE VALVE ASSEMBLY
– INSTALLATION OF BRAKE VALVE ASSEMBLY
– REMOVAL OF SLACK ADJUSTER ASSEMBLY
– INSTALLATION OF SLACK ADJUSTER ASSEMBLY
– DISASSEMBLY OF SLACK ADJUSTER
– ASSEMBLY OF SLACK ADJUSTER
– REMOVAL OF BRAKE ASSEMBLY (FRONT, REAR)
– INSTALLATION OF BRAKE ASSEMBLY (FRONT, REAR)
– DISASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR)
– ASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR)
– REMOVAL OF HYDRAULIC PUMP (SWITCH & PPC, LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY
– INSTALLATION OF HYDRAULIC PUMP (SWITCH & PPC LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY
– REMOVAL OF HYDRAULIC TANK ASSEMBLY
– INSTALLATION OF HYDRAULIC TANK ASSEMBLY
– REMOVAL OF HYDRAULIC FILTER ASSEMBLY
– INSTALLATION OF HYDRAULIC FILTER ASSEMBLY
– REMOVAL OF PPC VALVE ASSEMBLY
– INSTALLATION OF PPC VALVE ASSEMBLY
– DISASSEMBLY OF PPC VALVE ASSEMBLY
– ASSEMBLY OF PPC VALVE ASSEMBLY
– REMOVAL OF MAIN CONTROL VALVE ASSEMBLY
– INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY
– ASSEMBLY OF MAIN CONTROL VALVE
– REMOVAL OF BUCKET CYLINDER ASSEMBLY
– INSTALLATION OF BUCKET CYLINDER ASSEMBLY
– REMOVAL OF BOOM CYLINDER ASSEMBLY
– INSTALLATION OF BOOM CYLINDER ASSEMBLY
– DISASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY
– ASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY
– REMOVAL OF CENTER HINGE PIN
– INSTALLATION OF CENTER HINGE PIN
– REMOVAL OF WORK EQUIPMENT
– INSTALLATION OF WORK EQUIPMENT ASSEMBLY
– REMOVAL OF BULKHEAD ASSEMBLY
– INSTALLATION OF BULKHEAD ASSEMBLY
– REMOVAL OF ENGINE HOOD ASSEMBLY
– INSTALLATION OF ENGINE HOOD ASSEMBLY
– REMOVAL OF FLOOR FRAME ASSEMBLY
– INSTALLATION OF FLOOR FRAME ASSEMBLY
– REMOVAL OF COUNTERWEIGHT
– INSTALLATION OF COUNTERWEIGHT
– REMOVAL OF FUEL TANK ASSEMBLY
– INSTALLATION OF FUEL TANK ASSEMBLY
– REMOVAL OF CAB ASSEMBLY
– INSTALLATION OF CAB ASSEMBLY
– REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY
– INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
– REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY
– INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY
– REMOVAL OF RECEIVER TANK
– INSTALLATION OF RECEIVER TANK
– REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY
– INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY
40 MAINTENANCE STANDARD
– ENGINE MOUNT
– TRANSMISSION MOUNT
– TORQUE CONVERTER CHARGING PUMP
– DAMPER
– TORQUE CONVERTER AND PTO
– TRANSMISSION
– TRANSFER
– MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
– LUBRICATION RELIEF VALVE
– DRIVE SHAFT
– CENTER SUPPORT
– DIFFERENTIAL
– FINAL DRIVE
– AXLE MOUNT
– CENTER HINGE PIN
– STEERING COLUMN
– STEERING PUMP
– STEERING VALVE
– STEERING CYLINDER MOUNT
– BRAKE VALVE
– SLACK ADJUSTER
– BRAKE
– PARKING BRAKE
– HYDRAULIC PUMP
– SWITCH AND PPC PUMP
– PPC VALVE
– CUT-OFF VALVE
– MAIN CONTROL VALVE
– HYDRAULIC CYLINDERS
– BUCKET LINKAGE
– BUCKET
– BUCKET POSITIONER AND BOOM KICK-OUT
– ROPS CAB