Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 PDF

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Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD

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Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD

Language : English
Pages : 918
Downloadable : Yes
File Type : PDF

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Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD

• MACHINE MODEL            SERIAL NO.
  WA600-3                            50363 and up

COVER 1
CONTENTS . 2
01 GENERAL . 27
GENERAL ASSEMBLY DRAWING . 28
SPECIFICATIONS . 29
WEIGHT TABLE . 32
LIST OF LUBRICANT AND WATER 33
10 STRUCTURE AND FUNCTION 35
POWER TRAIN 36
POWER TRAIN SYSTEM . 38
RADIATOR,HYDRAULIC OIL COOLER 40
TORQUE CONVERTER AND TRANSMISSION PIPING . 41
HYDRAULIC CIRCUIT FOR POWER TRAIN 42
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 44
TORQUE CONVERTER . 46
TRANSMISSION . 49
TRANSMISSION CONTROL VALVE . 58
TORQUE CONVERTER OIL COOLER 80
TORQUE CONVERTER OIL FILTER 81
TRANSFER . 83
DRIVE SHAFT 84
CENTER SUPPORT . 85
AXLE . 86
DIFFERENTIAL . 88
LIMITED SLIP DIFFERENTIAL 91
FINAL DRIVE 95
AXLE MOUNT . 98
CENTER HINGE PIN .100
STEERING PIPING 101
STEERING COLUMN 102
STEERING UNIT(ORBIT-ROLL VALVE) 103
STEERING VALVE .106
TWO-WAY RESTRICTION VALVE 117
STOP VALVE .118
EMERGENCY STEERING PIPING 119
DIVERTER VALVE(FOR EMERGENCY STEERING) .120
BRAKE PIPING .124
BRAKE CIRCUIT DIAGRAM 126
BRAKE VALVE 128
CHARGE VALVE .133
ACCUMULATOR(FOR BRAKE) .137
SLACK ADJUSTER .138
BRAKE 141
PARKING BRAKE 143
SPRING CYLINDER 145
PARKING BRAKE SOLENOID VALVE .146
HYDRAULIC PIPING .148
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .150
WORK EQUIPMENT LEVER LINKAGE .152
HYDRAULIC TANK .153
ACCUMULATOR(FOR PPC VALVE) .155
PPC VALVE 156
PPC RELIEV VALVE .160
CUT-OFF VALVE 161
MAIN CONTROL VALVE .164
LUBRICATION OF WORK EQUIPMENT 178
WORK EQUIPMENT LINKAGE .180
BUCKET .182
BUCKET POSITIONER AND BOOM KICK-OUT 183
OPERATION OF PROXIMITY SWITCH 185
ROPS CANOPY 189
CAB 190
CAB HEATER .191
AIR CONDITIONER 193
ELECTRIC CIRCUIT DIAGRAM .196
MACHINE MONITOR SYSTEM .202
MAIN MONITOR .203
MAINTENAMCE MONITOR 208
MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL 210
ENGINE STARTING CIRCUIT 226
ENGINE STOP CIRCUIT 228
5-AUTO PRIMING SYSTEM(APS) .229
ELECTRIC TRANSMISSION CONTROL 233
KICK-DOWN,HOLD SWITCH 236
KICK-DOWN ELECTRICAL CIRCUIT .237
ELECTRIC PARKING BRAKE CONTROL .243
20 TESTING AND ADJUSTING .253
STANDARD VALUE TABLE FOR ENGINE 254
STANDARD VALUE TABLE FOR CHASSIS .255
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 260
TESTING AND ADJUSTING 273
TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING .274
MEASURING ENGINE SPEED .275
MEASURING EXHAUST GAS COLOR 277
ADJUSTIN VALVE CLEARANCE .278
MEASURING COMPRESSION PRESSURE .279
MEASURING BLOW-BY PRESSURE .280
MEASURING ENGINE OIL PRESSURE 281
TESTING AND ADJUSTING FUEL INJECTION TIMING 282
REPLACING FAN BELT ADJUSTING AUTO-TENSIONER 284
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 285
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 285
MEASURING EXHAUST TEMPERATURE 286
MEASURING AIR SUPPLY PRESSURE(BOOST PRESSURE) 287
ADJUSTING SPEED SENSOR .288
ADJUSTING FUEL CONTROL CABLE .289
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE .290
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE .292
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT .297
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS .298
TESTING AND ADJUSTING STEERING OIL PRESSURE 300
TESTING AND ADJUSTING STEERING STOP VALVE 302
TESTING BRAKE OIL PRESSURE .303
MEASURING WEAR OF BRAKE DISC .304
MEASURING BRAKE PERFORMANCE 305
TESTING AND ADJUSTING PARKING BRAKE 306
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE .308
TESTING AND ADJUSTING PPC OIL PRESSURE .309
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 311
ADJUSTING WORK EQUIPMENT LEVER LINKAGE .313
TESTING AND ADJUSTING OF BUCKET POSITIONER .315
TESTING AND ADJUSTING OF BOOM KICK-OUT .316
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP 317
ADJUSTING MAIN MONITOR(SPEEDOMETER MODULE) .318
BLEEDING AIR .319
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 320
TROUBLESHOOTING 321
POINTS TO REMEMBER WHEN TROUBLESHOOTING 322
SEQUENCE OF EVENTS IN TROUBLESHOOTING 323
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .324
CHECKS BEFORE TROUBLESHOOTING 332
CONNECTOR TYPES AND MOUNTING LOCATIONS .333
CONNECTOR ARRANGEMENT DIAGRAM 336
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .340
METHOD OF USING TROUBLESHOOTING CHARTS .349
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 351
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 353
METHOD OF USING TROUBLESHOOTING CHARTS .354
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME) .358
S-2 ENGINE DOES NOT START 360
(1) ENGINE DOES NOT START .360
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED) 361
(3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 362
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY(FOLLOW-UP IS POOR) 363
S-4 ENGINE STOPS DURING OPERATIONS .364
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) .365
S-6 ENGINE LACKS OUTPUT 366
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION) 367
S-8 OIL COMSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE) .368
S-9 OIL BECOMES CONTAMINATED QUICKLY .369
S-10 FUEL CONSUMPTION IS EXCESSIVE .370
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN .371
S-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE) .372
S-13 OIL LEVEL RISES .373
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) .374
S-15 ABNORMAL NOISE IS MADE 375
S-16 VIBRATION IS EXCESSIVE 376
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 377
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR 380
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN .382
M-1 MAIN MONITOR DOES NOT WORK .383
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP 384
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY .385
M-4 ABNORMALITY IN SHIFT INDICATOR .386
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F 386
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R 386
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N 386
d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST 387
e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND 387
f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD 387
g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH 387
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP 389
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 390
a) L.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP .390
b) R.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP .390
M-7 ABNORMALITY IN PARKING LAMP DISPLAY 391
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP 391
b) PARKING LAMP DISPLAY STAYS LIGHTED UP .391
M-8 ABNORMALITY IN PREHEATING SYSTEM .392
a) PREHEATING DISPLAY DOES NOT LIGHT UP 392
b) PREHEATING DISPLAY STAYS LIGHTED UP .392
M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP 393
M-10 ABNORMALITY IN FRONT WORKING LAMP .394
a) NEITHER MONITOR DISPLAY NOR FRONG WORKIGN LAMP LIGHT UP .394
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP .394
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP 394
M-11 ABNORMALITY IN REAR WORKIGN LAMP 396
a) NEITHER MONITOR DISPLAY NOR RERA WORKING LAMP LIGHT UP 396
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP .396
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP 396
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF .398
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE 398
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED 398
c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON,BUT CUT-OFF FUNCTION IS NOT ACTUATED .399
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN .400
a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N .400
b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N 400
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED .401
a) ACTUATED CONTINUOUSLY .401
b) NOT ACTUATED 401
M-15 ABNORMALITY IN BUZZER .402
a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON .402
b) BUZZER ALWAYS SOUNDS 402
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY .403
M-17 ABNORMALITY IN FAILURE DISPLAY MODE .404
a) FAILURE DISPLAY MODE DOES NOT WORK 404
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE .404
M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY .405
a) EMERGENCY STEERING DISPLAY DOES NOT FLASH .405
b) EMERGENCY STEERING DISPLAY STAYS FLASHED 405
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) .407
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR .408
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK .410
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP 410
b) SOME LAMPS DO NOT LIGHT UP 410
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SECONDS .411
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT 412
K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES .413
a) ENGINE OIL LEVEL DISPLAY FLASHES 413
b) ENGINE WATER LEVEL DISPLAY FLASHES 414
K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES .415
a) ENGINE OIL PRESSURE DISPLAY FLASHES .415
b) BATTERY CHARGE DISPLAY FLASHES 416
c) BRAKE OIL PRESSURE DISPLAY FLASHES 417
d) AIR CLEANER CLOGGED DISPLAY FLASHES .418
K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND .419
K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS .420
K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH .421
a) CHECK LAMP 421
b) CAUTION LAMP 421
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP 422
a) CHECK LAMP 422
b) CAUTION LAMP 422
K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON 423
K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF 424
K-12 SERVICE METER DOES NOT WORK .425
K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED 425
K-14 ABNORMALITY IN GAUGES .426
a) ABNORMALITY IN FUEL GAUGE .426
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE .427
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE .428
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 429
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM .431
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE 432
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN .433
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER .434
E-1 ENGINE DOES NOT START .436
a) STARTING MOTOR DOES NOT TURN 436
b) STARTING MOTOR TURNS 442
E-2 ENGINE DOES NOT STOP .446
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING .446
E-4 ABNORMALITY IN APS SYSTEM 448
a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP 450
b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL 451
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL .452
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .453
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .453
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .454
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .454
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .455
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .455
j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP .456
E-5 PARKING BRAKE DOES NOT HAVE EFFECT .457
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON 457
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS 457
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING .458
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 460
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY .460
E-9 TRANSMISSION DOES NOT WORK PROPERLY 462
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT .464
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT 468
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT 470
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT .472
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT .478
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT .481
E-10 KICK-DOWN SWITCH DOES NOT WORK 486
E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON .489
E-12 KICK-DOWN ALWAYS WORKS 490
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND .492
E-14 BOOM KICK-OUT DOES NOT WORK .494
E-15 DEFECTIVE BUCKET POSITIONER .498
E-16 POWER WINDOW DOES NOT WORK 501
a) POWER WINDOW DOES NOT RISE 501
b) POWER WINDOW DOES NOT LOWER .502
E-17 ABNORMALITY IN FRONT WORKING LAMP .504
E-18 ABNORMALITY IN REAR WORKING LAMP 504
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF .504
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING .504
E-21 ABNORMALITY IN BUZZER .504
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 505
H-1 MACHINE DOES NOT START .506
H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES 507
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 508
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 509
H-5 STEERING DOES NOT TURN .510
H-6 TURNING,RESPONSE OF STEERING IS POOR .511
H-7 STEERING IS HEAVY 512
H-8 STEERING WHEEL SHAKES OR JERKS .513
H-9 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING .513
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 514
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 516
H-12 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR .517
H-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 518
H-14 NEITHER BOOM NOR BUCKET MOVE 519
H-15 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER .520
H-16 BOOM DOES NOT MOVE 521
H-17 BOOM IS SLOW OR BOOM LACKS POWER 522
H-18 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT 523
H-19 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 523
H-20 EXCESSIVE HYDRAULIC DRIFT OF BOOM .524
H-21 BUCKET DOES NOT MOVE 525
H-22 BUCKET IS SLOW OR LACKS POWER .526
H-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET .527
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)(ONLY FOR MACHINE WIGH JOYSTICK AND AUTOMATIC SHIFT CONTROL) 529
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM 530
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE .532
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM .536
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED 538
T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED .539
T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED .540
T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED .541
T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED .542
T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED .543
T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED .544
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED 545
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED .546
T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED 550
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED .553
T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED .554
T-13 SHIFT-UP DOES NOT WORK 555
T-14 SHIFT-DOWN DOES NOT WORK 555
T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING 556
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING 557
T-17 BUZZER DOES NOT WORK 558
T-18 ABNORMALITY IN NETWORK SYSTEM .559
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY .560
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM .561
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS .562
TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE)(ONLY FOR MACHINE WIGH JOYSTICK AND AUTOMATIC SHIFT CONTROL) .563
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM 564
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .566
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM 570
J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED .572
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED 573
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED .574
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED .575
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED 576
J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED .577
J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED 578
J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED 579
J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE 580
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT .581
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 582
J-12 DISCONNECTION IN STEERING LEFT SOLENOID .583
30 DISASSEMBLY AND ASSEMBLY 585
METHOD OF USING MANUAL .587
PRECAUTIONS WHEN CARRYING OUT OPERATION 588
SPECIAL TOOL LIST 590
SKETCHES OF SPECIAL TOOLS 598
STARTING MOTOR .607
REMOVAL AND INSTALLATION .607
ALTERNATOR .608
REMOVAL AND INSTALLATION .608
ENGINE OIL COOLER 609
REMOVAL AND INSTALLATION .609
FUEL INJECTION PUMP 610
REMOVAL AND INSTALLATION .610
WATER PUMP .611
REMOVAL AND INSTALLATION .611
NOZZLE HOLDER 612
REMOVAL AND INSTALLATION .612
TURBOCHARGER .613
REMOVAL 613
INSTALLATION .614
ENGINE FRONT SEAL 615
REPLACEMENT 615
ENGINE REAR SEAL .617
REPLACEMENT 617
CYLINDER HEAD 619
REMOVAL 619
INSTALLATION .624
THERMOSTAT .626
REMOVAL AND INSTALLATION .626
AFTERCOOLER CORE .627
REMOVAL 627
INSTALLATION .628
RADIATOR .629
REMOVAL 629
INSTALLATION .631
ENGINE AND TORQUE CONVERTER ASSEMBLY .632
REMOVAL 632
INSTALLATION .634
TORQUE CONVERTER .635
REMOVAL AND INSTALLATION .635
DISASSEMBLY 636
ASSEMBLY .641
TRANSMISSION .647
REMOVAL 647
INSTALLATION .649
DISASSEMBLY 650
ASSEMBLY .665
TRANSMISSION VALVE .681
REMOVAL AND INSTALLATION .681
TRANSFER .682
DISASSEMBLY 682
ASSEMBLY .691
CENTER SUPPORT .702
REMOVAL AND INSTALLATION .702
DISASSEMBLY 704
ASSEMBLY .706
DRIVE SHAFT 709
DISASSEMBLY 709
ASSEMBLY .712
FRONT AXLE .715
REMOVAL 715
INSTALLATION .716
FRONT DIFFERENTIAL .717
REMOVAL 717
INSTALLATION .718
REAR AXLE 719
REMOVAL 719
INSTALLATION .722
REAR DIFFERENTIAL 723
REMOVAL 723
INSTALLATION .724
DIFFERENTIAL GEAR 725
DISASSEMBLY 725
ASSEMBLY .729
FINAL DRIVE 737
REMOVAL 737
ASSEMBLY .741
ORBIT-ROLL .746
REMOVAL AND INSTALLATION .746
STEERING CYLINDER 747
REMOVAL 747
INSTALLATION .748
DISASSEMBLY 749
ASSEMBLY .751
STEERING VALVE .753
REMOVAL 753
INSTALLATION .754
CUT-OFF VALVE 755
REMOVAL AND INSTALLATION .755
BRAKE VALVE 756
REMOVAL AND INSTALLATION .756
BRAKE VALVE(R.H.) 757
DISASSEMBLY 757
ASSEMBLY .759
BRAKE VALVE(L.H.) 761
DISASSEMBLY 761
ASSEMBLY .763
SLACK ADJUSTER .765
REMOVAL AND INSTALLATION .765
DISASSEMBLY 766
ASSEMBLY .767
BRAKE 768
REMOVAL AND INSTALLATION .768
DISASSEMBLY 769
ASSEMBLY .772
HYDRAULIC PUMP .776
REMOVAL 776
INSTALLATION .777
HYDRAULIC TANK .778
REMOVAL 778
INSTALLATION .779
HYDRAULIC FILTER .780
REMOVAL AND INSTALLATION .780
PPC VALVE 781
REMOVAL AND INSTALLATION .781
DISASSEMBLY AND ASSEMBLY .782
WORK EQUIPMENT VALVE .783
REMOVAL 783
INSTALLATION .784
MAIN CONTROL VALVE .786
DISASSEMBLY 786
ASSEMBLY .790
DUMP CYLINDER 793
REMOVAL 793
INSTALLATION .794
LIFT CYLINDER 795
REMOVAL 795
INSTALLATION .796
LIFT CYLINDER AND DUMP CYLINDER 797
DISASSEMBLY 797
ASSEMBLY .799
CENTER HINGE PIN .802
REMOVAL 802
INSTALLATION .807
WORK EQUIPMENT .810
REMOVAL 810
INSTALLATION .814
BULCKHEAD 816
REMOVAL 816
INSTALLATION .817
FLOOR FRAME 818
REMOVAL 818
INSTALLATION .820
COUNTERWEIGHT 821
REMOVAL AND INSTALLATION .821
FUEL TANK 822
REMOVAL 822
INSTALLATION .823
CAB 824
REMOVAL 824
INSTALLATION .826
STOP VALVE .827
REMOVAL AND INSTALLATION .827
ACCUMULATOR 828
REMOVAL 828
INSTALLATION .829
ACCUMULATOR CHARGE VALVE .831
REMOVAL AND INSTALLATION .831
PARKING BRAKE SOLENOID VALVE .832
REMOVAL AND INSTALLATION .832
DIVERTER VALVE .833
REMOVAL AND INSTALLATION .833
EMERGENCY STEERIGN PUMP 834
REMOVAL AND INSTALLATION .834
PARKING BRAKE 835
REMOVAL 835
INSTALLATION .836
PARKING BRAKE CALIPERS .838
DISASSEMBLY 838
ASSEMBLY .839
PARKING BRAKE PAD 840
REMOVAL AND INSTALLATION .840
REAR TIRES .841
REMOVAL AND INSTALLATION .841
AIR CONDITIONER COMPRESSOR .842
REMOVAL AND INSTALLATION .842
AIR CONDITIONER CONDENSER 843
REMOVAL AND INSTALLATION .843
RECEIVER TANK 844
REMOVAL AND INSTALLATION .844
AIR CONDITIONER UNIT .845
REMOVAL 845
INSTALLATION .846
MONITOR 847
REMOVAL AND INSTALLATION .847
40 MAINTENANCE STANDARD 849
ENGINE MOUNT .850
TRANSMISSION MOUNT .851
TORQUE CONVERTER .852
TRANSMISSION .854
TRANSFER .858
TRANSMISSION CONTROL VALVE .860
DRIVE SHAFT 867
CENTER SUPPORT .868
DIFFERENTIAL .870
FINAL DRIVE 874
AXLE MOUNT .876
CENTER HINGE PIN .878
STEERING COLUMN 880
STEERING VALVE .881
EMERGENCY STEERING PUMP 882
DIVERTER VALVE .883
STEERING CYLINDER MOUNT 884
BRAKE VALVE 885
SLACK ADJUSTER .888
BRAKE 890
PARKING BRAKE 892
HYDRAULIC PUMP .894
PPC VALVE 896
CUT-OFF VALVE 898
MAIN CONTROL VALVE .900
HYDRAULIC CYLINDER .902
WORK EQUIPMENT LINKAGE .904
BUCKET .906
BUCKET POSITIONER AND BOOM KICK-OUT 907
ROPS CANOPY 908
90 OTHERS 909
FOR STANDARD MACHINE .911
ELECTRIC CIRCUIT DIAGRAM(1/4) 911
ELECTRIC CIRCUIT DIAGRAM(2/4) 912
ELECTRIC CIRCUIT DIAGRAM(3/4) 913
ELECTRIC CIRCUIT DIAGRAM(4/4) 914
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL 915
ELECTRIC CIRCUIT DIAGRAM(1/4) 915
ELECTRIC CIRCUIT DIAGRAM(2/4) 916
ELECTRIC CIRCUIT DIAGRAM(3/4) 917
ELECTRIC CIRCUIT DIAGRAM(4/4) 918COVER 1
CONTENTS . 2
01 GENERAL . 27
GENERAL ASSEMBLY DRAWING . 28
SPECIFICATIONS . 29
WEIGHT TABLE . 32
LIST OF LUBRICANT AND WATER 33
10 STRUCTURE AND FUNCTION 35
POWER TRAIN 36
POWER TRAIN SYSTEM . 38
RADIATOR,HYDRAULIC OIL COOLER 40
TORQUE CONVERTER AND TRANSMISSION PIPING . 41
HYDRAULIC CIRCUIT FOR POWER TRAIN 42
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 44
TORQUE CONVERTER . 46
TRANSMISSION . 49
TRANSMISSION CONTROL VALVE . 58
TORQUE CONVERTER OIL COOLER 80
TORQUE CONVERTER OIL FILTER 81
TRANSFER . 83
DRIVE SHAFT 84
CENTER SUPPORT . 85
AXLE . 86
DIFFERENTIAL . 88
LIMITED SLIP DIFFERENTIAL 91
FINAL DRIVE 95
AXLE MOUNT . 98
CENTER HINGE PIN .100
STEERING PIPING 101
STEERING COLUMN 102
STEERING UNIT(ORBIT-ROLL VALVE) 103
STEERING VALVE .106
TWO-WAY RESTRICTION VALVE 117
STOP VALVE .118
EMERGENCY STEERING PIPING 119
DIVERTER VALVE(FOR EMERGENCY STEERING) .120
BRAKE PIPING .124
BRAKE CIRCUIT DIAGRAM 126
BRAKE VALVE 128
CHARGE VALVE .133
ACCUMULATOR(FOR BRAKE) .137
SLACK ADJUSTER .138
BRAKE 141
PARKING BRAKE 143
SPRING CYLINDER 145
PARKING BRAKE SOLENOID VALVE .146
HYDRAULIC PIPING .148
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .150
WORK EQUIPMENT LEVER LINKAGE .152
HYDRAULIC TANK .153
ACCUMULATOR(FOR PPC VALVE) .155
PPC VALVE 156
PPC RELIEV VALVE .160
CUT-OFF VALVE 161
MAIN CONTROL VALVE .164
LUBRICATION OF WORK EQUIPMENT 178
WORK EQUIPMENT LINKAGE .180
BUCKET .182
BUCKET POSITIONER AND BOOM KICK-OUT 183
OPERATION OF PROXIMITY SWITCH 185
ROPS CANOPY 189
CAB 190
CAB HEATER .191
AIR CONDITIONER 193
ELECTRIC CIRCUIT DIAGRAM .196
MACHINE MONITOR SYSTEM .202
MAIN MONITOR .203
MAINTENAMCE MONITOR 208
MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL 210
ENGINE STARTING CIRCUIT 226
ENGINE STOP CIRCUIT 228
5-AUTO PRIMING SYSTEM(APS) .229
ELECTRIC TRANSMISSION CONTROL 233
KICK-DOWN,HOLD SWITCH 236
KICK-DOWN ELECTRICAL CIRCUIT .237
ELECTRIC PARKING BRAKE CONTROL .243
20 TESTING AND ADJUSTING .253
STANDARD VALUE TABLE FOR ENGINE 254
STANDARD VALUE TABLE FOR CHASSIS .255
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 260
TESTING AND ADJUSTING 273
TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING .274
MEASURING ENGINE SPEED .275
MEASURING EXHAUST GAS COLOR 277
ADJUSTIN VALVE CLEARANCE .278
MEASURING COMPRESSION PRESSURE .279
MEASURING BLOW-BY PRESSURE .280
MEASURING ENGINE OIL PRESSURE 281
TESTING AND ADJUSTING FUEL INJECTION TIMING 282
REPLACING FAN BELT ADJUSTING AUTO-TENSIONER 284
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 285
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 285
MEASURING EXHAUST TEMPERATURE 286
MEASURING AIR SUPPLY PRESSURE(BOOST PRESSURE) 287
ADJUSTING SPEED SENSOR .288
ADJUSTING FUEL CONTROL CABLE .289
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE .290
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE .292
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT .297
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS .298
TESTING AND ADJUSTING STEERING OIL PRESSURE 300
TESTING AND ADJUSTING STEERING STOP VALVE 302
TESTING BRAKE OIL PRESSURE .303
MEASURING WEAR OF BRAKE DISC .304
MEASURING BRAKE PERFORMANCE 305
TESTING AND ADJUSTING PARKING BRAKE 306
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE .308
TESTING AND ADJUSTING PPC OIL PRESSURE .309
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 311
ADJUSTING WORK EQUIPMENT LEVER LINKAGE .313
TESTING AND ADJUSTING OF BUCKET POSITIONER .315
TESTING AND ADJUSTING OF BOOM KICK-OUT .316
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP 317
ADJUSTING MAIN MONITOR(SPEEDOMETER MODULE) .318
BLEEDING AIR .319
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 320
TROUBLESHOOTING 321
POINTS TO REMEMBER WHEN TROUBLESHOOTING 322
SEQUENCE OF EVENTS IN TROUBLESHOOTING 323
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .324
CHECKS BEFORE TROUBLESHOOTING 332
CONNECTOR TYPES AND MOUNTING LOCATIONS .333
CONNECTOR ARRANGEMENT DIAGRAM 336
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .340
METHOD OF USING TROUBLESHOOTING CHARTS .349
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 351
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 353
METHOD OF USING TROUBLESHOOTING CHARTS .354
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME) .358
S-2 ENGINE DOES NOT START 360
(1) ENGINE DOES NOT START .360
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED) 361
(3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 362
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY(FOLLOW-UP IS POOR) 363
S-4 ENGINE STOPS DURING OPERATIONS .364
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) .365
S-6 ENGINE LACKS OUTPUT 366
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION) 367
S-8 OIL COMSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE) .368
S-9 OIL BECOMES CONTAMINATED QUICKLY .369
S-10 FUEL CONSUMPTION IS EXCESSIVE .370
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN .371
S-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE) .372
S-13 OIL LEVEL RISES .373
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) .374
S-15 ABNORMAL NOISE IS MADE 375
S-16 VIBRATION IS EXCESSIVE 376
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 377
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR 380
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN .382
M-1 MAIN MONITOR DOES NOT WORK .383
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP 384
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY .385
M-4 ABNORMALITY IN SHIFT INDICATOR .386
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F 386
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R 386
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N 386
d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST 387
e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND 387
f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD 387
g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH 387
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP 389
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 390
a) L.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP .390
b) R.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP .390
M-7 ABNORMALITY IN PARKING LAMP DISPLAY 391
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP 391
b) PARKING LAMP DISPLAY STAYS LIGHTED UP .391
M-8 ABNORMALITY IN PREHEATING SYSTEM .392
a) PREHEATING DISPLAY DOES NOT LIGHT UP 392
b) PREHEATING DISPLAY STAYS LIGHTED UP .392
M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP 393
M-10 ABNORMALITY IN FRONT WORKING LAMP .394
a) NEITHER MONITOR DISPLAY NOR FRONG WORKIGN LAMP LIGHT UP .394
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP .394
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP 394
M-11 ABNORMALITY IN REAR WORKIGN LAMP 396
a) NEITHER MONITOR DISPLAY NOR RERA WORKING LAMP LIGHT UP 396
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP .396
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP 396
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF .398
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE 398
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED 398
c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON,BUT CUT-OFF FUNCTION IS NOT ACTUATED .399
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN .400
a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N .400
b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N 400
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED .401
a) ACTUATED CONTINUOUSLY .401
b) NOT ACTUATED 401
M-15 ABNORMALITY IN BUZZER .402
a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON .402
b) BUZZER ALWAYS SOUNDS 402
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY .403
M-17 ABNORMALITY IN FAILURE DISPLAY MODE .404
a) FAILURE DISPLAY MODE DOES NOT WORK 404
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE .404
M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY .405
a) EMERGENCY STEERING DISPLAY DOES NOT FLASH .405
b) EMERGENCY STEERING DISPLAY STAYS FLASHED 405
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) .407
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR .408
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK .410
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP 410
b) SOME LAMPS DO NOT LIGHT UP 410
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SECONDS .411
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT 412
K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES .413
a) ENGINE OIL LEVEL DISPLAY FLASHES 413
b) ENGINE WATER LEVEL DISPLAY FLASHES 414
K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES .415
a) ENGINE OIL PRESSURE DISPLAY FLASHES .415
b) BATTERY CHARGE DISPLAY FLASHES 416
c) BRAKE OIL PRESSURE DISPLAY FLASHES 417
d) AIR CLEANER CLOGGED DISPLAY FLASHES .418
K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND .419
K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS .420
K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH .421
a) CHECK LAMP 421
b) CAUTION LAMP 421
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP 422
a) CHECK LAMP 422
b) CAUTION LAMP 422
K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON 423
K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF 424
K-12 SERVICE METER DOES NOT WORK .425
K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED 425
K-14 ABNORMALITY IN GAUGES .426
a) ABNORMALITY IN FUEL GAUGE .426
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE .427
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE .428
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 429
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM .431
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE 432
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN .433
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER .434
E-1 ENGINE DOES NOT START .436
a) STARTING MOTOR DOES NOT TURN 436
b) STARTING MOTOR TURNS 442
E-2 ENGINE DOES NOT STOP .446
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING .446
E-4 ABNORMALITY IN APS SYSTEM 448
a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP 450
b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL 451
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL .452
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .453
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .453
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .454
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .454
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .455
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL .455
j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP .456
E-5 PARKING BRAKE DOES NOT HAVE EFFECT .457
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON 457
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS 457
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING .458
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 460
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY .460
E-9 TRANSMISSION DOES NOT WORK PROPERLY 462
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT .464
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT 468
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT 470
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT .472
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT .478
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT .481
E-10 KICK-DOWN SWITCH DOES NOT WORK 486
E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON .489
E-12 KICK-DOWN ALWAYS WORKS 490
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND .492
E-14 BOOM KICK-OUT DOES NOT WORK .494
E-15 DEFECTIVE BUCKET POSITIONER .498
E-16 POWER WINDOW DOES NOT WORK 501
a) POWER WINDOW DOES NOT RISE 501
b) POWER WINDOW DOES NOT LOWER .502
E-17 ABNORMALITY IN FRONT WORKING LAMP .504
E-18 ABNORMALITY IN REAR WORKING LAMP 504
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF .504
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING .504
E-21 ABNORMALITY IN BUZZER .504
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 505
H-1 MACHINE DOES NOT START .506
H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES 507
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 508
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 509
H-5 STEERING DOES NOT TURN .510
H-6 TURNING,RESPONSE OF STEERING IS POOR .511
H-7 STEERING IS HEAVY 512
H-8 STEERING WHEEL SHAKES OR JERKS .513
H-9 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING .513
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 514
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG 516
H-12 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR .517
H-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 518
H-14 NEITHER BOOM NOR BUCKET MOVE 519
H-15 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER .520
H-16 BOOM DOES NOT MOVE 521
H-17 BOOM IS SLOW OR BOOM LACKS POWER 522
H-18 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT 523
H-19 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 523
H-20 EXCESSIVE HYDRAULIC DRIFT OF BOOM .524
H-21 BUCKET DOES NOT MOVE 525
H-22 BUCKET IS SLOW OR LACKS POWER .526
H-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET .527
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)(ONLY FOR MACHINE WIGH JOYSTICK AND AUTOMATIC SHIFT CONTROL) 529
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM 530
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE .532
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM .536
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED 538
T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED .539
T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED .540
T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED .541
T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED .542
T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED .543
T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED .544
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED 545
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED .546
T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED 550
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED .553
T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED .554
T-13 SHIFT-UP DOES NOT WORK 555
T-14 SHIFT-DOWN DOES NOT WORK 555
T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING 556
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING 557
T-17 BUZZER DOES NOT WORK 558
T-18 ABNORMALITY IN NETWORK SYSTEM .559
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY .560
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM .561
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS .562
TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE)(ONLY FOR MACHINE WIGH JOYSTICK AND AUTOMATIC SHIFT CONTROL) .563
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM 564
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .566
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM 570
J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED .572
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED 573
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED .574
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED .575
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED 576
J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED .577
J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED 578
J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED 579
J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE 580
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT .581
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 582
J-12 DISCONNECTION IN STEERING LEFT SOLENOID .583
30 DISASSEMBLY AND ASSEMBLY 585
METHOD OF USING MANUAL .587
PRECAUTIONS WHEN CARRYING OUT OPERATION 588
SPECIAL TOOL LIST 590
SKETCHES OF SPECIAL TOOLS 598
STARTING MOTOR .607
REMOVAL AND INSTALLATION .607
ALTERNATOR .608
REMOVAL AND INSTALLATION .608
ENGINE OIL COOLER 609
REMOVAL AND INSTALLATION .609
FUEL INJECTION PUMP 610
REMOVAL AND INSTALLATION .610
WATER PUMP .611
REMOVAL AND INSTALLATION .611
NOZZLE HOLDER 612
REMOVAL AND INSTALLATION .612
TURBOCHARGER .613
REMOVAL 613
INSTALLATION .614
ENGINE FRONT SEAL 615
REPLACEMENT 615
ENGINE REAR SEAL .617
REPLACEMENT 617
CYLINDER HEAD 619
REMOVAL 619
INSTALLATION .624
THERMOSTAT .626
REMOVAL AND INSTALLATION .626
AFTERCOOLER CORE .627
REMOVAL 627
INSTALLATION .628
RADIATOR .629
REMOVAL 629
INSTALLATION .631
ENGINE AND TORQUE CONVERTER ASSEMBLY .632
REMOVAL 632
INSTALLATION .634
TORQUE CONVERTER .635
REMOVAL AND INSTALLATION .635
DISASSEMBLY 636
ASSEMBLY .641
TRANSMISSION .647
REMOVAL 647
INSTALLATION .649
DISASSEMBLY 650
ASSEMBLY .665
TRANSMISSION VALVE .681
REMOVAL AND INSTALLATION .681
TRANSFER .682
DISASSEMBLY 682
ASSEMBLY .691
CENTER SUPPORT .702
REMOVAL AND INSTALLATION .702
DISASSEMBLY 704
ASSEMBLY .706
DRIVE SHAFT 709
DISASSEMBLY 709
ASSEMBLY .712
FRONT AXLE .715
REMOVAL 715
INSTALLATION .716
FRONT DIFFERENTIAL .717
REMOVAL 717
INSTALLATION .718
REAR AXLE 719
REMOVAL 719
INSTALLATION .722
REAR DIFFERENTIAL 723
REMOVAL 723
INSTALLATION .724
DIFFERENTIAL GEAR 725
DISASSEMBLY 725
ASSEMBLY .729
FINAL DRIVE 737
REMOVAL 737
ASSEMBLY .741
ORBIT-ROLL .746
REMOVAL AND INSTALLATION .746
STEERING CYLINDER 747
REMOVAL 747
INSTALLATION .748
DISASSEMBLY 749
ASSEMBLY .751
STEERING VALVE .753
REMOVAL 753
INSTALLATION .754
CUT-OFF VALVE 755
REMOVAL AND INSTALLATION .755
BRAKE VALVE 756
REMOVAL AND INSTALLATION .756
BRAKE VALVE(R.H.) 757
DISASSEMBLY 757
ASSEMBLY .759
BRAKE VALVE(L.H.) 761
DISASSEMBLY 761
ASSEMBLY .763
SLACK ADJUSTER .765
REMOVAL AND INSTALLATION .765
DISASSEMBLY 766
ASSEMBLY .767
BRAKE 768
REMOVAL AND INSTALLATION .768
DISASSEMBLY 769
ASSEMBLY .772
HYDRAULIC PUMP .776
REMOVAL 776
INSTALLATION .777
HYDRAULIC TANK .778
REMOVAL 778
INSTALLATION .779
HYDRAULIC FILTER .780
REMOVAL AND INSTALLATION .780
PPC VALVE 781
REMOVAL AND INSTALLATION .781
DISASSEMBLY AND ASSEMBLY .782
WORK EQUIPMENT VALVE .783
REMOVAL 783
INSTALLATION .784
MAIN CONTROL VALVE .786
DISASSEMBLY 786
ASSEMBLY .790
DUMP CYLINDER 793
REMOVAL 793
INSTALLATION .794
LIFT CYLINDER 795
REMOVAL 795
INSTALLATION .796
LIFT CYLINDER AND DUMP CYLINDER 797
DISASSEMBLY 797
ASSEMBLY .799
CENTER HINGE PIN .802
REMOVAL 802
INSTALLATION .807
WORK EQUIPMENT .810
REMOVAL 810
INSTALLATION .814
BULCKHEAD 816
REMOVAL 816
INSTALLATION .817
FLOOR FRAME 818
REMOVAL 818
INSTALLATION .820
COUNTERWEIGHT 821
REMOVAL AND INSTALLATION .821
FUEL TANK 822
REMOVAL 822
INSTALLATION .823
CAB 824
REMOVAL 824
INSTALLATION .826
STOP VALVE .827
REMOVAL AND INSTALLATION .827
ACCUMULATOR 828
REMOVAL 828
INSTALLATION .829
ACCUMULATOR CHARGE VALVE .831
REMOVAL AND INSTALLATION .831
PARKING BRAKE SOLENOID VALVE .832
REMOVAL AND INSTALLATION .832
DIVERTER VALVE .833
REMOVAL AND INSTALLATION .833
EMERGENCY STEERIGN PUMP 834
REMOVAL AND INSTALLATION .834
PARKING BRAKE 835
REMOVAL 835
INSTALLATION .836
PARKING BRAKE CALIPERS .838
DISASSEMBLY 838
ASSEMBLY .839
PARKING BRAKE PAD 840
REMOVAL AND INSTALLATION .840
REAR TIRES .841
REMOVAL AND INSTALLATION .841
AIR CONDITIONER COMPRESSOR .842
REMOVAL AND INSTALLATION .842
AIR CONDITIONER CONDENSER 843
REMOVAL AND INSTALLATION .843
RECEIVER TANK 844
REMOVAL AND INSTALLATION .844
AIR CONDITIONER UNIT .845
REMOVAL 845
INSTALLATION .846
MONITOR 847
REMOVAL AND INSTALLATION .847
40 MAINTENANCE STANDARD 849
ENGINE MOUNT .850
TRANSMISSION MOUNT .851
TORQUE CONVERTER .852
TRANSMISSION .854
TRANSFER .858
TRANSMISSION CONTROL VALVE .860
DRIVE SHAFT 867
CENTER SUPPORT .868
DIFFERENTIAL .870
FINAL DRIVE 874
AXLE MOUNT .876
CENTER HINGE PIN .878
STEERING COLUMN 880
STEERING VALVE .881
EMERGENCY STEERING PUMP 882
DIVERTER VALVE .883
STEERING CYLINDER MOUNT 884
BRAKE VALVE 885
SLACK ADJUSTER .888
BRAKE 890
PARKING BRAKE 892
HYDRAULIC PUMP .894
PPC VALVE 896
CUT-OFF VALVE 898
MAIN CONTROL VALVE .900
HYDRAULIC CYLINDER .902
WORK EQUIPMENT LINKAGE .904
BUCKET .906
BUCKET POSITIONER AND BOOM KICK-OUT 907
ROPS CANOPY 908
90 OTHERS 909
FOR STANDARD MACHINE .911
ELECTRIC CIRCUIT DIAGRAM(1/4) 911
ELECTRIC CIRCUIT DIAGRAM(2/4) 912
ELECTRIC CIRCUIT DIAGRAM(3/4) 913
ELECTRIC CIRCUIT DIAGRAM(4/4) 914
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL 915
ELECTRIC CIRCUIT DIAGRAM(1/4) 915
ELECTRIC CIRCUIT DIAGRAM(2/4) 916
ELECTRIC CIRCUIT DIAGRAM(3/4) 917
ELECTRIC CIRCUIT DIAGRAM(4/4) 918

DESCRIPTION:

Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 – PDF DOWNLOAD

• MACHINE MODEL            SERIAL NO.
  WA600-3                            50363 and up

GENERAL PRECAUTIONS:
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual care- fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while work- ing.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from fall- ing. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to pro- vide safe footing.

PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carry- ing out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the nega- tive (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to pre- vent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

G.B 25/12/24