Service manual Komatsu WA600-3, WA600-3D 50001 & Up | SEBM013218

Komatsu WA600-3, WA600-3D 50001 & Up SEBM013218 (Preview)

COVER
CONTENTS
01 GENERAL
– GENERAL ASSEMBLY DRAWING
– SPECIFICATIONS
– WEIGHT TABLE
– LIST OF LUBRICANT AND COOLANT
10 STRUCTURE AND FUNCTION
– POWER TRAIN
– POWER TRAIN SYSTEM
– RADIATOR,HYDRAULIC OIL COOLER
– RADIATOR, HYDRAULIC OIL COOLER (WITH SUCTION FAN)
– TORQUE CONVERTER AND TRANSMISSION PIPING
– HYDRAULIC CIRCUIT FOR POWER TRAIN
– HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
– TORQUE CONVERTER
– TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)
– TRANSMISSION
– TRANSMISSION CONTROL VALVE
– TORQUE CONVERTER OIL COOLER
– TORQUE CONVERTER OIL FILTER
– TRANSFER
– DRIVE SHAFT
– CENTER SUPPORT
– AXLE
– DIFFERENTIAL
– LIMITED SLIP DIFFERENTIAL(OP)
– FINAL DRIVE
– AXLE MOUNT
– CENTER HINGE PIN
– STEERING PIPING
– STEERING COLUMN
– STEERING UNIT (ORBIT-ROLL VAVLE)
– STEERING VALVE
– TWO-WAY RESTRICTION VALVE
– STOP VALVE
– EMERGENCY STEERING PIPING
– DIVERTER VALVE (FOR EMERGENCY STEERING)
– BRAKE PIPING
– BRAKE CIRCUIT DIAGRAM
– BRAKE VALVE
– CHARGE VALVE
– ACCUMULATOR (FOR BRAKE)
– SLACK ADJUSTER
– BRAKE
– PARKING BRAKE
– SPRING CYLINDER
– PARKING BRAKE SOLENOID VALVE
– HYDRAULIC PIPING
– WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
– WORK EQUIPMENT LEVER LINKAGE
– HYDRAULIC TANK
– ACCUMULATOR (FOR PPC VALVE)
– PPC VALVE
– PPC RELIEF VALVE
– CUT-OFF VALVE
– MAIN CONTROL VALVE
– AUTO GREASE SYSTEM
– LUBRICATION OF WORK EQUIPMENT
– WORK EQUIPMENT LINKAGE
– BUCKET
– BUCKET POSITIONER AND BOOM KICK-OUT
– OPERATION OF PROXIMITY SWITCH
– ROPS CANOPY
– CAB
– CAR HEATER
– AIR CONDITIONER
– ELECTRIC CIRCUIT DIAGRAM
– MACHINE MONITOR SYSTEM
– MAIN MONITOR
– MANITENANCE MONITOR
– MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL
– ENGINE STARTING CIRCUIT
– ENGINE STOP CIRCUIT
– AUTO PRIMING SYSTEM (APS) (SERIAL NO.:50001-52000)
– PRE-HEATING CIRCUIT (SERIAL NO.:52001 AND UP)
– ELECTRIC TRANSMISSION CONTROL
– KICK-DOWN,HOLD SWITCH
– KICK-DOWN ELECTRICAL CIRCUIT
– ELECTRIC PARKING BRAKE CONTROL
– E.C.S.S.(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)
20 TESTING AND ADJUSTING
– STANDARD VALUE TABLE FOR ENGINE
– STANDARD VALUE TABLE FOR CHASSIS
– STANDARD VALUE TABLE FOR ELECTRICAL PARTS
– TESTING AND ADJUSTING
— TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
— MEASURING ENGINE SPEED
— MEASURING EXHAUST GAS COLOR
— ADJUSTING VALVE CLEARANCE
— TESTING AND ADJUSTING INJECTOR LIFT (SERIAL NO.:52001 AND UP)
— MEASURING COMPRESSION PRESSURE
— MEASURING BLOW-BY PRESSURE
— MEASURING ENGINE OIL PRESSURE
— TESTING AND ADJUSTING FUEL INJECTON TIMING (SERIAL NO.:50001-52000)
— REPLACING FAN BELT ADJUSTING AUTO-TENSIONER
— TESTING AND ADJUSTING ALTERNATOR BELT TENSION
— TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
— HANDLING EQUIPMENT IN FUEL CIRCUIT (SERIAL NO.:52001 AND UP)
— MEASURING FUEL PUMP OUTPUT PORT PRESSURE (SERIAL NO.:52001 AND UP)
— BLEEDING AIR FROM FUEL CIRCUIT (SERIAL NO.:52001 AND UP)
— MEASURING EXHAUST TEMPERATURE
— MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
— ADJUSTING SPEED SENSOR
— ADJUSTIN FUEL CONTROL CABLE (SERIAL NO.:50001-52000)
— METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.:50001-52000)
— TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE
— PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT
— PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
— TESTING AND ADJUSTING STEERING OIL PRESSURE
— TESTING AND ADJUSTING STEERING STOP VALVE
— TESTING BRAKE OIL PRESSURE
— MEASURING WEAR OF BRAKE DISC
— MEASURING BRAKE PERFORMANCE
— TESTING AND ADJUSTING PARKING BRAKE
— TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE
— TESTING AND ADJUSTING PPC OIL PRESSURE
— MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
— ADJUSTING WORK EQUIPMENT LEVER LINKAGE
— TESTING AND ADJUSTING OF BUCKET POSITIONER
— TESTING AND ADJUSTING OF BOOM KICK-OUT
— TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP
— ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
— BLEEDING AIR
— RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
– TROUBLESHOOTING
— POINTS TO REMEMBER WHEN TROUBLESHOOTING
— SEQUENCE OF EVENTS IN TROUBLESHOOTING
— POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
— CHECKS BEFORE TROUBLESHOOTING
— CONNECTOR TYPES AND MOUNTING LOCATIONS
— CONNECTOR ARRANGEMENT DIAGRAM
— CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
— METHOD OF USING TROUBLESHOOTING CHARTS
— METHOD OF USING MATRIX TROUBLESHOOTING TABLES
— TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
— METHOD OF USING TROUBLESHOOTING CHART
— S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)
— S-2 ENGINE DOES NOT START
—- (1) ENGINE DOES NOT TURN
—- (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
—- (3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
— S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)
— S-4 ENGINE STOPS DURING OPERATIONS
— S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
— S-6 ENGINE LACKS OUTPUT
— S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
— S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
— S-9 OIL BECOMES CONTAMINATED QUICKLY
— S-10 FUEL CONSUMPTION IS EXCESSIVE
— S-11 OIL IS COOLING, OR COOLANT SPURTS BACK,OR COOLANT LEVEL GOES DOWN
— S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
— S-13 OIL LEVEL RISES
— S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
— S-15 ABNORMAL NOISE IS MADE
— S-16 VIBRATION IS EXCESSIVE
— TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE)
— METHOD OF ERROR CODE DISPLAY
— ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED
— SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM
— EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)
— EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)
— EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)
— EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)
— EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)
— EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)
— EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)
— EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)
— EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)
— EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)
— EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)
— EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)
— EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL)
— EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIHG LEVEL)
— EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)
— EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))
— EA-17 ERROR CODE [144] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM HIGH LEVEL)
— EA-18 ERROR CODE [145] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM LOW LEVEL)
— EA-19 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)
— EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)
— EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMERATURE SENSOR SYSTEM LOW LEVEL)
— EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)
— EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)
— EA-24 ERROR CODE [234] (OVERSPEED)
— EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)
— EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)
— EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)
— EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL)
— EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)
— EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)
— EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)
— EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)
— EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)
— EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)
— EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))
— EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)
— EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)
— EA-38 ERROR CODE [432] (IDLE VALIDATION PROCESS ERROR)
— EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL)
— EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)
— EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)
— EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)
— EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)
— EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
— EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)
— EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)
— EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)
— EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLE VALIDATION SWITCH SYSTEM)
— EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)
— TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
— ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR
— ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
— 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 DIRCETIONAL LEVER IS AT F
—- b) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT R
—- c) DOES NOT DISPLAY N EVEN WHEN DIRCETIONAL LEVER IS AT N
—- d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST
—- e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND
—- f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD
—- g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH
— M-5 HIGH BEAM DISPLAY 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 LAMP DISPLAY
—- a) PARKING LAMP DISPLAY DOES NOT LIGHT UP
—- b) PARKING LAMP DISPLAY STAYS LIGHTED UP
— M-8 ABNORMALITY IN PREHEATING DISPLAY
—- a) PREHEATIGN DISPLAY DOES NOT LIGHT UP
—- b) PREHEATIGN DISPLAY STAYS LIGHTED UP
— M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP
— M-10 ABNORMALITY IN FRONT WORKING LAMP
—- a) NEITHER MONITOR DISPLAY NOR FRONT WORKIGN LAMP LIGHT UP
—- b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
—- c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP
— M-11 ABNORMALITY IN REAR WORKIGN LAMP
—- a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
—- b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
—- c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP
— M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
—- a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE
—- b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED
—- c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED
— M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN
—- a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AN N
—- b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRCETIONAL LEVER IS AT POSITION OTHER THAN N
— 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 FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON
—- b) BUZZER ALWAYS SOUNDS
— M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY
— M-17 ABNORMALITY IN FAILURE DISPLAY MODE
—- a) FAILURE DISPLAY MODE DOES NOT WORK
—- b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE
— M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY
—- a) EMERGENCY STEERING DISPLAY DOES NOT FLASH
—- b) EMERGENCY STEERING DISPLAY STAYS FLASHED
— M-19 ABNORMALITY IN AUTO-GREASING SYSTEM
—- a) FORCED GREASING CANNOT BE CARRIED OUT
—- b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)
—- c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES REPIDLY (2 TIMES/SEC)
—- d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)
—- e) MONITOR DISPLAY GOES OUT
— M-20 ABNORMALITY IN ECSS SYSTEM
—- a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED
—- b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK
— M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)
— TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
— ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR
— K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SCONDS,MAINTENANCE MONITOR DOES NOT WORK
—- a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP
—- 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 SCONDS
— K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTIGN SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT
— K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES
—- a) ENGINE OIL LEVEL DISPLAY FLASHES
—- b) ENGINE COOLANT LEVEL DISPLAY FLASHES
— K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES
—- a) ENGINE OIL PRESSURE DISPLAY FLASHES
—- b) BATTERY CHARGE DISPLAY FLASHES
—- c) BRAKE OIL PRESSURE DISPLAY FLASHES
—- d) AIR CLEANER CLOGGED DISPLAY FLASHES
— K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND
— K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS
— K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH
—- a) CHECK LAMP
—- b) CAUTION LAMP
— K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP
—- a) CHECK LAMP
—- b) CAUTION LAMP
— K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON
— K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF
— K-12 SERVICE METER DOES NOT WORK
— K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED
— K-14 ABNORMALITY IN GAUGES
—- a) ABNORMALITY IN FUEL GAUGE
—- b) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE
—- c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
— TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
— ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM
— ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE
— ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
— ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER
— E-1 ENGINE DOES NOT START
—- a) STARTING MOTOR DOES NOT TURN
—- b) STARTING MOTOR TURNS
— E-2 ENGINE DOES NOT STOP (SERIAL NO.:50001-52000)
— E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (SERIAL NO.:50001-52000)
— E-4A ABNORMALITY IN APS SYSTEM (SERIAL NO.:50001-52000)
—- a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP
—- b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL
—- c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL
—- d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
—- e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
—- f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
—- g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
—- h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
—- i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
—- j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP
— E-4B PREHEATING FAULT (SERIAL NO.:52001 AND UP)
— E-5 PARKING BRAKE DOES NOT HAVE EFFECT
—- a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON
—- b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS
— 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 TRANSMISSION DOES NOT WORK PROPELY
—- a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT
—- b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT
—- c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT
—- d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRCETIONAL SOLENOID CIRCUIT
—- e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT
—- f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT
— E-10 KICK-DOWN SWITCH DOES NOT WORK
— E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON
— E-12 KICK-DOWN ALWAYS WORKS
— E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND
— E-14 BOOM KICK-OUT DOES NOT WORK
— E-15 DEFECTIVE BUCKET POSITIONER
— E-16 POWER WINDOW DOES NOT WORK
—- a) POWER WINDOW DOES NOT RISE
—- b) POWER WINDOW DOES NOT LOWER
— E-17 ABNORMALITY IN FRONT WORKING LAMP
— E-18 ABNORMALITY IN REAR WORKING LAMP
— E-19 ABNORMALITY IN TRANSMISSION CUT-OFF
— E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
— E-21 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,OR LACKS POWER IN ALL SPEED RANGES
—- H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
—- H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
— STEERING SYSTEM
—- H-5 STEERING WHEEL DOES NOT TURN
—- H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]
—- H-7 TURNING,RESPONSE OF STEERING IS POOR
—- H-8 TURNING,RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]
—- H-9 STEERING IS HEAVY
—- H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]
—- H-11 STEERING WHEEL SHAKES OR JERKS
—- H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]
—- H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING
— BRAKE SYSTEM
—- H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
—- H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
—- H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR
—- H-17 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)
— WORK EQUIPMENT
—- H-18 NEITHER LIFT ARM NOR BUCKET MOVE
—- H-19 BOTH LIFT ARM AND BUCKET ARE SLOW OR LACK POWER
—- H-20 LIFT ARM DOES NOT MOVE
—- H-21 LIFT ARM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]
—- H-22 LIFT ARM IS SLOW OR BOOM LACKS POWER
—- H-23 LIFT ARM IS SLOW OR BOOM LACKS POWER [MACHINES WITH REMOTE BOOM CONTROL]
—- H-24 LIFT ARM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT
—- H-25 LIFT ARM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE
—- H-26 REMOTE LIFT ARM CONTROL DOES NOT WORK [MACHINES WITH REMOTE BOOM CONTROL]
—- H-27 EXCESSIVE HYDRAULIC DRIFT OF LIFT ARM
—- H-28 BUCKET DOES NOT MOVE
—- H-29 BUCKET IS SLOW OR LACKS POWER
—- H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET
—- H-31 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]
— TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)
— METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
— JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM
— ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE
— ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM
— T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED
— T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED
— T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED
— T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED
— T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED
— T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED
— T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY 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 SHIFT SWITCH SYSTEM)IS DISPLAYED
— T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED
— T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED
— T-13 SHIFT-UP DOES NOT WORK
— T-14 SHIFT-DOWN DOES NOT WORK
— T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING
— T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING
— T-17 BUZZER DOES NOT WORK
— T-18 ABNORMALITY IN NETWORK SYSTEM
— T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY
— T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
— T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS
— TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)
— JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM
— ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
— ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM
— J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED
— J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED
— J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED
— J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED
— J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED
— J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED
— J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED
— J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED
— J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE
— J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT
— J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
— J-12 DISCONNECTION IN STEERING LEFT SOLENOID
— TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)
— ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
— 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) ERROR CODE [d4] IS DISPLAYED
—- f) ERROR CODE [d5] IS DISPLAYED
—- g) ERROR CODE [d6] IS DISPLAYED
—- h) NO ABNORMALITY DISPLAY IS GIVEN
— D-2 ECSS CANNOT BE CANCELED
30 DISASSEMBLY AND ASSEMBLY
– METHOD OF USING MANUAL
– PRECAUTIONS WHEN CARRYING OUT OPERATION
– SPECIAL TOOL LIST
– SKETCHES OF SPECIAL TOOLS
– STARTING MOTOR
— REMOVAL AND INSTALLATION
– ALTERNATOR
— REMOVAL AND INSTALLATION
– ENGINE OIL COOLER (SERIAL NO.:50001-52000)
— REMOVAL AND INSTALLATION
– FUEL INJECTION PUMP (SERIAL NO.:50001-52000)
— REMOVAL AND INSTALLATION
– WATER PUMP (SERIAL NO.:50001-52000)
— REMOVAL AND INSTALLATION
– NOZZLE HOLDER (SERIAL NO.:50001-52000)
— REMOVAL AND INSTALLATION
– TURBOCHARGER (SERIAL NO.:50001-52000)
— REMOVALL
— INSTALLATION
– ENGINE FRONT SEAL (SERIAL NO.:50001-52000)
— REPLACEMENT
– ENGINE REAR SEAL (SERIAL NO.:50001-52000)
— REPLACEMENT
– CYLINDER HEAD (SERIAL NO.:50001-52000)
— REMOVAL
— INSTALLATION
– THERMOSTAT (SERIAL NO.:50001-52000)
— REMOVAL AND INSTALLATION
– AFTERCOOLER CORE (SERIAL NO.:50001-52000)
— REMOVAL
— INSTALLATION
– RADIATOR
— REMOVAL
— INSTALLATION
– RADIATOR (WITH SUCTION FAN)
— REMOVAL
— INSTALLATION
– ENGINE AND TORQUE CONVERTER ASSEMBLY
— REMOVAL
— INSTALLATION
– TORQUE CONVERTER
— REMOVAL AND INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION VALVE
— REMOVAL AND ASSEMBLY
– TRANSFER
— DISASSEMBLY
— ASSEMBLY
– CENTER SUPPORT
— REMOVAL AND INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– DRIVE SHAFT
— DISASSEMBLY
— ASSEMBLY
– FRONT AXLE
— REMOVAL
— INSTALLATION
– FRONT DIFFERENTIAL
— REMOVAL
— INSTALLATION
– REAR AXLE
— REMOVAL
— INSTALLATION
– REAR DIFFERENTIAL
— REMOVAL
— INSTALLATION
– DIFFERENTIAL GEAR
— DISASSEMBLY
— ASSEMBLY
– LIMITED SLIP DIFFERENTIAL
— DISASSEMBLY
— ASSEMBLY
– FINAL DRIVE
— REMOAL
— ASSEMBLY
– ORBIT-ROLL
— REMOVAL AND INSTALLATION
– STEERING CYLINFER
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– STEERING VALVE
— REMOVAL
— INSTALLATION
– CUT-OFF VALVE
— REMOVAL AND INSTALLATION
– BRAKE VALVE
— REMOVAL AND INSTALLATION
– BRAKE VALVE (R.H.)
— DISASSEMBLY
— ASSEMBLY
– BRAKE VALVE (L.H.)
— DISASSEMBLY
— ASSEMBLY
– SLACK ADJUSTER
— REMOVAL AND INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– BRAKE
— REMOVAL AND INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– HYDRAULIC PUMP
— REMOVAL
— INSTALLATION
– HYDRAULIC TANK
— REMOVAL
— INSTALLATION
– HUDRAULIC FILTER
— REMOVAL AND INSTALLATION
– PPC VALVE
— REMOVAL AND INSTALLATION
— DISADDEMBLY AND ASSEMBLY
– WORK EQUIPMENT VALVE
— REMOVAL
— INSTALLATION
– MAIN CONTROL VALVE
— DISASSEMBLY
— ASSEMBLY
– DUMP CYLINDER
— REMOVAL
— INSTALLATION
– LIFT CYLINDER
— REMOVAL
— INSTALLATION
– LIFT DYLINDER AND DUMP CYLINDER
— DISASSEMBLY
— ASSEMBLY
– CENTER HINGE PIN
— REMOVAL
— INSTALLATION
– WORK EQUIPMENT
— REMOVAL
— INSTALLATION
– BULKHEAD
— REMOVAL
— INSTALLATION
– FLOOR FRAME
— REMOVAL
— INSTALLATION
– COUNTERWEIGHT
— REMOVAL AND INSTALLATION
– FUEL TANK
— REMOVAL
— INSTALLATION
– CAB
— REMOVAL
— INSTALLATION
– STOP VALVE
— REMOVAL AND INSTALLATION
– ACCUMULATOR
— REMOVAL AND INSTALLATION
– ASSUMULATOR CHARGR VALVE
— REMOVAL AND INTALLATION
– PARKING BRAKE SOLENOID VALVE
— REMOVAL AND SINTALLATION
– DIVERTER VALVE
— REMOVAL AND INSTALLATION
– EMERGENCY STEERING PUMP
— REMOVAL AND INSTALLATION
– PARKING BRAKE
— REMOVAL AND INSTALLATION
– PARKING BRAKE CALIPERS
— DISASSEMBLY
— ASSEMBLY
– PARKING BRAKE PAD
— REMOVAL AND INSTALLATION
– REAR TIRES
— REMOVAL AND INSTALLATION
– AIR CONDITIONER COMPRESSOR
— REMOVAL
— INSTALLATION
– AIR CONDITIONER CONDENSER
— REMOVAL AND INSTALLATION
– RECEIVER TANK
— REMOVAL AND INSTALLATION
– AIR CONDITIONER UNIT
— REMOVAL
— INSTALLATION
– MONITOR
— REMOVAL AND INSTALLATION
40 MAINTENANCE STANDARD
– ENGINE MOUNT
– TRANSMISSION MOUNT
– TORQUE CONVERTER
– TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)
– TRANSMISSION
– TRANSFER
– TRANSMISSION CONTROL VALVE
– DRIVE SHAFT
– CENTER SUPPORT
– DIFFERENTIAL
– LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)
– FINAL DRIVE
– AXLE MOUNT
– STEERING COLUMN
– STEERING VLAVE
– EMERGENCY STEERING PUMP
– DIVERTER VALVE
– STEERING CYLINDER MOUNT
– BRAKE VALVE
– SLACK ADJUSTER
– BRAKE
– PARKING BRAKE
– HYDRAULIC PUMP
– PPC VALVE
– CUT-OFF VALVE
– MAIN CONTROL VALVE
– HYDRAULIC CYLINDER
– WORK EQUIPMENT LINKAGE
– BUCKET
– BUCKET POSITIONER AND BOOM KICK-OUT
– ROPS CANOPY
90 OTHERS
– FOR STANDARD MACHINE (SERIAL NO.:50001-52000)
— ELECTRIC CIRCUIT DIAGRAM (1/4)
— ELECTRIC CIRCUIT DIAGRAM (2/4)
— ELECTRIC CIRCUIT DIAGRAM (3/4)
— ELECTRIC CIRCUIT DIAGRAM (4/4)
– FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.50001-52000)
— ELECTRIC CIRCUIT DIAGRAM (1/4)
— ELECTRIC CIRCUIT DIAGRAM (2/4)
— ELECTRIC CIRCUIT DIAGRAM (3/4)
— ELECTRIC CIRCUIT DIAGRAM (4/4)
– FOR STANKARD MACHINE (SERIAL NO.52001 AND UP)
— ELECTRIC CIRCUIT DIAGAM (1/5)
— ELECTRIC CIRCUIT DIAGAM (2/5)
— ELECTRIC CIRCUIT DIAGAM (3/5)
— ELECTRIC CIRCUIT DIAGAM (4/5)
— ELECTRIC CIRCUIT DIAGAM (5/5)
– FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.52001 AND UP)
— ELECTRIC CIRCUIT DIAGRAM (1/3)
— ELECTRIC CIRCUIT DIAGRAM (2/3)
— ELECTRIC CIRCUIT DIAGRAM (3/3)