Komatsu Wheel Loaders WA800L-3 Shop Manual (Preview)
COVER
CONTENTS
01 GENERAL
– GENERAL ASSEMBLY DRAWING
– SPECIFICATIONS
– WEIGHT TABLE
– LIST OF LUBRICANT AND WATER
10 STRUCTURE AND FUNCTION
– POWER TRAIN
– POWER TRAIN SYSTEM
– ENGINE CONTROL
– RADIATOR AND COOLER
– DAMPER
– TORQUE CONVERTER AND TRNSMISSION PIPING
– TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
– TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
– TORQUE CONVERTER
– TRANSMISSION
– TRANSFER
– TRANSMISSION CONTROL VALVE
– TORQUE CONVERTER OIL COOLER
– DRIVE SHAFT
– CENTER SUPPORT
– AXLE
– DIFFERENTIAL
– FINAL DRIVE
– CENTER HINGE PIN
– AXLE MOUNT
– TIRE AND WHEEL
– STEERING PIPING
– JOYSTICK STEERING LINKAGE
– STEERING PUMP
– SWITCH PUMP
– STEERING DEMAND VALVE
– EPC VALVE
– ROTARY VALVE
– TWO-WAY RESTRICTOR VALVE
– DIVERTER VALVE
– 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 LEVER LINKAGE
– HYDRAULIC TANK
– MAIN PISTON PUMP
– ES VALVE (ENGINE SENSING VALVE)
– SERVO VALVE
– PPC VALVE (PROPORTIONAL PRESSURE VALVE)
– PPC RELIEF VALVE
– ACCUMULATOR (FOR PPC VALVE)
– MAIN CONTROL VALVE
– LUBRICATION OF WORK EQUIPMENT
– WORK EQUIPMENT LINKAGE
– BUCKET POSITIONER AND BOOM KICK-OUT
– OPERATION OF PROXIMITY SWITCH
– CAB AND ROPS CANOPY
– AIR CONDITIONER
– MACHINE MONITOR SYSTEM
– MAIN MONITOR
– MAINTENANCE MONITOR
– ENGINE STARTING CIRCUIT
– ENGINE STOP CIRCUIT
– PREHEATING CIRCUIT
– ELECTRICAL TRANSMISSION CONTROL
– KICK-DOWN, HOLD SWITCH
– AUTOMATIC TRANSMISSION (ATM) SYTEM
– AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
– ELECTRIC PARKING BRAKE CONTROL
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
— MEASURING COMPRESSION PRESSURE
— MEASURING BLOW-BY PRESSURE
— TESTING AND ADJUSTING FUEL INJECTION TIMING
— MEASURING ENGINE OIL PRESSURE
— MEASURING EXHAUST TEMPERATURE
— MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
— TESTING AND ADJUSTING ALTERNATOR BELT TENSION
— TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
— MEASURING ACCELERATOR PEDAL
— TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE
— PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS
— TESTING AND ADJUSTING STEERING OIL PRESSURE
— TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE
— BLEEDING AIR FROM STEERING CIRCUIT
— TESTING AND ADJUSTING STEERING STOPPER BOLT
— TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR
— TESTING WHEEL BRAKE PERFORMANCE
— TESTING WHEEL BRAKE OIL PRESSURE DROP
— MEASURING WEAR OF WHEEL BRAKE DISC
— TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE
— BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
— TESTING PARKING BRAKE PERFORMANCE
— MEASURING PARKING RAKE SOLENOID OUTPUT PRESSURE
— CHECKING AND ADJUSTING PARKING BRAKE PAD
— TESTING AND ADJUSTING PPC PRESSURE
— ADJUSTING PPC VALVE LINKAGE
— TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
— BLEEDING AIR FROM PISTON PUMP
— BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
— ADJUSTING WORK EQUIPMENT LEVER LINKAGE
— RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
— TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH
— TESTING AND ADJUSTING BOOM PROXIMITY SWITCH
— TESTING PROXIMITY ACTUATION PILOT LAMP
— ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR
– TROUBLESHOOTING
— POINTS TO REMEMBER WHEN TROUBLESHOOTING
— SEQUENCE OF EVENTS IN TROUBLESHOOTING
— POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
— CHECKS BEFORE TROUBLESHOOTING
— TYPES AND LOCATIONS OF CONNECTORS
— CONNECTOR LOCATION STEREOGRAM
— CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
— T-BRANCH BOX AND T-BRANCH TABLE
— EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
— METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
— CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION
— TRANSMISSION CONTROLLER LED DISPLAY
— METHOD OF USING JUDGEMENT TABLE
— METHOD OF USING TROUBLESHOOTING CHARTS
— METHOD OF USING MATRIX TROUBLESHOOTING TABLES
— TROUBLESHOOTING OF ENGINE (S MODE)
— METHOD OF USING TROUBLESHOOTING CHARTS
— S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
— S-2 ENGINE DOES NOT START
—- (1) ENGINE DOES NOT TURN
—- (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (INCLUDING CASES WITH V-TYPE ENGINE WHERE THERE IS NO FUEL INJECTION FOR THE BANK ON ONE SIDE)
—- (3) EXHAUST GAS 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 (FOR V TYPE ENGINE, INCLUDING CASES WHERE ONE BANK STOPS)
— S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
— S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH V-TYPE ENGINE, FOR CASES WHERE THERE IS INJECTION FOR ONLY ONE BANK, GO TO TROUBLESHOOTING S-2-(2) OR S-4.)
— S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
— S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
— S-9 OIL BECOMES CONTAMINATED QUICKLY
— S-10 FUEL CONSUMPTION IS EXCESSIVE
— S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER 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 TRANSMISSION CONTROL SYSTEM (T MODE)
— JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS
— 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, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP 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, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED
— T-4 FAILURE CODE [14] (SHORT CIRCUIT, 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 CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED
— T-7 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVER SWITCH SYSTEM) IS DISPLAYED
— T-8 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED
— T-9 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED
— T-10 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
— T-11 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM
— T-12 TRANSMISSION CUT-OFF SIGNAL SYSTEM
— T-13 NEUTRALIZER SIGNAL SYSTEM
— T-14 BUZZER SIGNAL SYSTEM
— T-15 NETWORK SYSTEM
— T-16 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM
— T-17 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
— T-18 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS
— TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
— TROUBLE DATA DISPLAY
— ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
— M-1 MAIN MONITOR DOES NOT WORK
— M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE S 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 SWITCH IS AT F
—- b) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT R
—- c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL SWITCH IS AT N (DISPLAY 1ST-3RD)
— M-5 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-6 ABNORMALITY IN PARKING DISPLAY
—- a) PARKING LAMP DISPLAY DOES NOT LIGHT UP
—- b) PARKING LAMP DISPLAY STAYS LIGHTED UP
— M-7 NIGHT LIGHTING DOES NOT LIGHT UP
— M-8 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 FRONT WORKING LAMP DOES NOT LIGHT UP
— M-9 ABNORMALITY IN REAR WORKING LAMP
—- a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
—- b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
—- c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP
— M-10 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 (TRANSMISSION CUT-OFF 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 ACTUATED 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-11 ABNORMALITY IN LOW IDLE SELECTION
—- a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLE SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE
—- b) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLE SPEED DOES NOT RISE
—- c) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLE SPEED DOES NOT LOWER
— M-12 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY
— M-13 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY
—- a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP
—- b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP
— M-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
—- a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL SWITCH IS AT N
—- b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL SWITCH IS AT POSITION OTHER THAN N
— M-15 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-16 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-17 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY
— M-18 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-19 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER
— M-20 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 RAPIDLY (2 TIMES/SEC)
—- d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY
—- e) MONITOR DISPLAY GOES OUT
— 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 SYSTEM
— K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOSE 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 SECONDS)
— K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), 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 BRAKE OIL PRESSURE IS CORRECT.)
—- d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (R.H.) IS NOT CLOGGED.)
—- e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (L.H.) IS NOT CLOGGED.)
—- f) TRANSMISSION OIL FILTER DISPLAY FLASHES (THE TRANSMISSION OIL FILTER MUST NOT BE CLOGGED.)
— K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND
— K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS
— K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES
—- a) CHECK LAMP
—- b) CAUTION LAMP
— K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP
—- a) CHECK LAMP
—- b) CAUTION LAMP
— K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON
— K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF
— K-12 SERVICE METER DOES NOT WORK
— K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED
— K-14 ABNORMALITY IN GAUGE DISPLAY
—- 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, ENGINE STOPPING AND PREHEATING
— ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE
— 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
— E-3 ABNORMALITY IN PREHEATING SYSTEM
—- a) DOES NOT CARRY OUT PREHEATING
—- b) ONLY MONITOR DISPLAY LIGHTS UP
—- c) MONITOR DISPLAY DOES NOT LIGHT UP WHEN PREHEATING IS COMPLETED
—- d) MONITOR DISPLAY KEEPS LIGHTING UP WHEN PREHEATING IS NOT COMPLETED
— E-4 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 WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)
— E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
— E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON
— E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)
— E-8 KICK-DOWN SWITCH DOES NOT WORK
—- a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY
—- b) KICK-DOWN CANNOT BE CANCELED
— E-9 BOOM KICK-OUT DOES NOT WORK
— E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION
— E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP
— E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP
— E-13 ABNORMALITY IN TRANSMISSION CUT-OFF
— E-14 ABNORMALITY IN LOW IDLING SELECTION
— E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
— E-16 ABNORMALITY IN BUZZER
— TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
— H-1 MACHINE DOES NOT MOVE
— H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)
— H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
— H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
— H-5 STEERING DOES NOT TURN
— H-6 TURNING, RESPONSE OF STEERING IS POOR
— H-7 JOYSTICK LEVER IS HEAVY
— H-8 STEERING WHEEL SHAKES OR JERKS
— H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT
— H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
— H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
— H-12 BOOM DOES NOT RISE
— H-13 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER
— H-14 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT
— H-15 BOOM CYLINDER CANNOT HOLD DOWN BUCKET
— H-16 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT
— H-17 BOOM FLUCTUATES WHILE WORKING
— H-18 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE
— H-19 BUCKET DOES NOT TILT BACK
— H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER
— H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK
— H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET
— H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT
— H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE “HOLD”)
— H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT
— H-26 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY
— TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)
— JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM
— OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
— ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL
— A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED
— A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED
— A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED
— A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED
— A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED
— A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED
— A-7 FAILURE CODE [63] (DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND, OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED
— A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT
— A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)
— A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE
30 DISASSEMBLY AND ASSEMBLY
– METHOD OF USING MANUAL
– PRECAUTIONS WHEN CARRYING OUT OPERATION
– SPECIAL TOOL LIST
– SKETCHES OF SPECIAL TOOLS
– ENGINE RELATED PARTS
— STARTING MOTOR
— ALTERNATOR
— ENGINE OIL COOLER
— FUEL INJECTION PUMP FOR LEFT BANK
— FUEL INJECTION PUMP FOR RIGHT BANK
— WATER PUMP
— NOZZELE HODLER
— TURBOCHARGER
— ENGINE FRONT SEAL
— ENGINE REAR SEAL
— CYLINDER HEAD
– REMOVAL AND INSTALLATION OF RADIATOR
– REMOVAL AND INSTALLATION OF ENGINE
– REMOVAL AND INSTALLATION OF DAMPER
– DISASSEMBLY AND ASSEMBLY OF DAMPER
– REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
– DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
– DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE
– DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
– REMOVAL AND INSTALLATION OF TRANSMISSION VALVE
– DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE
– DISASSEMBLY AND ASSEMBLY OF TRANSFER
– DISASSEMBLY AND ASSEMBLY OF PTO
– REMOVAL AND INSTALLATION OF CENTER SUPPORT
– DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT
– DISASSEMBLY AND ASSEMBLY OF DRIVE SHAFT
– REMOVAL AND INSTALLATION OF FRONT AXLE
– REMOVAL AND INSTALLATION OF REAR AXLE
– REMOVAL AND INSTALLATION OF DIFFERENTIAL
– DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
– DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE
– REMOVAL AND INSTALLATION OF ROTARY VALVE
– REMOVAL AND INSTALLATION OF EMERGENCY STEERING PUMP
– REMOVAL AND INSTALLATION OF DIVERTER VALVE
– DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE
– REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE
– DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE
– REMOVAL AND INSTALLATION OF STEERING CYLINDER
– REMOVAL AND INSTALLATION OF STEERING VALVE
– REMOVAL AND INSTALLATION OF BRAKE VALVE
– REMOVAL AND INSTALLATION OF SLACK ADJUSTER
– DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER
– REMOVAL AND INSTALLATION OF BRAKE
– DISASSEMBLY AND ASSEMBLY OF BRAKE
– REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS
– DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS
– REMOVAL AND INSTALLATION OF PARKING BRAKE PAD
– REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER
– REMOVAL AND INSTALLATION OF BRAKE OIL TANK
– REMOVAL AND INSTALLATION OF HYDRAULIC PUMP
– REMOVAL AND INSTALLATION OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY
– REMOVAL AND INSTALLATION OF PPC VALVE
– DISASSEMBLY AND ASSEMBLY OF PPC VALVE
– REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
– DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE
– REMOVAL AND INSTALLATION OF CAB
– REMOVAL AND INSTALLATION OF FLOOR FRAME
– REMOVAL AND INSTALLATION OF CENTER HINGE PIN
– REMOVAL AND INSTALLATION OF WORK EQUIPMENT
– REPLACEMENT OF BOOM FRONT END BUSH
– REMOVAL AND INSTALLATION OF BUCKET CYLINDER
– REMOVAL AND INSTALLATION OF LIFT CYLINDER
– DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
– REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
– REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR
– REMOVAL AND INSTALLATION OF RECEIVER TANK
– REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER
– REMOVAL AND INSTALLATION OF TRANSMISSION AND JOYSTICK STEERING CONTROLLER
– REMOVAL AND INSTALLATION OF MAIN MONITOR
– REMOVAL AND INSTALLATION OF FUEL TANK
– REMOVAL AND INSTALLATION OF COUNTERWEIGHT
40 MAINTENANCE STANDARD
– ENGINE MOUNT
– TRANSMISSION MOUNT
– DAMPER
– TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
– TORQUE CONVERTER
– TORQUE CONVERTER REGULATOR VALVE
– TRANSMISSION (1/2)
– TRANSMISSION (2/2)
– TRANSFER
– TRANSMISSION CONTROL VALVE
– DRIVE SHAFT
– CENTER SUPPORT
– DIFFERENTIAL (1/2)
– DIFFERENTIAL (2/2)
– FINAL DRIVE
– AXLE MOUNT
– CENTER HINGE PIN
– STEERING DEMAND VALVE
– DIVERTER VALVE
– STEERING CYLINDER MOUNT
– EMERGENCY STEERING PUMP
– BRAKE VALVE
– SLACK ADJUSTER
– BRAKE
– PARKING BRAKE
– PPC VALVE
– PPC RELIEF VALVE
– CONTROL PUMP
– STEERING PUMP
– SWITCH PUMP
– MAIN PISTON PUMP
– MAIN CONTROL VALVE
– HYDRAULIC CYLINDER
– WORK EQUIPMENT LINKAGE
– BUCKET POSITIONER AND BOOM KICK-OUT
– ROPS CANOPY
90 OTHERS
– HYDRAULIC CIRCUIT DIAGRAM
– ELECTRICAL CIRCUIT DIAGRAM (1/5)
– ELECTRICAL CIRCUIT DIAGRAM (2/5)
– ELECTRICAL CIRCUIT DIAGRAM (3/5)
– ELECTRICAL CIRCUIT DIAGRAM (4/5)
– ELECTRICAL CIRCUIT DIAGRAM (5/5)
– ELECTRICAL CIRCUIT DIAGRAM (ENGINE SHUT-DOWN)
– ELECTRICAL CIRCUIT DIAGRAM (AUTO-GREASING)
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