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Komatsu WA600-3 Avance Loader Repair Manual SEBM013213 PDF
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KOMATSU AVANCE LOADER WA600-3 SHOP MANUAL SEBM013213 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU AVANCE LOADER WA600-3 SHOP MANUAL SEBM013213 – PDF DOWNLOAD
Language : English
Pages : 1221
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA600-3 SHOP MANUAL SEBM013213 – PDF DOWNLOAD
MAIN MENU........................................................................................................................................ 0 COVER............................................................................................................................................ 1 CONTENTS......................................................................................................................................... 2 SAFETY........................................................................................................................................... 9 FOREWORD......................................................................................................................................... 11 GENERAL...................................................................................................................................... 11 HOW TO READ THE SHOP MANUAL.................................................................................................................. 12 HOISTING INSTRUCTIONS........................................................................................................................ 13 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................................................................................... 14 COATING MATERIALS............................................................................................................................ 16 STANDARD TIGHTENING TORQUE................................................................................................................... 18 ELECTRIC WIRE CODE........................................................................................................................... 21 CONVERSION TABLE............................................................................................................................. 22 UNITS........................................................................................................................................ 28 01 GENERAL....................................................................................................................................... 29 GENERAL ASSEMBLY DRAWING..................................................................................................................... 30 SPECIFICATIONS............................................................................................................................... 35 WEIGHT TABLE................................................................................................................................. 41 LIST OF LUBRICANT AND WATER.................................................................................................................. 44 10 STRUCTURE AND FUNCTION........................................................................................................................ 46 POWER TRAIN.................................................................................................................................. 47 POWER TRAIN SYSTEM........................................................................................................................... 49 RADIATOR, HYDRAULIC OIL COOLER............................................................................................................... 53 TORQUE CONVERTER AND TRANMISSION PIPING...................................................................................................... 58 HYDRAULIC CIRCUIT FOR POWER TRAIN............................................................................................................ 61 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.................................................................................................... 63 TORQUE CONVERTER............................................................................................................................. 67 TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.: 52001 AND UP).................................................................................. 73 TRANSMISSION................................................................................................................................. 76 TRANSMISSION CONTROL VALVE................................................................................................................... 85 TORQUE CONVERTER OIL COOLER.................................................................................................................. 105 TORQUE CONVERTER OIL FILTER.................................................................................................................. 106 TRANSFER..................................................................................................................................... 108 DRIVE SHAFT.................................................................................................................................. 109 CENTER SUPPORT............................................................................................................................... 110 AXLE......................................................................................................................................... 111 DIFFERENTIAL................................................................................................................................. 113 LIMITED SLIP DIFFERENTIAL.................................................................................................................... 116 FINAL DRIVE.................................................................................................................................. 120 AXLE MOUNT................................................................................................................................... 123 CENTER HINGE PIN............................................................................................................................. 125 STEERING PIPING.............................................................................................................................. 126 STEERING COLUMN.............................................................................................................................. 129 STEERING UNIT (ORBIT-ROLL VALVE)............................................................................................................. 130 STEERING VALVE............................................................................................................................... 133 TWO-WAY RESTRICTION VALVE.................................................................................................................... 144 STOP VALVE................................................................................................................................... 145 EMERGENCY STEERING PIPING.................................................................................................................... 146 DIVERTER VALVE (FOR EMERGENCY STEERING)...................................................................................................... 147 BRAKE PIPING................................................................................................................................. 151 BRAKE CIRCUIT DIAGRAM........................................................................................................................ 155 BRAKE VALVE.................................................................................................................................. 159 CHARGE VALVE................................................................................................................................. 164 ACCUMULATOR (FOR BRAKE)...................................................................................................................... 168 SLACK ADJUSTER............................................................................................................................... 169 BRAKE........................................................................................................................................ 172 PARKING BRAKE................................................................................................................................ 174 SPRING CYLINDER.............................................................................................................................. 176 PARKING BRAKE SOLENOID VALVE................................................................................................................. 177 HYDRAULIC PIPING............................................................................................................................. 179 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..................................................................................................... 183 WORK EQUIPMENT LEVER LINKAGE................................................................................................................. 187 HYDRAULIC TANK............................................................................................................................... 188 ACCUMULATOR (FOR PPC VALVE).................................................................................................................. 190 PPC VALVE.................................................................................................................................... 191 PPC RELIEF VALVE............................................................................................................................. 195 CUT-OFF VALVE................................................................................................................................ 196 MAIN CONTROL VALVE........................................................................................................................... 199 AUTO GREASE SYSTEM .......................................................................................................................... 213 LUBRICATION OF WORK EQUIPMENT................................................................................................................ 225 WORK EQUIPMENT LINKAGE....................................................................................................................... 227 BUCKET....................................................................................................................................... 229 BUCKET POSITIONER AND BOOM KICK-OUT.......................................................................................................... 230 OPERATION OF PROXIMITY SWITCH................................................................................................................ 234 ROPS CANOPY.................................................................................................................................. 238 CAB.......................................................................................................................................... 239 CAB HEATER................................................................................................................................... 240 AIR CONDITIONER.............................................................................................................................. 242 ELECTRIC CIRCUIT DIAGRAM..................................................................................................................... 247 MACHINE MONITOR SYSTEM....................................................................................................................... 253 MAIN MONITOR................................................................................................................................. 256 MAINTENANCE MONITOR.......................................................................................................................... 261 MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL............................................................................................ 263 ENGINE STARTING CIRCUIT...................................................................................................................... 279 ENGINE STOP CIRCUIT.......................................................................................................................... 282 AUTO PRIMING SYSTEMS (APS) (SERIAL NO.: 50001-52000)........................................................................................ 284 PRE-HEATING CIRCUIT (SERIAL NO.: 52001 AND UP)............................................................................................... 288 ELECTRIC TRANSMISSION CONTROL................................................................................................................ 290 KICK-DOWN, HOLD SWITCH....................................................................................................................... 293 KICK-DOWN ELECTRICAL CIRCUIT................................................................................................................. 294 ELECTRIC PARKING BRAKE CONTROL............................................................................................................... 300 E.C.S.S. (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)....................................................................................... 309 20 TESTING AND ADJUSTING......................................................................................................................... 324 STANDARD VALUE TABLE......................................................................................................................... 325 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS............................................................................................ 325 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS........................................................................................... 328 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................ 339 TESTING AND ADJUSTING........................................................................................................................ 352 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................... 353 MEASURING ENGINE SPEED................................................................................................................... 356 MEASURING EXHAUST GAS COLOR.............................................................................................................. 361 ADJUSTING VALVE CLEARANCE................................................................................................................ 362 TESTING AND ADJUSTING INJECTOR LIFT (SERIAL NO.: 52001 AND UP).......................................................................... 364 MEASURING COMPRESSION PRESSURE........................................................................................................... 366 MEASURING BLOW-BY PRESSURE............................................................................................................... 369 MEASURING ENGINE OIL PRESSURE............................................................................................................ 370 TESTING AND ADJUSTING FUEL INJECTION TIMING (SERIAL NO.: 50001-52000)................................................................... 371 REPLACING FAN BELT ADJUSTING AUTO-TENSIONER.............................................................................................. 373 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................ 374 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR........................................................................ 375 HANDLING EQUIPMENT IN FUEL CIRCUIT (SERIAL NO.: 52001 AND UP)........................................................................... 376 MEASURING FUEL PUMP OUTLET PORT PRESSURE (SERIAL NO.: 52001 AND UP)..................................................................... 376 BLEEDING AIR FROM FUEL CIRCUIT (SERIAL NO.: 52001 AND UP)............................................................................... 377 MEASURING EXHAUST TEMPERATURE............................................................................................................ 379 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)........................................................................................... 382 ADJUSTING SPEED SENSOR................................................................................................................... 383 ADJUSTING FUEL CONTROL CABLE (SERIAL NO.: 50001-52000)................................................................................... 384 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.: 50001-52000)................................................................... 385 TESTING AND ADJUSTING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE........................................................................ 387 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT.................................................................. 396 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS............................................................................... 397 TESTING AND ADJUSTING STEERING OIL PRESSURE.............................................................................................. 401 TESTING AND ADJUSTING STEERING STOP VALVE................................................................................................ 403 TESTING BRAKE OIL PRESSURE............................................................................................................... 404 MEASURING WEAR OF BRAKE DISC............................................................................................................. 405 MEASURING BRAKE PERFORMANCE.............................................................................................................. 406 TESTING AND ADJUSTING PARKING BRAKE...................................................................................................... 407 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE..................................................................... 409 TESTING AND ADJUSTING PPC OIL PRESSURE................................................................................................... 410 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................. 412 ADJUSTING WORK EQUIPMENT LEVER LINKAGE................................................................................................... 414 TESTING AND ADJUSTING OF BUCKET POSITIONER............................................................................................... 416 TESTING AND ADJUSTING OF BOOM KICK-OUT................................................................................................... 417 TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP............................................................................................ 418 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE).............................................................................................. 419 BLEEDING AIR............................................................................................................................. 420 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................ 421 PM CLINIC INSPECTION TABLE............................................................................................................... 422 TROUBLESHOOTING.............................................................................................................................. 424 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................. 425 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................... 426 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................... 427 CHECKS BEFORE TROUBLESHOOTING............................................................................................................ 435 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................... 436 CONNECTOR ARRANGEMENT DIAGRAM............................................................................................................ 439 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................... 451 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................... 468 METHOD OF USING MATRIX TROUBLESHOOTING TABLES............................................................................................ 470 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................................................................................................ 472 METHODS OF USING TROUBLESHOOTING CHARTS.............................................................................................. 473 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAY TAKES TIME)......................................................................... 477 S-2 ENGINE DOES NOT START............................................................................................................ 479 (1) ENGINE DOES NOT TURN......................................................................................................... 479 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..................................................... 480 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..................................................... 481 S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR)............................................................................. 482 S-4 ENGINE STOPS DURING OPERATIONS................................................................................................... 483 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................ 484 S-6 ENGINE LACKS OUTPUT.............................................................................................................. 485 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................................................................................... 486 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).......................................................................... 487 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................................................................. 488 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................... 489 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN........................................................ 490 S-12 OIL PRESSURE LAMP LIGHT UP (DROP IN OIL PRESSURE)............................................................................... 491 S-13 OIL LEVEL RISES................................................................................................................. 492 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................ 493 S-15 ABNORMAL NOISE IS MADE.......................................................................................................... 494 S-16 VIBRATION IS EXCESSIVE.......................................................................................................... 495 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA) MODE.................................................................................... 496 METHOD OF ERROR CODE DISPLAY......................................................................................................... 498 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..................................................... 501 SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM.......................................................................................... 509 EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)............................................................................. 511 EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR).......................................................................... 511 EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)............................................. 512 EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM).................................................................. 513 EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)................................................. 515 EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL).................................................. 516 EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)................................................... 517 EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL).................................................... 518 EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM).................................................................. 519 EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)...................................................... 520 EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)....................................................... 521 EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)......................................................... 522 EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SYSTEM LOW LEVEL)................................................................. 523 EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIGH LEVEL)........................................................ 524 EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)......................................................... 525 EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL1))...................................................................... 526 EA-17 ERROR CODE [144] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM HIGH LEVEL)................................................... 527 EA-18 ERROR CODE [145] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM LOW LEVEL).................................................... 528 EA-19 ERROR CODE [151] (ABNORMAL RISE IN WATER TEMPERATURE).......................................................................... 528 EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL).............................................. 529 EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM LOW LEVEL)............................................... 529 EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)................................................ 530 EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)....................................................... 531 EA-24 ERROR CODE [234] (OVERSPEED)................................................................................................... 533 EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)........................................................... 534 EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE).......................................................................... 535 EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)........................................................................... 535 EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL).................................................... 536 EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)..................................................... 536 EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)............................................................ 537 EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)........................................................................... 538 EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATIONS)........................................................... 538 EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)........................................................................ 539 EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)............................................................. 540 EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL2))...................................................................... 541 EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE).................................................. 542 EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)............................................................ 544 EA-38 ERROR CODE [432] (IDLING VALIDATION PROCESS ERROR)............................................................................. 546 EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL).................................................................... 548 EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)................................................................... 548 EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL).................................................. 549 EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)................................................... 550 EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)............................................................ 551 EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)................................................................. 552 EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)................................................................... 552 EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)........................................................................... 552 EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)................................................................ 553 EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLING VALIDATION SWITCH SYSTEM)............................................................ 553 EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)........................................................... 554 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).......................................................................................... 556 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR.......................................................................................... 559 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN......................................................................................... 563 M-1 MAIN MONITOR DOES NOT WORK....................................................................................................... 564 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMP STAY LIT UP........................................ 565 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY....................................................................................... 566 M-4 ABNORMALITY IN SHIFT INDICATOR................................................................................................... 567 A) DISPLAYS N EVEN WHEN DIRECTION LEVER IS AT F.................................................................................. 567 B) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R................................................................................ 567 C) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N........................................................................ 567 D) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST.................................................................. 568 E) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND.................................................................. 568 F) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LVER IS AT 3RD................................................................... 568 G) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH.................................................................. 568 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP.............................................................................................. 570 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................................................ 571 A) L.H. TURN SIGNAL DOES NOT LIGHT UP............................................................................................ 571 B) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP.................................................................................... 571 M-7 ABNORMALITY IN PARKING LAMP DISPLAY.............................................................................................. 572 A) PARKING LAMP DISPLAY DOES NOT LIGHT UP........................................................................................ 572 B) PARKING LAMP DISPLAY STAYS LIT UP............................................................................................. 572 M-8 ABNORMALITY IN PREHEATING DISPLAY................................................................................................ 573 A) PREHEATING DISPLAY DOES NOT LIGHT UP.......................................................................................... 573 B) PREHEATING DISPLAY STAYS LIT UP............................................................................................... 573 M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP...................................................................................... 576 M-10 ABNORMALITY IN FRONT WORKING LAMP............................................................................................... 577 A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP....................................................................... 577 B) WORKING LAMP LIGHT UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................................................................... 577 C) MONITOR DISPLAY LIGHT UP BUT WORKING LAMP DOES NOT LIGHT UP................................................................... 577 M-11 ABNORMALITY IN REAR WORKING LAMP................................................................................................ 579 A) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP........................................................................ 579 B) WORKING LAMP LIGHT UP BUT MONITOR DISPLAY DOES NOT LIGHT UP................................................................... 579 C) MONITOR DISPLAY LIGHT UP BUT WORKING LAMP DOES NOT LIGHT UP................................................................... 579 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF............................................................................................. 581 A) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE..................... 581 B) WHEN TRANMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED............................................ 581 C) TRANSMISSION CUT-OFF SWITCH IS TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED................................................ 582 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING................................................................................... 583 A) A WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N.... 583 B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT .... 583 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATE........ 584 A) ACTUATED CONTINUOUSLY......................................................................................................... 584 B) NOT ACTUATED.................................................................................................................. 584 M-15 ABNORMALITY IN BUZZER........................................................................................................... 585 A) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON....................................... 585 B) BUZZER ALWAYS SOUNDS.......................................................................................................... 585 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY........................................................................... 586 M-17 ABNORMALITY IN FAILURE DISPLAY MODE............................................................................................. 587 A) FAILURE DISPLAY MODE DOES NOT WORK............................................................................................ 587 B) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE................................................. 587 M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY....................................................................................... 588 A) EMERGENCY STEERING DISPLAY DOES NOT FLASH..................................................................................... 588 B) EMERGENCY STEERING DISPLAY STAYS FLASHED...................................................................................... 588 M-19 ABNORMALITY IN AUTO-GREASING SYSTEM............................................................................................. 589 A) FORCED GREASING CANNOT BE CARRIED OUT......................................................................................... 589 B) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)................................................................................. 589 C) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIME/SEC)..................................................... 589 D) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)................................................................................... 590 E) MONITOR DISPLAY GOES OUT...................................................................................................... 590 M-20 ABNORMALITY IN ECSS SYSTEM...................................................................................................... 591 A) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED................................................................................ 591 B) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK..................................................................... 591 C) MONITOR LAMP DOES NOT LIGHT UP................................................................................................ 591 M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)............................................................... 594 TROUBLESHOOTIGN OF MAINTENANCE MONITOR SYSTEM (K MODE)................................................................................... 595 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR................................................................................... 596 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL DISPLAYS ON MAINTENANCE MONITOR DO NOT LIGHT OF 3 SEC MAINTENANCE MONITOR DOES NO......... 600 A) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP..................................................................................... 600 B) SOME LAMPS DO NOT LIGHT UP.................................................................................................... 600 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SEC.................. 601 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWTICH IS TURNED ON WITHIN 3 SEC, NO LAMPS ON MAINTENANCE MONITOR GO OU........ 602 K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TURNED ON, CHECK ITEM DISPLAY FLASHES.............................................. 603 A) ENGINE OIL LEVEL DISPALY FLASHES.............................................................................................. 603 B) ENGINE WATER LEVEL DISPLAY FLASHES............................................................................................ 604 K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TURNED ON, CAUTION ITEM DISPLAY FLASHES............................................ 605 A) ENGINE OIL PRESSURE DISPLAY FLASHES........................................................................................... 605 B) BATTERY CHARGE DISPLAY FLASHES................................................................................................ 608 C) BRAKE OIL PRESSURE DISPLAY FLASHES............................................................................................ 609 D) AIR CLEANER CLOGGED DISPLAY FLASHES........................................................................................... 610 K-6 CAUTION ITEM DISPLAY IS FLASHING, BUT CAUTION BUZZER DOES NOT SOUND.............................................................. 611 K-7 NO MONITOR DISPLAY LIGHT UP, BUT CAUTION BUZZER SOUNDS........................................................................... 612 K-8 CAUTION ITEM DISPLAY IS FLASHING, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH.................................. 613 A) CHECK LAMP.................................................................................................................... 613 B) CAUTION LAMP.................................................................................................................. 613 K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP............................... 614 A) CHECK LAMP.................................................................................................................... 614 B) CAUTION LAMP.................................................................................................................. 614 K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON.................................................. 615 K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF................................................................ 616 K-12 SERVICE METER DOES NOT WORK..................................................................................................... 617 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED............................................................................ 617 K-14 ABNORMALITY IN GAUGES........................................................................................................... 618 A) ABNORMALITY IN FUEL GAUGE..................................................................................................... 618 B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE................................................................................. 619 C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE......................................................................... 620 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................................................ 621 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING, APS SYSTEM............................................ 624 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE........................................................................ 626 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN......................................................................................... 627 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER................................................................... 628 E-1 ENGINE DOES NOT START............................................................................................................ 630 A) STARTING MOTOR DOES NOT TURN.................................................................................................. 630 B) STARTING MOTOR TURNS.......................................................................................................... 636 E-2 ENGINE DOES NOT STOP (SERIAL NO.: 50001-52000).................................................................................. 646 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (SERIAL NO.: 50001-52000)................................................................ 646 E-4A ABNORMALITY IN APS SYSTEM (SERIAL NO.: 50001-52000)............................................................................ 648 A) WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOTLIGHT UP, BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP......... 650 B) WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20c, PREHEATING LAMP FLASHES, BUT PILOT LED ON.... 651 C) AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START, BUT PILOT LET ON APS CONTROLL.... 652 D) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL........................................................................... 653 E) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL........................................................................... 653 F) LED 3 OF PILOT ON APS CONTROLLER SHOWS ABNORMAL............................................................................... 654 G) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL........................................................................... 654 H) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL........................................................................... 655 I) LED 6 OF PILOT ON APS CONTROLLER SHOWS ABNORMAL............................................................................... 655 J) WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHT UP....................................................................... 656 E-4B PREHEATING FAULT................................................................................................................ 657 E-5 PARKING BRAKE DOES NTO HAVE EFFECT............................................................................................... 659 A) PARKING BRAKE HAS NOT EFFECT WHEN PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON......................... 659 B) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS............................ 659 E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING............................................................................... 660 E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...................................................................... 662 E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORKS NORMALLY.......................... 662 E-9 TRANSMISSION DOES NOT WORK PROPERLY.............................................................................................. 664 A) ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT........................ 666 B) NO CONTINUITY IN TRABEL FORWARD SOLENOID CIRCUIT.............................................................................. 670 C) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT.............................................................................. 672 D) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT............................................................... 674 E) ABNORMALITY IN SHIFT SOLENOID CIRCUIT......................................................................................... 680 F) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT..................................................................... 683 E-10 KICK-DOWN SWITCH DOES NOT WORK.................................................................................................. 688 E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON................................................................... 691 E-12 KICK-DOWN ALWAYS WORKS.......................................................................................................... 692 E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND....................................................................... 694 E-14 BOOM KICK-OUT DOES NOT WORK..................................................................................................... 696 E-15 DEFECTIVE BUCKET POSITIONER..................................................................................................... 700 E-16 POWER WINDOW DOES NOT WORK...................................................................................................... 703 A) POWER WINDOW DOES NOT RISE.................................................................................................... 703 B) POWER WINDOW DOES NOT LOWER................................................................................................... 704 E-17 ABNORMALITY IN FRONT WORKING LAMP............................................................................................... 706 E-18 ABNORMALITY IN REAR WORKING LAMP................................................................................................ 706 E-19 ABNORMALITY IN TRANSMISSION CUT-OFF............................................................................................. 706 E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING................................................................................... 706 E-21 ABNORMALITY IN BUZZER........................................................................................................... 706 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).............................................................................. 707 POWER TRAIN.......................................................................................................................... 708 H-1 MACHINE DOES NOT START....................................................................................................... 708 H-2 TRAVEL SPEED IS SLOW, OR LACKS POWER IN ALL SPEED RANGES..................................................................... 709 H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.................................................................... 710 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................... 711 STEERING SYSTEM...................................................................................................................... 712 H-5 STEERING WHEEL DOES NOT TURN................................................................................................. 712 H-6 STEERING DOES NOT TURN (MACHINE WITH JOYSTICK)............................................................................... 713 H-7 TURNING, RESPONSE OF STEERING IS POOR........................................................................................ 714 H-8 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]................................................................ 716 H-9 STEERING IS HEAVY............................................................................................................ 718 H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]................................................................................... 718 H-11 STEERING WHEEL SHAKES OR JERKS.............................................................................................. 719 H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]......................................................... 720 H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING...................................................... 720 BRAKE SYSTEM......................................................................................................................... 722 H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.......................................................................... 722 H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG................................................................................ 724 H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR....................................................................... 725 H-17 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)........................................... 726 WORK EQUIPMENT....................................................................................................................... 727 H-18 NEITHER BOOM NO BUCKET MOVE................................................................................................. 727 H-19 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER................................................................................. 728 H-20 BOOM DOES NOT MOVE.......................................................................................................... 729 H-21 BOOM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]...................................................................... 730 H-22 BOOM IS SLOW OR BOOM LACK POWER............................................................................................. 731 H-23 BOOM IS SLOW OR BOOM LACK POWER [MACHINES WITH REMOTE BOOM CONTROL]......................................................... 732 H-24 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT................................................................ 733 H-25 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.................................................... 733 H-26 REMOTE BOOM CONTROL DOES NOT WORK [MACHINES WITH REMOTE CONTROL]............................................................ 734 H-27 EXCESSIVE HYRAULIC DRIFT OF BOOM............................................................................................ 735 H-28 BUCKET DOES NOT MOVE........................................................................................................ 736 H-29 BUCKET IS SLOW OR LACKS POWER............................................................................................... 737 H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET......................................................................................... 738 H-31 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]................................................. 739 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) ( ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL).................... 741 METHOD FOR DISPLAYING ACTION CODE AND FAILURE CODE................................................................................... 743 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM...................................................................................... 744 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE.......................................................... 746 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM........................................................................... 750 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY) IS DISPLAYED............ 754 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID) IS DISPLAYED.................. 755 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID) IS DISPLAYED.................. 756 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECITON, OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID) IS DISPLAYED................ 757 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID) IS DISPLAYED................ 758 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID) IS DISPLAYED................ 759 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID) IS DISPLAYED................ 760 T-8 FAILURE CODE [19] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED........................... 761 T-9 FAILURE CODE [20] (SHORT CIRCUIT, OR DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.................................... 762 T-10 FAILURE CODE [21] (SHORT CIRCUIT, OR DISCONNECTION IN SHIFT SWITCH SYSTEM) IS DISPLAYED......................................... 766 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED........................................................... 769 T-12 FAILURE CODE [23] (SHORT CIRCUIT, OR DISCONNECTON IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED................................... 770 T-13 SHIFT-UP DOES NOT WORK.......................................................................................................... 773 T-14 SHIFT-DOWN DOES NOT WORK........................................................................................................ 773 T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING.............................................................................. 774 T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING...................................................................................... 775 T-17 BUZZER DOES NOT WORK............................................................................................................ 776 T-18 ABNORMALITY IN NETWORK SYSTEM................................................................................................... 777 T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY............................................................................. 778 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM..................................................................................... 779 T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS................................................................................. 780 TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)........................ 781 JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM.......................................................................................... 782 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................... 784 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM.............................................................................. 788 J-1 FAILURE CODE [56] (SHORT CIRCUIT, OR DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED......................................... 790 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUT PUT)) IS DISPLAYED...................... 791 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WITH SIGNAL IS OUTPUT)) IS DISPLAYED........................ 792 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED.................................... 793 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED..................................... 794 J-6 FAILURE CODE [61] (SHORT CIRCUIT, OR DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT ) IS DISPLAYED.......................... 795 J-7 FAILURE CODE [62] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED............................ 796 J-8 FAILURE CODE [63] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED........................ 797 J-9 ABNORMALITY IN POWER SUPPLY, OR POWER SUPPLY VOLTAGE............................................................................. 798 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT................................................................................. 799 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID........................................................................................ 800 J-12 DISCONNECTION IN STEERING LEFT SOLENOID......................................................................................... 801 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)........................................................... 803 ACTION TAKEN BY TRANMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................... 804 ELECTRICAL CIRCUIT DIAGRAM FOR ECSS.................................................................................................. 808 D-1 ECSS DOES NOT WORK............................................................................................................... 811 A) ERROR CODE [D0] IS DISPLAYED.................................................................................................. 812 B) ERROR CODE [D1] IS DISPLAYED.................................................................................................. 812 C) ERROR CODE [D2] IS DISPLAYED.................................................................................................. 813 D) ERROR CODE [D3] IS DISPLAYED.................................................................................................. 813 E) ERROR CODE [D4] IS DISPLAYED.................................................................................................. 814 F) ERROR CODE [D5] IS DISPLAYED.................................................................................................. 814 G) ERROR CODE [D6] IS DISPLAYED.................................................................................................. 816 H) NO ABNORMALITY DISPLAY IS GIVEN............................................................................................... 819 D-2 ECSS CANNOT BE CANCELLED......................................................................................................... 825 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 827 METHOD OF USING MANUAL....................................................................................................................... 829 PRECAUTIONS WHEN CARRYING OUT OPERATION...................................................................................................... 830 SPECIAL TOOL LIST............................................................................................................................ 832 SKETCHES OF SPECIAL TOOLS ................................................................................................................... 842 STARTING MOTOR............................................................................................................................... 852 REMOVAL AND INSTALLATION................................................................................................................. 852 ALTERNATOR................................................................................................................................... 853 REMOVAL AND INSTALLATION................................................................................................................. 853 ENGINE OIL COOLER (SERIAL NO.: 50001-52000).................................................................................................. 856 REMOVAL AND INSTALLATION................................................................................................................. 856 FUEL INJECTION PUMP (SERIAL NO.: 50001-52000)................................................................................................ 857 REMOVAL AND INSTALLATION................................................................................................................. 857 WATER PUMP (SERIAL NO.: 50001-52000)........................................................................................................ 858 REMOVAL AND INSTALLATION................................................................................................................. 858 NOZZLE HOLDER (SERIAL NO.: 50001-52000)...................................................................................................... 859 REMOVAL AND INSTALLATION................................................................................................................. 859 TURBOCHARGER (SERIAL NO.: 50001-5200)........................................................................................................ 860 REMOVAL.................................................................................................................................. 860 INSTALLATION............................................................................................................................. 861 ENGINE FRONT SEAL (SERIAL NO.: 50001-52000)................................................................................................. 862 REPLACEMENT.............................................................................................................................. 862 ENGINE REAR SEAL (SERIAL NO.: 50001-52000)................................................................................................... 864 REPLACEMENT.............................................................................................................................. 864 CYLINDER HEAD (SERIAL NO.: 50001-52000)................................................................................................... 866 REMOVAL.................................................................................................................................. 866 INSTALLATION............................................................................................................................. 871 THERMOSTAT (SERIAL NO.: 50001-52000)........................................................................................................ 873 REMOVAL AND INSTALLATION................................................................................................................. 873 AFTERCOOLER (SERIAL NO.: 50001-52000)....................................................................................................... 874 REMOVAL.................................................................................................................................. 874 INSTALLATION............................................................................................................................. 875 RADIATOR..................................................................................................................................... 876 REMOVAL.................................................................................................................................. 876 INSTALLATION............................................................................................................................. 878 ENGINE AND TORQUE CONVERTER ASSEMBLY......................................................................................................... 883 REMOVAL.................................................................................................................................. 883 INSTALLATION............................................................................................................................. 885 TORQUE CONVERTER............................................................................................................................. 890 REMOVAL AND INSTALLATION................................................................................................................. 890 DISASSEMBLY.............................................................................................................................. 893 ASSEMBLY................................................................................................................................. 898 TRANSMISSION................................................................................................................................. 916 REMOVAL.................................................................................................................................. 916 INSTALLATION............................................................................................................................. 918 DISASSEMBLY.............................................................................................................................. 919 ASSEMBLY................................................................................................................................. 934 TRANSMISSION VALVE........................................................................................................................... 950 REMOVAL AND ASSEMBLY..................................................................................................................... 950 TRANSFER..................................................................................................................................... 951 DISASSEMBLY.............................................................................................................................. 951 ASSEMBLY................................................................................................................................. 960 CENTER SUPPORT............................................................................................................................... 971 REMOVAL AND INSTALLATION................................................................................................................. 971 DISASSEMBLY ............................................................................................................................. 973 ASSEMBLY................................................................................................................................. 975 DRIVE SHAFT.................................................................................................................................. 978 DISASSEMBLY.............................................................................................................................. 978 ASSEMBLY................................................................................................................................. 981 FRONT AXLE................................................................................................................................... 984 REMOVAL.................................................................................................................................. 984 INSTALLATION............................................................................................................................. 985 FRONT DIFFERENTIAL........................................................................................................................... 986 REMOVAL.................................................................................................................................. 986 INSTALLATION............................................................................................................................. 987 REAR AXLE.................................................................................................................................... 988 REMOVAL.................................................................................................................................. 988 INSTALLATION............................................................................................................................. 991 REAR DIFFERENTIAL............................................................................................................................ 992 REMOVAL.................................................................................................................................. 992 INSTALLATION............................................................................................................................. 993 DIFFERENTIAL GEAR............................................................................................................................ 994 DISASSEMBLY.............................................................................................................................. 994 ASSEMBLY................................................................................................................................. 998 LIMITED SLIP DIFFERENTIAL ...................................................................................................................1006 DISASSEMBLY..............................................................................................................................1006 ASSEMBLY.................................................................................................................................1011 FINAL DRIVE..................................................................................................................................1022 REMOVAL..................................................................................................................................1022 ASSEMBLY.................................................................................................................................1024 ORBIT-ROLL...................................................................................................................................1027 REMOVAL AND INSTALLATION.................................................................................................................1027 STEERING CYLINDER............................................................................................................................1028 REMOVAL..................................................................................................................................1028 INSTALLATION.............................................................................................................................1029 DISASSEMBLY..............................................................................................................................1030 ASSEMBLY.................................................................................................................................1032 STEERING VALVE...............................................................................................................................1034 REMOVAL..................................................................................................................................1034 INSTALLATION.............................................................................................................................1035 CUT-OFF VALVE................................................................................................................................1036 REMOVAL AND INSTALLATION................................................................................................................1036 BRAKE VALVE..................................................................................................................................1037 REMOVAL AND INSTALLATION.................................................................................................................1037 BRAKE VALVE (R.H.)...........................................................................................................................1038 DISASSEMBLY..............................................................................................................................1038 ASSEMBLY.................................................................................................................................1040 BRAKE VALVE (L.H.)...........................................................................................................................1042 DISASSEMBLY..............................................................................................................................1042 ASSEMBLY.................................................................................................................................1044 SLACK ADJUSTER...............................................................................................................................1046 REMOVAL AND INSTALLATION.................................................................................................................1046 DISASSEMBLY..............................................................................................................................1047 ASSEMBLY.................................................................................................................................1048 BRAKE........................................................................................................................................1049 REMOVAL AND INSTALLATION.................................................................................................................1049 DISASSEMBLY..............................................................................................................................1050 ASSEMBLY.................................................................................................................................1053 HYDRAULIC PUMP...............................................................................................................................1057 REMOVAL..................................................................................................................................1057 INSTALLATION.............................................................................................................................1058 HYDRAULIC TANK...............................................................................................................................1061 REMOVAL..................................................................................................................................1061 INSTALLATION.............................................................................................................................1062 HYDRAULIC FILTER.............................................................................................................................1063 REMOVAL AND INSTALLATION.................................................................................................................1063 PPC VALVE....................................................................................................................................1064 REMOVAL AND INSTALLATION.................................................................................................................1064 DISASSEMBLY AND ASSEMBLY.................................................................................................................1065 WORK EQUIPMENT VALVE.........................................................................................................................1066 REMOVAL..................................................................................................................................1066 INSTALLATION.............................................................................................................................1067 MAIN CONTROL VALVE...........................................................................................................................1069 DISASSEMBLY..............................................................................................................................1069 ASSEMBLY.................................................................................................................................1073 DUMP CYLINDER................................................................................................................................1076 REMOVAL..................................................................................................................................1076 INSTALLATION.............................................................................................................................1077 LIFT CYLINDER................................................................................................................................1078 REMOVAL..................................................................................................................................1078 INSTALLATION.............................................................................................................................1079 LIFT CYLINDER AND DUMP CYLINDER..............................................................................................................1080 DISASSEMBLY..............................................................................................................................1080 ASSEMBLY.................................................................................................................................1082 CENTER HINGE PIN.............................................................................................................................1085 REMOVAL..................................................................................................................................1085 INSTALLATION.............................................................................................................................1090 WORK EQUIPMENT...............................................................................................................................1093 REMOVAL..................................................................................................................................1093 INSTALLATION.............................................................................................................................1097 BULKHEAD.....................................................................................................................................1099 REMOVAL..................................................................................................................................1099 INSTALLATION.............................................................................................................................1100 FLOOR FRAME..................................................................................................................................1101 REMOVAL..................................................................................................................................1101 INSTALLATION.............................................................................................................................1103 COUNTERWEIGHT................................................................................................................................1104 REMOVAL AND INSTALLATION.................................................................................................................1104 FUEL TANK....................................................................................................................................1105 REMOVAL..................................................................................................................................1105 INSTALLATION.............................................................................................................................1106 CAB..........................................................................................................................................1109 REMOVAL..................................................................................................................................1109 INSTALLATION.............................................................................................................................1111 STOP VALVE...................................................................................................................................1112 REMOVAL AND INSTALLATION.................................................................................................................1112 ACCUMULATOR..................................................................................................................................1113 REMOVAL AND INSTALLATION.................................................................................................................1113 ACCUMULATOR CHARGE VALVE.....................................................................................................................1114 REMOVAL AND INSTALLATION.................................................................................................................1114 PARKING BRAKE SOLENOID VALVE.................................................................................................................1115 REMOVAL AND INSTALLATION.................................................................................................................1115 DIVERTER VALVE...............................................................................................................................1116 REMOVAL AND INSTALLATION.................................................................................................................1116 EMERGENCY STEERING PUMP......................................................................................................................1117 REMOVAL AND INSTALLATION.................................................................................................................1117 PARKING BRAKE................................................................................................................................1118 REMOVAL AND INSTALLATION.................................................................................................................1118 PARKING BRAKE CALIPERS.......................................................................................................................1119 DISASSEMBLY..............................................................................................................................1119 ASSEMBLY.................................................................................................................................1120 PARKING BRAKE PAD............................................................................................................................1121 REMOVAL AND INSTALLATION.................................................................................................................1121 REAR TIRES...................................................................................................................................1122 REMOVAL AND INSTALLATION.................................................................................................................1122 AIR CONDITIONER COMPRESSOR...................................................................................................................1123 REMOVAL..................................................................................................................................1123 INSTALLATION.............................................................................................................................1124 AIR CONDITIONER CONDENSER....................................................................................................................1126 REMOVAL AND INSTALLATION.................................................................................................................1126 RECEIVER TANK................................................................................................................................1127 REMOVAL AND INSTALLATION.................................................................................................................1127 AIR CONDITIONER UNIT.........................................................................................................................1128 REMOVAL..................................................................................................................................1128 INSTALLATION.............................................................................................................................1129 MONITOR......................................................................................................................................1130 REMOVAL AND INSTALLATION.................................................................................................................1130 40 MAINTENANCE STANDARD..........................................................................................................................1132 ENGINE MOUNT.................................................................................................................................1133 TRANSMISSION MOUNT...........................................................................................................................1135 TORQUE CONVERTER.............................................................................................................................1137 TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.: 52001 AND UP)..................................................................................1140 TRANSMISSION.................................................................................................................................1143 TRANSFER.....................................................................................................................................1147 TRANSMISSION CONTROL VALVE...................................................................................................................1149 DRIVE SHAFT..................................................................................................................................1154 CENTER SUPPORT...............................................................................................................................1155 DIFFERENTIAL.................................................................................................................................1157 LIMITED SLIP DIFFERENTIAL (OP)...............................................................................................................1161 FINAL DRIVE..................................................................................................................................1163 AXLE MOUNT...................................................................................................................................1165 CENTER HINGE PIN.............................................................................................................................1167 STEERING COLUMN..............................................................................................................................1169 STEERING VALVE...............................................................................................................................1170 EMERGENCY STEERING PUMP......................................................................................................................1171 DIVERTER VALVE...............................................................................................................................1172 STEERING CYLINDER MOUNT......................................................................................................................1173 BRAKE VALVE .................................................................................................................................1174 SLACK ADJUSTER...............................................................................................................................1177 BRAKE .......................................................................................................................................1179 PARKING BRAKE................................................................................................................................1181 HYDRAULIC PUMP...............................................................................................................................1183 PPC VALVE....................................................................................................................................1189 CUT-OFF VALVE................................................................................................................................1191 MAIN CONTROL VALVE...........................................................................................................................1193 HYDRAULIC CYLINDER...........................................................................................................................1195 WORK EQUIPMENT LINKAGE.......................................................................................................................1197 BUCKET.......................................................................................................................................1199 BUCKET POSITIONER AND BOOM KICK-OUT..........................................................................................................1200 ROPS CANOPY..................................................................................................................................1202 90 OTHERS........................................................................................................................................1204 ELECTRIC CIRCUIT DIAGRAM ....................................................................................................................1206 FOR STANDARD MACHINE (SERIAL NO.: 50001-52000)..........................................................................................1206 ELECTRIC CIRCUIT DIAGRAM (1/4).......................................................................................................1206 ELECTRIC CIRCUIT DIAGRAM (2/4).......................................................................................................1207 ELECTRIC CIRCUIT DIAGRAM (3/4).......................................................................................................1208 ELECTRIC CIRCUIT DIAGRAM (4/4).......................................................................................................1209 FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.: 50001-52000)..........................................................1210 ELECTRIC CIRCUIT DIAGRAM (1/4).......................................................................................................1210 ELECTRIC CIRCUIT DIAGRAM (2/4).......................................................................................................1211 ELECTRIC CIRCUIT DIAGRAM (3/4).......................................................................................................1212 ELECTRIC CIRCUIT DIAGRAM (4/4).......................................................................................................1213 FOR STANDARD MACHINE (SERIAL NO.: 52001 AND UP)..........................................................................................1214 ELECTRIC CIRCUIT DIAGRAM (1/5).......................................................................................................1214 ELECTRIC CIRCUIT DIAGRAM (2/5).......................................................................................................1215 ELECTRIC CIRCUIT DIAGRAM (3/5).......................................................................................................1216 ELECTRIC CIRCUIT DIAGRAM (4/5).......................................................................................................1217 ELECTRIC CIRCUIT DIAGRAM (5/5).......................................................................................................1218 FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO. 52001 AND UP)..........................................................1219 ELECTRIC CIRCUIT DIAGRAM (1/3).......................................................................................................1219 ELECTRIC CIRCUIT DIAGRAM (2/3).......................................................................................................1220 ELECTRIC CIRCUIT DIAGRAM (3/3).......................................................................................................1221
DESCRIPTION:
KOMATSU AVANCE LOADER WA600-3 SHOP MANUAL SEBM013213 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding. the manual Is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure. but also serves as reference material for troubleshooting.
In addition. this section may contain hydraulic circuit diagrams. electric circuit diagrams. and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing. installing. disassembling and assembling each component. as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 29/12/24
