Komatsu.WA600-3 avance Wheel Loader Service Repair Shop Manual (50001 and up) - SEBM013218

This Complete Service Repair Workshop Manual PDF Download for the WA600-3 avance Komatsu Wheel Loader (SN: 50001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WA600-3 Wheel Loader
Serial Numbers : 50001 and up

Komatsu WA600-3D (TBG SPEC.) Wheel Loader
Serial Numbers : 50001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEBM013218
Total Pages : 1200


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
CONTENTS

01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND COOLANT

10 STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN SYSTEM
RADIATOR,HYDRAULIC OIL COOLER
RADIATOR, HYDRAULIC OIL COOLER (WITH SUCTION FAN)
TORQUE CONVERTER AND TRANSMISSION PIPING
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
TORQUE CONVERTER
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)
TRANSMISSION
TRANSMISSION CONTROL VALVE
TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER OIL FILTER
TRANSFER
DRIVE SHAFT
CENTER SUPPORT
AXLE
DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL(OP)
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN
STEERING UNIT (ORBIT-ROLL VAVLE)
STEERING VALVE
TWO-WAY RESTRICTION VALVE
STOP VALVE
EMERGENCY STEERING PIPING
DIVERTER VALVE (FOR EMERGENCY STEERING)
BRAKE PIPING
BRAKE CIRCUIT DIAGRAM
BRAKE VALVE
CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
SLACK ADJUSTER
BRAKE
PARKING BRAKE
SPRING CYLINDER
PARKING BRAKE SOLENOID VALVE
HYDRAULIC PIPING
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
HYDRAULIC TANK
ACCUMULATOR (FOR PPC VALVE)
PPC VALVE
PPC RELIEF VALVE
CUT-OFF VALVE
MAIN CONTROL VALVE
AUTO GREASE SYSTEM
LUBRICATION OF WORK EQUIPMENT
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
OPERATION OF PROXIMITY SWITCH
ROPS CANOPY
CAB
CAR HEATER
AIR CONDITIONER
ELECTRIC CIRCUIT DIAGRAM
MACHINE MONITOR SYSTEM
MAIN MONITOR
MANITENANCE MONITOR
MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
AUTO PRIMING SYSTEM (APS) (SERIAL NO.:50001-52000)
PRE-HEATING CIRCUIT (SERIAL NO.:52001 AND UP)
ELECTRIC TRANSMISSION CONTROL
KICK-DOWN,HOLD SWITCH
KICK-DOWN ELECTRICAL CIRCUIT
ELECTRIC PARKING BRAKE CONTROL
E.C.S.S.(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST GAS COLOR
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING INJECTOR LIFT (SERIAL NO.:52001 AND UP)
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FUEL INJECTON TIMING (SERIAL NO.:50001-52000)
REPLACING FAN BELT ADJUSTING AUTO-TENSIONER
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
HANDLING EQUIPMENT IN FUEL CIRCUIT (SERIAL NO.:52001 AND UP)
MEASURING FUEL PUMP OUTPUT PORT PRESSURE (SERIAL NO.:52001 AND UP)
BLEEDING AIR FROM FUEL CIRCUIT (SERIAL NO.:52001 AND UP)
MEASURING EXHAUST TEMPERATURE
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
ADJUSTING SPEED SENSOR
ADJUSTIN FUEL CONTROL CABLE (SERIAL NO.:50001-52000)
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.:50001-52000)
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
TESTING AND ADJUSTING STEERING OIL PRESSURE
TESTING AND ADJUSTING STEERING STOP VALVE
TESTING BRAKE OIL PRESSURE
MEASURING WEAR OF BRAKE DISC
MEASURING BRAKE PERFORMANCE
TESTING AND ADJUSTING PARKING BRAKE
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE
TESTING AND ADJUSTING PPC OIL PRESSURE
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
ADJUSTING WORK EQUIPMENT LEVER LINKAGE
TESTING AND ADJUSTING OF BUCKET POSITIONER
TESTING AND ADJUSTING OF BOOM KICK-OUT
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHART
S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
(1) ENGINE DOES NOT TURN
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
(3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS COOLING, OR COOLANT SPURTS BACK,OR COOLANT LEVEL GOES DOWN
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE)
METHOD OF ERROR CODE DISPLAY
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED
SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM
EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)
EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)
EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)
EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)
EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)
EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)
EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)
EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)
EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)
EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)
EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)
EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)
EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL)
EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIHG LEVEL)
EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)
EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))
EA-17 ERROR CODE [144] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM HIGH LEVEL)
EA-18 ERROR CODE [145] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM LOW LEVEL)
EA-19 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)
EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)
EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMERATURE SENSOR SYSTEM LOW LEVEL)
EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)
EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)
EA-24 ERROR CODE [234] (OVERSPEED)
EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)
EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)
EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)
EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL)
EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)
EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)
EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)
EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)
EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)
EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)
EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))
EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)
EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)
EA-38 ERROR CODE [432] (IDLE VALIDATION PROCESS ERROR)
EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL)
EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)
EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)
EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)
EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)
EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)
EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)
EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)
EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLE VALIDATION SWITCH SYSTEM)
EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
M-1 MAIN MONITOR DOES NOT WORK
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
M-4 ABNORMALITY IN SHIFT INDICATOR
a) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT F
b) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT R
c) DOES NOT DISPLAY N EVEN WHEN DIRCETIONAL LEVER IS AT N
d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST
e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND
f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD
g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
a) L.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP
b) R.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP
M-7 ABNORMALITY IN PARKING LAMP DISPLAY
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP
b) PARKING LAMP DISPLAY STAYS LIGHTED UP
M-8 ABNORMALITY IN PREHEATING DISPLAY
a) PREHEATIGN DISPLAY DOES NOT LIGHT UP
b) PREHEATIGN DISPLAY STAYS LIGHTED UP
M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP
M-10 ABNORMALITY IN FRONT WORKING LAMP
a) NEITHER MONITOR DISPLAY NOR FRONT WORKIGN LAMP LIGHT UP
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP
M-11 ABNORMALITY IN REAR WORKIGN LAMP
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED
c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN
a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AN N
b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRCETIONAL LEVER IS AT POSITION OTHER THAN N
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED
a) ACTUATED CONTINUOUSLY
b) NOT ACTUATED
M-15 ABNORMALITY IN BUZZER
a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON
b) BUZZER ALWAYS SOUNDS
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY
M-17 ABNORMALITY IN FAILURE DISPLAY MODE
a) FAILURE DISPLAY MODE DOES NOT WORK
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE
M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY
a) EMERGENCY STEERING DISPLAY DOES NOT FLASH
b) EMERGENCY STEERING DISPLAY STAYS FLASHED
M-19 ABNORMALITY IN AUTO-GREASING SYSTEM
a) FORCED GREASING CANNOT BE CARRIED OUT
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)
c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES REPIDLY (2 TIMES/SEC)
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)
e) MONITOR DISPLAY GOES OUT
M-20 ABNORMALITY IN ECSS SYSTEM
a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED
b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SCONDS,MAINTENANCE MONITOR DOES NOT WORK
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP
b) SOME LAMPS DO NOT LIGHT UP
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SCONDS
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTIGN SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT
K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES
a) ENGINE OIL LEVEL DISPLAY FLASHES
b) ENGINE COOLANT LEVEL DISPLAY FLASHES
K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES
a) ENGINE OIL PRESSURE DISPLAY FLASHES
b) BATTERY CHARGE DISPLAY FLASHES
c) BRAKE OIL PRESSURE DISPLAY FLASHES
d) AIR CLEANER CLOGGED DISPLAY FLASHES
K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND
K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS
K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH
a) CHECK LAMP
b) CAUTION LAMP
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP
a) CHECK LAMP
b) CAUTION LAMP
K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON
K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF
K-12 SERVICE METER DOES NOT WORK
K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED
K-14 ABNORMALITY IN GAUGES
a) ABNORMALITY IN FUEL GAUGE
b) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER
E-1 ENGINE DOES NOT START
a) STARTING MOTOR DOES NOT TURN
b) STARTING MOTOR TURNS
E-2 ENGINE DOES NOT STOP (SERIAL NO.:50001-52000)
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (SERIAL NO.:50001-52000)
E-4A ABNORMALITY IN APS SYSTEM (SERIAL NO.:50001-52000)
a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP
b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL
j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP
E-4B PREHEATING FAULT (SERIAL NO.:52001 AND UP)
E-5 PARKING BRAKE DOES NOT HAVE EFFECT
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY
E-9 TRANSMISSION DOES NOT WORK PROPELY
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRCETIONAL SOLENOID CIRCUIT
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT
E-10 KICK-DOWN SWITCH DOES NOT WORK
E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON
E-12 KICK-DOWN ALWAYS WORKS
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND
E-14 BOOM KICK-OUT DOES NOT WORK
E-15 DEFECTIVE BUCKET POSITIONER
E-16 POWER WINDOW DOES NOT WORK
a) POWER WINDOW DOES NOT RISE
b) POWER WINDOW DOES NOT LOWER
E-17 ABNORMALITY IN FRONT WORKING LAMP
E-18 ABNORMALITY IN REAR WORKING LAMP
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
E-21 ABNORMALITY IN BUZZER
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
POWER TRAIN
H-1 MACHINE DOES NOT START
H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
STEERING SYSTEM
H-5 STEERING WHEEL DOES NOT TURN
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]
H-7 TURNING,RESPONSE OF STEERING IS POOR
H-8 TURNING,RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]
H-9 STEERING IS HEAVY
H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]
H-11 STEERING WHEEL SHAKES OR JERKS
H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING
BRAKE SYSTEM
H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR
H-17 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)
WORK EQUIPMENT
H-18 NEITHER LIFT ARM NOR BUCKET MOVE
H-19 BOTH LIFT ARM AND BUCKET ARE SLOW OR LACK POWER
H-20 LIFT ARM DOES NOT MOVE
H-21 LIFT ARM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]
H-22 LIFT ARM IS SLOW OR BOOM LACKS POWER
H-23 LIFT ARM IS SLOW OR BOOM LACKS POWER [MACHINES WITH REMOTE BOOM CONTROL]
H-24 LIFT ARM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT
H-25 LIFT ARM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE
H-26 REMOTE LIFT ARM CONTROL DOES NOT WORK [MACHINES WITH REMOTE BOOM CONTROL]
H-27 EXCESSIVE HYDRAULIC DRIFT OF LIFT ARM
H-28 BUCKET DOES NOT MOVE
H-29 BUCKET IS SLOW OR LACKS POWER
H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET
H-31 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED
T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED
T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED
T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED
T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED
T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED
T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED
T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED
T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED
T-13 SHIFT-UP DOES NOT WORK
T-14 SHIFT-DOWN DOES NOT WORK
T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING
T-17 BUZZER DOES NOT WORK
T-18 ABNORMALITY IN NETWORK SYSTEM
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS
TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM
J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED
J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED
J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED
J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED
J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
J-12 DISCONNECTION IN STEERING LEFT SOLENOID
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)
ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
D-1 ECSS DOES NOT WORK
a) ERROR CODE [d0] IS DISPLAYED
b) ERROR CODE [d1] IS DISPLAYED
c) ERROR CODE [d2] IS DISPLAYED
d) ERROR CODE [d3] IS DISPLAYED
e) ERROR CODE [d4] IS DISPLAYED
f) ERROR CODE [d5] IS DISPLAYED
g) ERROR CODE [d6] IS DISPLAYED
h) NO ABNORMALITY DISPLAY IS GIVEN
D-2 ECSS CANNOT BE CANCELED

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER (SERIAL NO.:50001-52000)
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP (SERIAL NO.:50001-52000)
REMOVAL AND INSTALLATION
WATER PUMP (SERIAL NO.:50001-52000)
REMOVAL AND INSTALLATION
NOZZLE HOLDER (SERIAL NO.:50001-52000)
REMOVAL AND INSTALLATION
TURBOCHARGER (SERIAL NO.:50001-52000)
REMOVALL
INSTALLATION
ENGINE FRONT SEAL (SERIAL NO.:50001-52000)
REPLACEMENT
ENGINE REAR SEAL (SERIAL NO.:50001-52000)
REPLACEMENT
CYLINDER HEAD (SERIAL NO.:50001-52000)
REMOVAL
INSTALLATION
THERMOSTAT (SERIAL NO.:50001-52000)
REMOVAL AND INSTALLATION
AFTERCOOLER CORE (SERIAL NO.:50001-52000)
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
RADIATOR (WITH SUCTION FAN)
REMOVAL
INSTALLATION
ENGINE AND TORQUE CONVERTER ASSEMBLY
REMOVAL
INSTALLATION
TORQUE CONVERTER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION VALVE
REMOVAL AND ASSEMBLY
TRANSFER
DISASSEMBLY
ASSEMBLY
CENTER SUPPORT
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
DRIVE SHAFT
DISASSEMBLY
ASSEMBLY
FRONT AXLE
REMOVAL
INSTALLATION
FRONT DIFFERENTIAL
REMOVAL
INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
REAR DIFFERENTIAL
REMOVAL
INSTALLATION
DIFFERENTIAL GEAR
DISASSEMBLY
ASSEMBLY
LIMITED SLIP DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
REMOAL
ASSEMBLY
ORBIT-ROLL
REMOVAL AND INSTALLATION
STEERING CYLINFER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING VALVE
REMOVAL
INSTALLATION
CUT-OFF VALVE
REMOVAL AND INSTALLATION
BRAKE VALVE
REMOVAL AND INSTALLATION
BRAKE VALVE (R.H.)
DISASSEMBLY
ASSEMBLY
BRAKE VALVE (L.H.)
DISASSEMBLY
ASSEMBLY
SLACK ADJUSTER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
BRAKE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC PUMP
REMOVAL
INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
HUDRAULIC FILTER
REMOVAL AND INSTALLATION
PPC VALVE
REMOVAL AND INSTALLATION
DISADDEMBLY AND ASSEMBLY
WORK EQUIPMENT VALVE
REMOVAL
INSTALLATION
MAIN CONTROL VALVE
DISASSEMBLY
ASSEMBLY
DUMP CYLINDER
REMOVAL
INSTALLATION
LIFT CYLINDER
REMOVAL
INSTALLATION
LIFT DYLINDER AND DUMP CYLINDER
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN
REMOVAL
INSTALLATION
WORK EQUIPMENT
REMOVAL
INSTALLATION
BULKHEAD
REMOVAL
INSTALLATION
FLOOR FRAME
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
CAB
REMOVAL
INSTALLATION
STOP VALVE
REMOVAL AND INSTALLATION
ACCUMULATOR
REMOVAL AND INSTALLATION
ASSUMULATOR CHARGR VALVE
REMOVAL AND INTALLATION
PARKING BRAKE SOLENOID VALVE
REMOVAL AND SINTALLATION
DIVERTER VALVE
REMOVAL AND INSTALLATION
EMERGENCY STEERING PUMP
REMOVAL AND INSTALLATION
PARKING BRAKE
REMOVAL AND INSTALLATION
PARKING BRAKE CALIPERS
DISASSEMBLY
ASSEMBLY
PARKING BRAKE PAD
REMOVAL AND INSTALLATION
REAR TIRES
REMOVAL AND INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL
INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION
RECEIVER TANK
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
MONITOR
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT
TRANSMISSION MOUNT
TORQUE CONVERTER
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)
TRANSMISSION
TRANSFER
TRANSMISSION CONTROL VALVE
DRIVE SHAFT
CENTER SUPPORT
DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)
FINAL DRIVE
AXLE MOUNT
STEERING COLUMN
STEERING VLAVE
EMERGENCY STEERING PUMP
DIVERTER VALVE
STEERING CYLINDER MOUNT
BRAKE VALVE
SLACK ADJUSTER
BRAKE
PARKING BRAKE
HYDRAULIC PUMP
PPC VALVE
CUT-OFF VALVE
MAIN CONTROL VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
ROPS CANOPY

90 OTHERS
FOR STANDARD MACHINE (SERIAL NO.:50001-52000)
ELECTRIC CIRCUIT DIAGRAM (1/4)
ELECTRIC CIRCUIT DIAGRAM (2/4)
ELECTRIC CIRCUIT DIAGRAM (3/4)
ELECTRIC CIRCUIT DIAGRAM (4/4)
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.50001-52000)
ELECTRIC CIRCUIT DIAGRAM (1/4)
ELECTRIC CIRCUIT DIAGRAM (2/4)
ELECTRIC CIRCUIT DIAGRAM (3/4)
ELECTRIC CIRCUIT DIAGRAM (4/4)
FOR STANKARD MACHINE (SERIAL NO.52001 AND UP)
ELECTRIC CIRCUIT DIAGAM (1/5)
ELECTRIC CIRCUIT DIAGAM (2/5)
ELECTRIC CIRCUIT DIAGAM (3/5)
ELECTRIC CIRCUIT DIAGAM (4/5)
ELECTRIC CIRCUIT DIAGAM (5/5)
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.52001 AND UP)
ELECTRIC CIRCUIT DIAGRAM (1/3)
ELECTRIC CIRCUIT DIAGRAM (2/3)
ELECTRIC CIRCUIT DIAGRAM (3/3)

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