Komatsu WA700 Loader Factory Service & Shop Manual
Catalog:
Model:
Complete workshop service manual with electrical wiring diagrams for Komatsu WA700-1, WA700-3, WA700-3L Wheel Loader. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Komatsu WA700-1, WA700-3, WA700-3L Wheel Loader service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
CEAM004401 - Wheel Loader WA700-3L avance plus Operation & Maintenance Manual.pdf
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SEBM04270104 - Wheel Loader WA700-1 Shop Manual.pdf
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EXCERPT:
TESTING BRAKE PERFORMANCE
Conditions for measurement
1) Start the engine and then start the machine.
2) Place the speed control lever in the highest speed range and drive the machine.
3) When the machine is traveling at 20 km/h, depress the left brake pedal with 38 kg. * Decide the run-up road and point to apply the brakes, then apply the brakes when the braking point is reached.
4) Measure the distance from the braking point to the point when the machine stops. * Carry out the test three times and take the average value.
CHECKING BRAKE PISTON LEAKAGE
* Stop the machine on level ground, lower the work equipment to the ground and put blocks under the wheels.
Measuring procedure
1. Remove bleeder screw (1 ), then install brake test kit A in bleeder screw mount.
2. Start the engine and bleed the air. * Two worker are need for this operation: one depress the brake pedal and the other bleeds the air from bleeder screw (2). * Check that there is no leakage on air pipings and brake pipings.
3. Rise air pressure to upper limit of green range.
4. Depress the brake pedal fully, insert several washers in portion a, hold the pedal in position, and stop the engine.
5. When gauge reading is 43 to 53 kg/cm2, leave for 5 minutes and check how much pressure drops.
6. After measuring, loosen bleeder screw to release pressure, then remove brake test kit A. * After completing operation, bleed air from brake circuit again.
...
CEAM004401 - Wheel Loader WA700-3L avance plus Operation & Maintenance Manual....2
COVER....2
INTRODUCTION....8
FOREWORD....9
SAFETY INFORMATION....10
INTRODUCTION....11
INTENDED USE....11
FEATURES....11
BREAKING IN A NEW MACHINE....12
PLATE LOCATIONS....13
MACHINE SERIAL NUMBER PLATE....13
PLATE LOCATION....13
STAMP LOCATION....13
ENGINE SERIAL NUMBER PLATE....13
PLATE LOCATION....13
STAMP POSITION....13
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR....14
TABLE OF CONTENTS....15
SAFETY....26
GENERAL PRECAUTIONS AND SAFETY RULES....27
GENERAL SAFETY RULES....27
SAFETY FEATURES....28
CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT....28
UNAUTHORIZED MODIFICATIONS....28
WHEN LEAVING OPERATORS COMPARTMENT....29
MOUNTING AND DISMOUNTING....29
FIRE PREVENTION FOR FUEL AND OIL....30
PRECAUTIONS WHEN WORKING AROUND HIGH TEMPERATURES....30
DUST HAZARD PREVENTION....31
CRUSH OR PINCH POINT PREVENTION....31
FIRE EXTINGUISHER AND FIRST AID KIT....31
PRECAUTIONS WHEN USING ROPS....32
PRECAUTIONS FOR ATTACHMENTS....32
PRECAUTIONS WHEN HANDLING ACCUMULATOR....32
INDOOR VENTILATION....32
INSIDE OPERATOR’S COMPARTMENT....33
CAB GLASS, WASHER FLUID AND MIRRORS....33
PRECAUTIONS DURING OPERATION....34
BEFORE OPERATING THE MACHINE....34
SAFETY AT THE WORK SITE....34
BEFORE STARTING YOUR MACHINE....34
WHEN STARTING ENGINE....35
IN THE OPERATOR’S CAB....35
OPERATING YOUR MACHINE....36
AFTER STARTING THE MACHINE....36
CHANGING DIRECTIONS....36
PROHIBITED OPERATION....36
PRECAUTIONS WHEN TRAVELING....37
TRAVELING ON SLOPES....38
PRECAUTIONS WHEN OPERATING....39
PROPER METHOD OF USING BRAKES....40
OVERHEAD HIGH VOLTAGE CABLES....40
OPERATING ON SNOW....41
OPERATING ON LOOSE GROUND....41
PARKING YOUR MACHINE....42
PRECAUTIONS IN COLD AREAS....42
TRANSPORTING YOUR MACHINE....43
LOADING AND UNLOADING....43
SHIPPING....43
BATTERY MAINTAINANCE AND PRECAUTIONS....44
SAFETY PRECAUTIONS....44
STARTING WITH BOOSTER CABLES....45
CHARGING BATTERY....45
TOWING....47
TOWING PRECAUTIONS....47
MAINTENANCE PRECAUTIONS....48
BEFORE PERFORMING MAINTENANCE....48
NOTIFICATION OF FAILURE....48
WARNING TAGS....48
CLEANING BEFORE INSPECTION AND MAINTENANCE....48
KEEP YOUR WORK PLACE CLEAN AND TIDY....49
APPOINT A LEADER WHEN WORKING WITH OTHERS....49
RADIATOR COOLANT LEVEL....49
WORK EQUIPMENT SUPPORT....49
BEFORE CARRYING OUT INSPECTION AND MAINTENANCE....50
PROPER TOOL USAGE INFORMATION....50
REPLACEMENT OF CRITICAL PARTS....50
USE OF LIGHTING....51
PREVENTION OF FIRE....51
DURING THE MAINTENANCE PROCESS....52
PERSONAL....52
REPAIRING ATTACHMENTS....52
WORKING UNDER YOUR MACHINE....52
MAINTENANCE WITH CHASSIS RAISED....52
WORKING ON TOP OF MACHINE....52
MAINTENANCE WITH ENGINE RUNNING....53
PRECAUTIONS WHEN USING A HAMMER....53
DROPPING TOOLS OR PARTS INSIDE THE MACHINE....53
WELDING....54
WHEN AN ABNORMALITY IS LOCATED....54
HANDLING HIGH PRESSURE HOSES....54
SAFETY RULES TO FOLLOW WHEN ADDING FUEL OR OIL....54
PRECAUTIONS WHEN HANDLING HIGH PRESSURE SYSTEMS....55
CARRYING OUT MAINTENANCE AT HIGH TEMPERATURES OR HIGH PRESSURES....55
MAINTENANCE OF AIR CONDITIONER....55
FINAL CHECKS AFTER INSPECTION AND MAINTENANCE....56
DISPOSAL OF WASTE MATERIALS....56
TIRES....57
TIRE MAINTENANCE....57
HANDLING TIRES....57
STORAGE OF TIRES AFTER REMOVAL....58
SAFETY LABLE LOCATONS....59
SAFETY LABLES....61
OPERATION....70
GENERAL VIEW....71
VIEW OF CONTROLS AND GAUGES....72
OPERATORS COMPARTMENT....72
MAIN MONITOR....73
MAINTENANCE MONITOR....73
OVERVIEW OF COMPONENT....74
MACHINE MONITOR....74
ALERT DISPLAY INDICATORS (B, E)....74
GUAGE DISPLAY SYSTEM (A, C, D)....74
OPTION DISPLAY SYSTEM (F)....74
TESTING MACHINE MONITOR SYSTEM....75
WARNING DISPLAYS....76
CENTRAL LAMPS....76
CHECK LAMP....76
CAUTION LAMP....77
ENGINE COOLANT LEVEL CAUTION LAMP....77
ENGINE OIL LEVEL CAUTION LAMP....77
BRAKE OIL PRESSURE CAUTION LAMP....78
ENGINE OIL PRESSURE CAUTION LAMP....78
BATTERY CHARGE CAUTION LAMP....79
AIR CLEANER RESTRICTION LAMP....79
TRANSMISSION OIL FILTER LAMP....79
GROUND DRIVEN STEERING LAMP....80
METER DISPLAY PORTION....81
SYSTEM INDICATOR LAMPS AND GUAGES....81
PARKING BRAKE LAMP....81
PREHEATING AND AFTER HEATING LAMP....82
FRONT WORK LAMP INDICATOR....82
REAR WORK LAMP INDICATOR....82
TRANSMISSION CUT OFF INDICATOR LAMP....82
TURN SIGNAL INDICATOR LAMP....83
TRANSMISSION SHIFT SELECTION LAMP....83
FUEL GAUGE....83
ENGINE COOLANT TEMPERATURE GAUGE....83
TORQUE CONVERTER TEMPERATURE GAUGE....84
SERVICE HOUR METER....84
SPEEDOMETER....84
TRANSMISSION SHIFT INDICATOR....85
SWITCHES....86
IGNITION SWITCH....87
TRANSMISSION CUT OFF SWITCH....87
FRONT WORKING LAMPS....88
REAR WORK LAMPS....88
TRANSMISSION MANUAL SELECTION SWITCH....88
LAMP SWITCH AND TURN SIGNAL LEVER....89
LAMP SWITCH....89
TURN SIGNAL LEVER....89
HORN BUTTON....89
HAZARD LAMP SWITCH....90
FRONT WIPER SWITCH....90
REAR WIPER SWITCH....90
PREHEAT SWITCH....91
FUEL CUT-OFF SWITCH....91
PARKING BRAKE SWITCH....92
CIGARETTE LIGHTER....92
JOYSTICK STEERING ON/OFF SWITCH....92
JOYSTICK STEERING LEVER SWITCHES....93
STEP LIGHT SWITCH....93
CAB LAMP SWITCH....93
POWER WINDOW SWITCHES (RIGHT and LEFT)....94
MULTIPLE USE TOP SWITCH....94
MULTIPLE USE SIDE SWITCH....95
ENGINE LOW IDLE SELECTOR SWITCH....95
AUTO GREASE....95
CONTROL LEVERS AND PEDALS....96
SPEED CONTROL LEVER....97
DIRECTIONAL LEVER....97
SPEED CONTROL LEVER LOCK....98
SAFETY LOCK LEVER....98
BUCKET CONTROL LEVER....98
BOOM CONTROL LEVER....99
BRAKE PEDALS....100
ACCELERATOR PEDAL....100
JOYSTICK STEERING LEVER....100
JOYSTICK STEERING....101
EXPLANATION OF COMPONENTS....101
FUNCTION OF JOYSTICK STEER ING SYSTEM....102
OPERATION OF JOYSTICK STEERING....105
ADJUSTMENT OF STEERING WHEEL....105
JOYSTICK STEERING PRECAUTIONS....107
JOYSTICK CONSOLE ADJUSTMENT....108
AUTO-SHIFT SYSTEM....109
METHOD OF OPERATING....109
PRECAUTIONS WHEN CHANGING DIRECTION....110
MAIN MONITOR FAILURE CODE....111
MAIN MONITOR FAILURE DISPLAY....111
ERROR CODE LIST INDICATED ON MAIN MONITOR....112
TRANSMISSION CONTROL SYSTEM....112
JOYSTICK CONTROL SYSTEM....112
ELECTRONIC GOVERNOR CONTROL SYSTEM....113
STEERING COLUMN TILT LEVER....113
CAP LOCK....113
OPENING AND CLOSING CAPS WITH LOCKS....113
SAFETY BAR....115
TOWING PIN....115
BACKUP ALARM....116
DOOR OPEN LOCK....116
TOOL BOX....116
EMERGENCY STOP SWITCH AND FUEL STOP LEVER....117
SLOW BLOW FUSE....117
FUSES....117
FUSE CAPACITY AND CIRCUIT....118
LUNCH BOX TRAY....120
MANUAL STORAGE PLACE....120
24V POWER FOR ACCESSORIES....120
AIR CONDITIONER....121
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL....121
FAN SWITCHES....121
AIR CONDITIONER SWITCH....122
VENT SELECTOR SWITCH....122
FRESH/RECIRCULATING AIR SELECTOR SWITCH....122
TEMPERATURE CONTROL SWITCH....123
EXPLANATION OF OPERATION....123
COOL BOX....123
AM/FM STEREO CASSETTE RADIO....124
EXPLANATION OF COMPONENTS....124
POWER SWITCH VOLUME CONTROL KNOB....125
TONE CONTROL KNOB....125
BASS CONTROL....125
TREBLE CONTROL....125
EJECT BUTTON....126
CASSETTE DOOR....126
FAST FORWARD, REWIND, PROGRAM CHANGEOVER CONTROL....126
MEMORY SWITCH....126
DISPLAY CHANGEOVER....127
SEEK CONTROL....127
LOUD CONTROL....127
AUTO MEMORY....127
FM AM BAND SELECT....128
DISPLAY....128
TUNER SWITCH, MANUAL TUNING....128
PRESET SWITCH....128
METAL BUTTON (IN TAPE MODE)....129
HOUR AND MINUTE CORRECTION....129
EXPLANATION OF OPERATION METHODS....130
PRESETTING TO SELECTED STATIONS....130
AUTO MEMORY....130
RECEIVING RADIO BROADCASTS....131
AUTOMATIC TUNING....131
MANUAL TUNING....131
SELECTION BETWEEN MODES....132
ADJUSTING TIME....132
PLAYING A CASSETTE TAPE....133
CHANGING TAPE CHANNELS....133
FAST FORWARDING....133
REWINDING....134
PRECAUTIONS WHEN USING....134
PRECAUTIONS WHEN HANDLING ACCUMULATORS....135
OPERATION....136
CHECKS BEFORE OPERATING THE MACHINE....136
WALK AROUND CHECKS....136
CHECKS BEFORE STARTING YOUR WORK CYCLE....138
CHECKING MONITOR PANEL....139
CHECKING COOLANT LEVEl....139
CHECKING OIL LEVEL IN ENGINE AND ADDING OIL....140
CHECKING BRAKE OIL TANK LEVEL AND ADDING OIL....141
CHECKING FUEL LEVEL AND ADDING FUEl....141
CHECKING ELECTRICAL WIRING....142
CHECKING ELECTRICAL WIRING....142
CHECKING TIRE INFLATION PRESSURE....143
CHECKING PARKING BRAKE....143
CHECKING EFFECT OF BRAKE....144
CHECK HORN AND BACKUP ALARM....144
CHECK FLASHING OF LAMPS....144
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE....144
CHECK ENGINE EXHAUST COLOR AND SOUND....144
CHECK OPERATION OF GAUGES....144
CHECK PLAY IN STEERING WHEEL, CHECK OPERATION OF STEERING....144
OPERATOR’S SEAT....144
SEAT BELT....146
REAR VIEW MIRRORS....147
CHECKS BEFORE STARTING THE ENGINE....148
STARTING ENGINE....149
NORMAL STARTING CONDITIONS....149
STARTING IN COLD WEATHER....150
USING THE AUTOMATIC PRIMING SYSTEM (APS)....151
USING MANUAL PREHEATING....153
OPERATIONAL CHECKS AFTER STARTING ENGINE....155
MOVING THE MACHINE....157
STEERING WITH THE WHEEL....158
STEERING WITH JOYSTICK....159
CHANGING GEAR SPEED RANGES....160
CHANGING DIRECTION....161
TURNING....162
STOPPING MACHINE....163
OPERATION OF WORK EQUIPMENT....164
TYPICAL WORK OPERATIONS....165
BUCKET FILLING AND DIGGING OPERATIONS....165
LEVELING OPERATIONS....168
PUSHING OPERATION....168
LOADING AND CARRYING OPERATIONS....168
LOADING OPERATIONS....168
CROSS DRIVE LOADING....169
“V” SHAPE LOADING....169
PRECAUTIONS WHEN PILING UP LOADS....169
PRECAUTIONS FOR OPERATION....170
PERMISSIBLE WATER DEPTH....170
IF WHEEL BRAKE DOES NOT WORK....170
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES....170
PRECAUTIONS WHEN TRAVELING WITH YOUR MACHINE....171
ADJUSTING WORK EQUIPMENT....172
ADJUSTING BOOM KICKOUT....172
ADJUSTING BUCKET POSITIONER....173
BUCKET LEVEL INDICATOR....173
PARKING THE MACHINE....174
CHECKS AFTER OPERATION....176
STOPPING ENGINE....176
CHECKS AFTER STOPPING THE ENGINE....176
LOCK AND SECURE LOCATIONS....177
HANDLING THE TIRES....177
PRECAUTIONS WHEN HANDLING TIRES....177
TIRE PRESSURE....179
PRECAUTIONS WITH LOAD AND CARRY OPERATIONS....179
BUCKET REMOVAL AND INSTALLATION....180
TRANSPORTATION....183
LIFTING MACHINE....183
COLD WEATHER OPERATION....184
PRECAUTIONS FOR LOW TEMPERATURES....184
FUEL AND LUBRICANTS....184
COOLANT....184
BATTERY....184
PRECAUTIONS AFTER WORK COMPLETION....184
AFTER COLD WEATHER....185
WARM UP OPERATION FOR HYDRAULIC STEERING CIRCUIT IN COLD WEATHER....186
LONG TERM STORAGE....187
BEFORE STORAGE....187
DURING STORAGE....187
AFTER STORAGE....187
BASIC TROUBLESHOOTING....188
WHEN MACHINE RUNS OUT OF FUEL....188
PROCEDURES FOR BLEEDING AIR FROM FUEL SYSTEM....188
MAINTENANCE ON A/C SYSTEM....188
TOWING THE MACHINE....189
WHEN ENGINE CAN BE USED....189
WHEN ENGINE POWER CANNOT BE USED....190
RELEASING PARKING BRAKE....190
EMERGENCY TRAVEL OPERATION....191
IF BATTERY IS DISCHARGED....192
REMOVAL AND INSTALLATION OF BATTERY....192
PRECAUTIONS FOR CHARGING BATTERY....192
STARTING ENGINE WITH BOOSTER CABLE....193
TROUBLESHOOTING TABLE....194
ELECTRICAL SYSTEM....194
CHASSIS....195
ENGINE....196
MAINTENANCE....198
GUIDES TO MAINTENANCE....199
OUTLINE OF SERVICE....202
OUTLINE OF OIL, FUEL, AND COOLANT USED....203
OIL....203
FUEL....203
COOLANT....203
GREASE....203
STORING OIL AND FUEL....204
FILTERS....204
ELECTRIC SYSTEM....204
PARTS WEAR LIST....205
FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CHART....206
SELECTION OF FUEL, COOLANT AND LUBRICANTS....206
ENGINE OIL SPECIFICATIONS....207
NORMAL OPERATION....207
ARCTIC OPERATION....207
TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICA.....208
DRIVE AXLE OIL SPECIFICATIONS....208
DIESEL FUEL SPECIFICATIONS....208
COOLANT SPECIFICATIONS....209
GENERAL....209
WATER....209
ANTIFREEZE....209
SUPPLEMENTAL COOLANT ADDITIVES....210
STANDARD TIGHTENING TORQUES FOR FASTNERS....214
NECESSARY MAINTENANCE TOOLS....214
PERIODIC REPLACEMENT OF SAFETY RELATED PARTS....215
CHART OF CRITICAL PARTS....216
MAINTENANCE SCHEDULE CHART....217
SCHEDULED MAINTENANCE CHART....217
SERVICE PROCEDURE....220
INITIAL 50 HOURS OF SERVICE....220
LUBRICATION....220
INITIAL 250 HOURS OF SERVICE....220
FUEL FILTER CARTRIDGE....220
TRANSMISSION OIL FILTER ELEMENT....220
ENGINE VALVE CLEARANCE....220
WHEN REQUIRED....221
CLEAN OR REPLACE AIR CLEANER ELEMENT....221
CLEANING COOLING SYSTEM....223
CHECKING THE TRANSMISSION OIL LEVEL....225
CHECKING AXLE OIL LEVEL....226
CHECKING AXLE CASE VENT....227
CHECKING WINDOW WASHER FLUID LEVEL....228
CLEANING THE AIR CONDITIONER CONDENSER....228
CLEANING THE RADIATOR AND OIL COOLER FINS....229
CHECKING THE AUTOMATIC PRIMING SYSTEM (APS)....229
REPLACING BUCKET WEAR ITEMS....230
LUBRICATION....234
CHECKING AIR CONDITIONER....236
ADJUSTING PARKING BRAKE....236
BLEEDING AIR FROM BRAKE CIRCUIT....237
BLEEDING AIR FROM PPC CIRCUIT....238
BLEEDING AIR FROM THE HYDRAULIC CIRCUIT....238
BLEEDING AIR FROM THE HYDRAULIC TANK....239
BLEEDING AIR FROM THE PISTON PUMP....239
REPLACING SLOW BLOW FUSE....240
REPLACING FAN BELT AND AUTO TENSIONER....241
SELECTION AND INSPECTION OF TIRES....242
CHECKS BEFORE STARTING WORK CYCLE....243
CHECKING MONITOR PANEL....243
CHECKING THE COOLANT LEVEL....244
CHECKING OIL LEVEL IN ENGINE....244
CHECKING BRAKE OIL TANK LEVEL....245
CHECKING FUEL LEVEL....246
CHECKING ELECTRICAL WIRING....247
CHECKING TIRE INFLATION....247
CHECKING EFFECT OF PARKING BRAKE SYSTEM....247
CHECKING EFFECT OF BRAKES....248
CHECK HORN AND BACK UP ALARM....248
CHECK LAMPS, FOR DIRT OR DAMAGE....248
CHECK REAR VIEW MIRRORS FOR DIRT OR DAMAGE....248
CHECK ENGINE EXHAUST COLOR AND SOUND....248
CHECK OPERATION OF GAUGES....248
CHECK PLAY AND OPERATION OF STEERING....248
EVERY 50 HOURS OF SERVICE....249
DRAINING WATER AND SEDIMENT FROM FUEL TANK....249
EVERY 100 HOURS OF SERVICE....249
LUBRICATION....249
CHECKING OIL LEVEL IN HYDRAULIC TANK....252
AIR CONDITIONER FRESH AIR FILTER....253
EVERY 250 HOURS OF SERVICE....254
CHANGING ENGINE OIL AND FILTER CARTRIDGES....254
CHECKING THE BATTERY ELECTROLYTE LEVEL....256
CHECKING AND ADJUSTING THE ALTERNATOR BELT....256
CHECKING AND ADJUSTING THE REFRIGERENT COMPRESSOR BELT....257
CHECKING FOR LOOSE WHEEL HUB NUTS....258
AIR CONDITIONER RECIRCULATION FILTER....258
CHECKING FOR LOOSE WHEEL HUB NUTS....258
CHECKING FRAME AND BOOM....258
EVERY 500 HOURS OF SERVICE....259
REPLACING THE FUEL FILTER CARTRIDGE....259
REPLACING TRANSMISSION OIL FILTER....260
LUBRICATING THE CENTER DRIVE SHAFT....262
CHECK FAN BELT FOR WEAR....263
EVERY 1000 HOURS OF SERVICE....264
CHANGING TRANSMISSION OIL AND CLEANING STRAINER....264
CLEANING THE TRANSMISSION CASE VENT....266
LUBRICATION....267
CHECKING PARTS OF TURBOCHARGER....269
CLEANING THE FUEL STRAINER....270
CHECKING ROPS CANOPY....270
REPLACING THE CORROSION RESISTOR CARTRIDGE....270
EVERY 2000 HOURS OF SERVICE....272
CHANGING HYDRAULIC OIL AND FILTER ELEMENT....272
CLEANING THE HYDRAULIC TANK STRAINER....275
REPLACING THE HYDRAULIC TANK VENT ELEMENT....276
CHANGING AXLE OIL....277
REPLACING AIR CONDITIONER CAB FILTER....279
CLEANING THE PPC CIRCUIT STRAINER....279
CLEANING THE ENGINE CRANCASE VEVT ELEMENT....280
CHECKING ALTERNATOR AND STARTER MOTOR....280
CHECKING ENGINE VALVE CLEARANCE....280
CHECKING TURBOCHARGER....280
CHECKING PLAY OF TURBOCHARGER ROTOR SHAFT....280
CHECKING ACCUMULATOR....281
EVERY 4000 HOURS OF SERVICE....282
CHECKING WATER PUMP....282
CHECKING ENGINE VIBRATION DAMPER....282
CHECKING FAN AND TENSIONER PULLEY....282
REPLACING THE INJECTION PUMP SCREEN FILTER....282
CLEANING THE INJECTION PUMP OIL INLET STRAINER....283
SPECIFICATIONS....284
WA700-3L SPECIFICATIONS....285
OPTIONS, ATTACHMENTS....288
OPTIONAL PARTS AND ATTACHMENTS....289
SELECTING BUCKETS AND TIRES....290
CEBM004402 - Wheel Loader WA700-3L avance plus Shop Manual....294
COVER....294
CONTENTS....295
01 GENERAL....324
GENERAL ASSEMBLY DRAWING....325
SPECIFICATIONS....326
WEIGHT TABLE....329
LIST OF LUBRICANT AND WATER....331
REMARKS....332
10 STRUCTURE AND FUNCTION....334
POWER TRAIN SYSTEM....337
DAMPER....339
OPERATION....339
TORQUE CONVERTER AND TRANSMISSION....341
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....341
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....343
TORQUE CONVERTER AND TRANSMISSION PIPING....344
TORQUE CONVERTER AND PTO....345
TRANSMISSION....348
OPERATION OF CLUTCH....351
FORWARD 1ST....352
FORWARD 2ND....353
FORWARD 3RD....354
FORWARD 4TH....355
REVERSE 1ST....356
TRANSMISSION CONTROL VALVE....357
TRANSMISSION SOLENOID VALVE....358
UPPER VALVE....359
MAIN RELIEF VALVE....359
LOWER VALVE....360
MAIN RELIEF VALVE....361
PILOT REDUCING VALVE....362
TRANSMISSION SOLENOID VALVE....363
PRIORITY VALVE....364
MODULATING VALVE AND QUICK RETURN VALVE....365
REDUCING VALVE....368
QUICK FILL VALVE (FOR 2ND CLUTCH)....369
TORQUE CONVERTER RELIEF VALVE....370
LUBRICATING RELIEF VALVE....371
EMERGENCY MANUAL SPOOL....372
LUBRICATION BYPASS VALVE....373
HYDRAULIC CIRCUIT SCHEMATIC....375
FORWARD 1ST....375
TRANSFER....377
AXLE....378
FRONT AXLE....378
REAR AXLE....379
DIFFERENTIAL....380
FRONT DIFFERENTIAL....380
REAR DIFFERENTIAL....381
FINAL DRIVE....382
STEERING....384
STEERING PIPING DIAGRAM....384
STEERING AND SWITCH PUMP....385
STEERING UNIT (ORBIT-ROLL VALVE)....387
STEERING DEMAND VALVE....390
OVERLOAD RELIEF VALVE....391
MAIN RELIEF VALVE....393
OPERATION OF DEMAND VALVE....395
WHEN STEERING SPOOL IS OPERATED....396
OPERATION OF STEERING VALVE....398
TWO-WAY RESTRICTOR....401
STOP VALVE....402
DIVERTER VALVE....403
GROUND DRIVEN STEERING RELIEF VALVE....406
BRAKE....407
BRAKE PIPING....407
BRAKE CIRCUIT DIAGRAM....408
BRAKE VALVE....409
BRAKE VALVE (RIGHT)....409
BRAKE VALVE (LEFT)....410
CHARGE VALVE....415
ACCUMULATOR (FOR BRAKE)....419
SLACK ADJUSTER....420
BRAKE....422
PARKING BRAKE....424
PARKING BRAKE CALIPER....425
SPRING CYLINDER....426
PARKING BRAKE SOLENOID VALVE....427
HYDRAULIC....429
HYDRAULIC PIPING....429
HYDRAULIC CIRCUIT DIAGRAM....431
MAIN PISTON PUMP....434
PISTON PUMP (HPV90 + HPF90)....435
CONTROL PUMP (BAR025)....440
CONTROL PUMP RELIEF VALVE....441
ES VALVE (ENGINE SENSING VALVE)....442
SERVO VALVE....443
PRESSURE DIFFERENTIAL VALVE....444
PPC VALVE (PROPORTIONAL PRESSURE VALVE)....445
PPC RELIEF VALVE....449
ACCUMULATOR (FOR PPC VALVE)....450
MAIN CONTROL VALVE....451
WORK EQUIPMENT....453
WORK EQUIPMENT LUBRICATION....453
WORK EQUIPMENT LINKAGE....455
BUCKET POSITIONER AND BOOM KICK-OUT....457
BUCKET POSITIONER....458
BOOM KICK-OUT....458
PROXIMITY SWITCH - OPERATION....459
BOOM RAISE....459
BUCKET TILT....461
AIR CONDITIONER....463
AIR CONDITIONER PIPING....463
AIR CONDITIONER CONDENSER....464
AIR CONDITIONER COMPRESSOR....465
DRY RESERVOIR....466
MAIN MONITOR SYSTEM....467
MAIN MONITOR....468
MAIN MONITOR DISPLAY FUNCTION TABLE....469
MAIN MONITOR SWITCH FUNCTION....471
TROUBLE DATA DISPLAY MODE....472
MAINTENANCE MONITOR....473
MAINTENANCE MONITOR DISPLAY FUNCTION TABLE....474
AUTOMATIC TRANSMISSION SYSTEM (ATM)....476
SYSTEM STRUCTURE DIAGRAM....477
JOYSTICK....490
JOYSTICK TRANSMISSION SYSTEM....490
TRANSMISSION AND JOYSTICK CONTROLLER....491
ELECTRICAL....494
ENGINE STARTING CIRCUIT....494
ENGINE STOP CIRCUIT....496
AUTO PRIMING SYSTEM (APS)....497
APS CONTROLLER....498
APS ASSISTER....498
ELECTRICAL TRANSMISSION CONTROL....501
COMBINATION SWITCH....503
KICK-DOWN, HOLD SWITCH....505
KICK-DOWN ELECTRICAL CIRCUIT....506
PARKING BRAKE SWITCH....513
PARKING BRAKE VALVE....514
PARKING SAFETY RELAY....514
NEUTRALIZER RELAY....514
EMERGENCY BRAKE SWITCH....514
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (1 0F 6)....522
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (2 OF 6)....524
ELECTRICALCIRCUIT DIAGRAM FOLDOUT (3 OF 6)....526
ELECTRICAL CIRUIT DIAGRAM FOLDOUT (4 OF 6)....528
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (5 OF 6)....530
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (6 OF 6)....532
ELECTRICAL CIRCUIT DIAGRAM (2) (1 OF 4)....534
ELECTRICAL CIRCUIT DIAGRAM (2) (2 OF 4)....536
ELECTRICAL CIRCUIT DIAGRAM (2) (3 OF 4)....538
ELECTRICAL CIRCUIT DIAGRAM (2) (4 OF 4)....540
20 TESTING, ADJUSTING AND TROUBLESHOOTING....542
STANDARD VALUE TABLE....545
ENGINE TABLE - IN CHASSIS....545
CHASSIS TABLE....546
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....551
SERVICE TOOLS....559
ENGINE....561
ADJUSTING ENGINE STOP MOTOR CABLE....561
ADJUSTING ENGINE STOP SOLENOID....561
MEASURING AND ADJUSTING VALVE CLEARANCE....561
MEASURING BLOW-BY PRESSURE....561
MEASURING COMPRESSION PRESSURE....561
MEASURING COOLANT TEMPERATURE....561
MEASURING ENGINE LUBRICATING OIL PRESSURE....561
MEASURING ENGINE SPEEDS....561
MEASURING EXHAUST COLOR....561
MEASURING EXHAUST GAS TEMPERATURE....561
MEASURING FUEL FILTER INLET RESTRICTION....561
TEST AND ADJUSTING FAN BELT TENSION....561
TEST AND ADJUSTING FUEL INJECTION TIMING....561
ACCELERATOR PEDAL....562
OPERATING FORCE....562
ADJUSTING PEDAL TRAVEL, POTENTIOMETER....563
ADJUSTING PEDAL MICRO SWITCH....565
TORQUE CONVERTER & TRANSMISSION PRESSURE....566
EMERGENCY MANUAL SPOOL....569
OPERATION....569
STEERING....571
STEERING OIL PRESSURE....571
MEASURING....571
ADJUSTING....571
STEERING STOPPER BOLT....572
ADJUSTING....572
JOYSTICK STEERING....573
ADJUSTING....573
JOYSTICK LEVER NEUTRAL DETECTION SWITCH....574
ADJUSTING....574
BRAKE....575
BRAKE OIL PRESSURE....575
TESTING....575
BRAKE DISC....576
MEASURING WEAR....576
BRAKE PERFORMANCE....577
MEASURING....577
PARKING BRAKE....578
TESTING....578
MEASURING PAD....578
MEASURING CLEARANCE....578
ADJUSTING....579
ACCUMULATOR CHARGE PRESSURE....580
TESTING....580
ADJUSTING....580
WORK EQUIPMENT....581
PPC RELIEF VALVE....581
MEASURING HYDRUALIC PRESSURE....581
ADJUSTING HYDRAULIC PRESSURE....582
HYDRAULIC PRESSURE....583
TESTING....583
ADJUSTING....584
PISTON PUMP....585
BLEEDING AIR....585
LEVER LINKAGE....586
ADJUSTING....586
BUCKET POSITIONER....588
TESTING....588
ADJUSTING....588
BOOM KICK-OUT....589
TESTING....589
ADJUSTING....589
PROXIMITY SWITCH ACTUATION PILOT LAMP....590
LAMP (RED)....590
MAIN MONITOR (SPEEDOMETER MODULE)....591
ADJUSTMENT PROCEDURE....591
BLEEDING AIR....592
BLEEDING AIR FROM BRAKE SYSTEM....592
BLEEDING AIR FROM HYDRAULIC CYLINDERS....592
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....593
BLEEDING AIR FROM HYDRAULIC TANK....593
BLEEDING AIR FROM THE PISTON PUMP....594
BLEEDING AIR FROM THE HYDRAULIC CIRCUIT....595
TROUBLESHOOTING GENERAL....596
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1319
SEQUENCE OF EVENTS IN TROUBLESHOOTING....294
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....342
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT....342
CHECKS BEFORE TROUBLESHOOTING....610
JUDGEMENT OF POWER TRAIN....347
PRECAUTIONS WHEN TROUBLESHOOTING....317
SAFETY....294
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING....317
PREVENTING RECURRENCE OF TROUBLE....294
HYDRAULIC EQUIPMENT....317
OIL CHECKS....613
CLEANING FRAGMENTS OF DAMAGED PARTS....318
METHOD OF USING TROUBLESHOOTING CHARTS....318
CATEGORY OF TROUBLESHOOTING CODE NUMBER....318
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE....318
METHOD OF USING MATRIX TROUBLESHOOTING TABLES....319
METHOD OF USING ENGINE RELATED CHARTS....618
TROUBLESHOOTING ELECTRICAL CONNECTORS....624
CONNECTOR TYPES....626
CONNECTOR PIN ARRANGEMENT....323
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....323
ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM....406
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE....642
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ACTION....644
TRANSMISSION CONTROLLER LED DISPLAY....522
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....648
E-1 ENGINE DOES NOT START....317
A. STARTING MOTOR DOES NOT TURN....651
B. STARTING MOTOR TURNS....657
E-2 ABNORMALITY IN APS SYSTEM....660
A. WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOT LIGHT UP, BUT NO PILOT LED ON .....662
B. WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 2O° C, PREHEATING .....663
C. AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START, B.....664
D. LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....665
E. LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....665
F. LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....666
G. LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....666
H. LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....667
I. LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....667
J. WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP....668
E-3 PARKING BRAKE DOES NOT HAVE EFFECT....669
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON....669
B. PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE D.....669
E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING....671
E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON....673
E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORK.....673
E-7 TRANSMISSION DOES NOT WORK PROPERLY....675
A. ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY.....677
B. NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT....681
C. NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT....683
D. SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT....685
E. ABNORMALITY IN SHIFT SOLENOID CIRCUIT....691
F. SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT....694
E-8 KICK-DOWN SWITCH DOES NOT WORK....699
E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON....702
E-10 KICK-DOWN ALWAYS WORKS....703
E-11 KICK-DOWN SWICTH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND....705
E-12 BOOM KICK-OUT DOES NOT WORK....707
E-13 DEFECTIVE BUCKET POSITIONER....709
E-14 POWER WINDOW DOES NOT WORK....711
A. WINDOW DOES NOT GO UP....711
B. WINDOW DOES NOT GO DOWN....712
E-15 ABNORMALITY IN FRONT WORKING LAMP....714
E-16 ABNORMALITY IN REAR WORKING LAMP....714
E-17 ABNORMALITY IN TRANSMISSION CUT-OFF....714
E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING....714
E-19 ABNORMALITY IN BUZZER....714
TROUBLESHOOTING OF ELECTRIC ENGINE THROTTLE & APS CONTROLLERS (G MODE)....716
JUDGEMENT TABLE....320
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS....720
ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS....726
POINTS TO REMEMBER WHEN TROUBLESHOOTING....447
JUDGEMENT TABLE FOR ENGINE CONTROLLER....729
G-1 [90] [OFF or 101] ABNORMALITY IN POWER SOURCE SYSTEM....730
G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM....730
G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR....731
G-4 G-4 [90] [56] ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM....731
G-5 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM....732
G-6 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM....733
G-7 [91] [14] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM....734
G-8 [91] [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM....735
G-9 [91] [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM....736
G-10 [91] [1d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM....737
G-11 [92] [12] ABNORMALITY IN RACK SENSOR SYSTEM....738
G-12 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM....739
G-13 [93] [1b] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM....740
G-14 [94] [1c] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM....741
G-15 [93, 94] [1b, 1c] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM....742
G-16 [95] [40] ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM....742
G-17 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM....743
G-18 [99] [22] ENGINE OVERRUN....745
G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY)....745
G-20 ENGINE DOES NOT START....747
G-21 ENGINE DOES NOT STOP....750
G-22 DEFECTIVE ACTUATION OF APS....751
A. PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE AL.....751
B. 1. PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20C WHEN APS SWITCH IS ON (C.....753
B. 2. PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20C WHEN APS SWITCH IS ON .....753
C. NOZZLE DOES NOT INJECT FUEL WHEN STARTING SWITCH IS TURNED TO START AFTER COMPLETION OF PREHEA.....753
D. APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY....313
E. APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY....313
F. APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY....755
G. APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY....755
H. APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) GIVES ABNORMAL DISPLAY....756
I. APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY....313
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....758
POWER TRAIN....760
H-1 MACHINE DOES NOT START....760
H-2 MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES)....761
H-3 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR....762
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH....763
STEERING....764
H-5 STEERING DOES NOT TURN....764
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]....765
H-7 TURNING, RESPONSE OF STEERING IS POOR....766
H-8 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]....767
H-9 STEERING IS HEAVY....769
H-10 STEERING WHEEL SHAKES OR JERKS....770
H-11 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]....771
H-12 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING....771
BRAKES....772
H-13 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR....772
H-14 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG....774
H-15 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR....775
H-16 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS....776
WORK EQUIPMENT....777
H-17 NEITHER BOOM NOR BUCKET MOVE....777
H-18 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER....778
H-19 BOOM DOES NOT MOVE....779
H-20 BOOM IS SLOW OR BOOM LACKS POWER....780
H-21 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT....781
H-22 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....781
H-23 EXCESSIVE HYDRAULIC DRIFT OF BOOM....782
H-24 BUCKET DOES NOT MOVE....783
H-25 BUCKET IS SLOW OR LACKS POWER....784
H-26 EXCESSIVE HYDRAULIC DRIFT OF BUCKET....785
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)....786
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS....788
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....789
ELECTRICAL CIRCUIT DIAGRAM....793
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED....794
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED....795
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED....796
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED....797
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED....798
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DIS.....799
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPL.....800
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYST.....801
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE....802
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM....803
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID....804
J-12 DISCONNECTION IN STEERING LEFT SOLENOID....805
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)....806
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC.....808
A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP....808
B. SOME LAMPS DO NOT LIGHT UP....808
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OU.....809
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO .....810
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH....811
A. ENGINE OIL LEVEL DISPLAY FLASHES....811
B. ENGINE WATER LEVEL DISPLAY FLASHES....812
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH....813
A. ENGINE OIL PRESSURE DISPLAY FLASHES....813
B. BATTERY CHARGE LEVEL DISPLAY FLASHES....814
C. BRAKE OIL PRESSURE DISPLAY FLASHES....815
D. AIR CLEANER (L.H.) DISPLAY FLASHES....816
E. AIR CLEANER (R.H.) DISPLAY FLASHES....817
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND....818
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS....819
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH....820
A. CHECK LAMP....820
B. CAUTION LAMP....820
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION .....821
A. CHECK LAMP....821
B. CAUTION LAMP....821
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE.....822
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP....823
K-12 SERVICE METER DOES NOT WORK....824
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED....824
K-14 ABNORMALITY IN GAUGE ITEMS....826
A. ABNORMALITY IN FUEL GAUGE....826
B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE....827
C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE....828
TROUBLESHOOTING OF MAIN MONITOR (M MODE)....830
M-1 MAIN MONITOR DOES NOT WORK....832
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP....833
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY....834
M-4 ABNORMALITY IN SHIFT INDICATOR....835
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F....835
B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R....835
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER .....835
D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER .....836
E. DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R)....836
F. DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R)....836
G. DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R)....837
H. DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R)....837
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP....839
A. L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP....839
B. R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP....839
M-6 ABNORMALITY IN PARKING DISPLAY....840
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP....840
B. PARKING LAMP DISPLAY STAYS LIGHTED UP....840
M-7 NIGHT LIGHTING DOES NOT LIGHT UP....841
M-8 ABNORMALITY IN FRONT WORKING LAMP....842
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP....842
B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP....842
C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP....842
M-9 ABNORMALITY IN REAR WORKING LAMP....844
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP....844
B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP....844
C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP....844
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF....846
STANDARD SPECIFICATION....846
A. WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES.....846
B. WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED....846
C. TRANSMISSION CUT-OFF SWITCH TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED....847
AUTO-SHIFT SPECIFICATION....848
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED.....848
B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF.....848
C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION .....848
D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH.....848
E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT.....849
M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING....850
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WH.....850
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W.....850
M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU.....852
A. ACTUATED CONTINUOUSLY....852
B. NOT ACTUATED....852
M-13 ABNORMALITY IN BUZZER....853
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)....853
B. BUZZER ALWAYS SOUNDS....853
M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY....854
M-15 ABNORMALITY IN FAILURE DISPLAY MODE....855
A. DOES NOT ENTER FAILURE DISPLAY MODE....855
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE....855
M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY....856
A. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED....856
B. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED....856
C. PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED....856
D. PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED....857
M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY....858
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP....858
B. EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP....858
M-18 ABNORMALITY IN AUTO-GREASING SYSTEM....859
A. FORCED GREASING CANNOT BE CARRIED OUT....859
B. MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SET)....859
C. WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)....859
D. MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)....860
E. MONITOR DISPLAY GOES OUT....860
M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM....861
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED....861
B. MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK....861
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....862
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....864
S-2 ENGINE DOES NOT START....869
A. ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)....869
B. EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....871
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....872
S-4 ENGINE STOPS DURING OPERATIONS....873
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....875
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)....876
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....877
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....878
S-9 OIL BECOMES CONTAMINATED QUICKLY....879
S-10 FUEL CONSUMPTION IS EXCESSIVE....880
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....881
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....882
S-13 OIL LEVEL RISES....883
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....884
S-15 ABNORMAL NOISE IS MADE....885
S-16 VIBRATION IS EXCESSIVE....887
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)....888
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS....889
CONTROLLER ACTIONS DURING ABNORMALITY....891
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LA.....897
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI.....898
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI.....899
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN.....900
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLEN.....901
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN.....902
T-7 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN.....903
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS.....905
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED....907
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED....909
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED....911
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED....912
A. TRANSMISSION CONTROLLER SYSTEM....912
B. ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM....912
T-13 HOLD SWITCH SYSTEM....915
T-14 KICK-DOWN SWITCH SYSTEM....915
T-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM....916
T-16 NEUTRALIZER RELAY SIGNAL SYSTEM....917
T-17 BUZZER SIGNAL SYSTEM....918
T-18 NETWORK SYSTEM....919
T-19 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM....920
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM....921
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER....922
SERVICE TOOLS....318
GAUGE MANIFOLD....1254
STRUCTURE AND HANDLING OF GAUGE MANIFOLD....925
CHARGING HOSES....356
GAS LEAK DETECTOR....928
HALIDE TORCH LEAK DETECTOR....319
ELECTRIC LEAK TESTER....361
VALVE FOR SERVICE CANS....932
MAINTENANCE PROCEDURE....933
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING....372
PROHIBITED WORK....372
OTHER PRECAUTIONS....933
BLEEDING AIR FROM REFRIGERATION CIRCUIT....384
PURPOSE....384
CONNECTING GAUGE MANIFOLD....391
EVACUATION....1256
AIR-TIGHTNESS CHECK....322
GAS-LEAK CHECK....322
EVACUATION (REPEATING)....322
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT....322
CHARGING FROM THE HIGH-PRESSURE SIDE....385
CHARGING FROM THE LOW PRESSURE SIDE....939
WHEN THE AMBIENT TEMPERATURE IS LOW....940
WHEN THE AMBIENT TEMPERATURE IS HIGH....322
REPLACING SERVICE CANS....323
CHECKING THE AMOUNT OF REFRIGERANT....323
REMOVAL OF GAUGE MANIFOLD....323
DISCHARGING THE REFRIGERANT....943
DAILY CHECKS....323
CHECK REFRIGERANT LEVEL....944
CLEANING THE CONDENSER....944
CHECKING THE V-BELT....944
CHECKING OIL LEVEL....945
PROCEDURE FOR CHECKING....323
PROCEDURE FOR CHECKING OIL LEVEL....323
ADDING AND REMOVING OIL....946
ADDING OIL BY EVACUATION....323
TROUBLESHOOTING....414
VISUAL AND ACOUSTICAL CHECKS....416
DEFECTIVE COOLING....294
TROUBLESHOOTING TABLE....318
DEFECTIVE HEATING....318
TROUBLESHOOTING USING GAUGE MANIFOLD....953
PREPARATIONS BEFORE MEASURING....492
INSUFFICIENT REFRIGERANT....492
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER....954
AIR INSIDE REFRIGERATION SYSTEM....955
MOISTURE IN REFRIGERATING SYSTEM....956
REFRIGERANT DOES NOT CIRCULATE....957
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE....958
DEFECTIVE COMPRESSION BY COMPRESSOR....959
30 DISASSEMBLY AND ASSEMBLY....960
METHOD OF USING MANUAL....964
PRECAUTIONS DURING OPERATION....965
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK....965
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK....966
PRECAUTIONS WHEN COMPLETING THE OPERATIONS....967
OTHER PRECAUTIONS....319
SPECIAL TOOL LIST....968
SKETCHES OF SPECIAL TOOLS....972
ENGINE....976
ALTERNATOR....976
CYLINDER HEAD....976
ENGINE FRONT SEAL....976
ENGINE OIL COOLER....976
ENGINE REAR SEAL....976
FUEL INJECTION PUMP....976
NOZZLE HOLDER....323
STARTING MOTOR....976
THERMOSTAT....976
TURBOCHARGER....323
WATER PUMP....323
HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER....977
REMOVAL....977
INSTALLATION....978
DAMPER, ENGINE....979
REMOVAL....979
INSTALLATION....981
DAMPER....982
REMOVAL....982
INSTALLATION....983
DISASSEMBLY....984
ASSEMBLY....986
PTO....990
DISASSEMBLY....990
ASSEMBLY....992
TORQUE CONVERTER, TRANSMISSION....995
REMOVAL....995
INSTALLATION....999
TORQUE CONVERTER....1000
DISASSEMBLY....1000
ASSEMBLY....1004
TRANSMISSION....1009
DISASSEMBLY....1009
ASSEMBLY....1023
TRANSMISSION VALVE....1038
REMOVAL....1038
INSTALLATION....1038
TRANSMISSION CONTROL VALVE....1039
LOWER VALVE....1039
DISASSEMBLY....1040
ASSEMBLY....1040
UPPER VALVE....1041
DISASSEMBLY....1042
ASSEMBLY....1044
MAIN RELIEF VALVE....1045
DISASSEMBLY....1046
ASSEMBLY....1046
TRANSFER....1047
DISASSEMBLY....1047
ASSEMBLY....1054
CENTER SUPPORT....1064
REMOVAL....1064
INSTALLATION....1065
DISASSEMBLY....1066
ASSEMBLY....1068
DRIVE SHAFT....1071
DISASSEMBLY....1071
ASSEMBLY....1073
FRONT AXLE....1075
REMOVAL....1075
INSTALLATION....1076
FRONT DIFFERENTIAL....1077
REMOVAL....1077
INSTALLATION....1079
REAR AXLE....1080
REMOVAL....1080
INSTALLATION....1085
REAR DIFFERENTIAL....1086
REMOVAL....1086
INSTALLATION....1087
DIFFERENTIAL....1088
DISASSEMBLY....1088
ASSEMBLY....1092
FINAL DRIVE....1101
DISASSEMBLY....1101
ASSEMBLY....1105
ORBITROL STEERING VALVE....1109
REMOVAL....1109
INSTALLATION....1110
STEERING CYLINDER....1111
REMOVAL....1111
INSTALLATION....1113
STEERING DEMAND VALVE....1114
REMOVAL....1114
INSTALLATION....1115
BRAKE VALVE....1116
REMOVAL....1116
INSTALLATION....1117
BRAKE VALVE (RIGHT)....1118
DISASSEMBLY....1118
ASSEMBLY....1120
BRAKE VALVE (LEFT)....1122
DISASSEMBLY....1122
ASSEMBLY....1124
SLACK ADJUSTER....1126
REMOVAL....1126
INSTALLATION....1126
DISASSEMBLY....1127
ASSEMBLY....1128
BRAKE....1129
REMOVAL....1129
INSTALLATION....1130
DISASSEMBLY....1131
ASSEMBLY....1135
HYDRAULIC PUMP....1141
REMOVAL....1141
INSTALLATION....1142
PISTON PUMP....1143
DISASSEMBLY....1143
ASSEMBLY....1149
HYDRAULIC TANK....1165
REMOVAL....1165
INSTALLATION....1166
PPC VALVE....1167
REMOVAL....1167
INSTALLATION....1168
DISASSEMBLY....1169
ASSEMBLY....1169
WORK EQUIPMENT CONTROL VALVE....1170
REMOVAL....1170
INSTALLATION....1171
DISASSEMBLY....1172
ASSEMBLY....1174
DUMP CYLINDER....1176
REMOVAL....1176
INSTALLATION....1176
LIFT CYLINDER....1177
REMOVAL....1177
INSTALLATION....1178
STEERING, LIFT, DUMP CYLINDER....1179
DISASSEMBLY....1179
ASSEMBLY....1181
CENTER HINGE PIN....1183
REMOVAL....1183
INSTALLATION....1189
WORK EQUIPMENT....1193
REMOVAL....1193
INSTALLATION....1196
BULKHEAD....1198
REMOVAL....1198
INSTALLATION....1199
FLOOR FRAME....1200
REMOVAL....1200
INSTALLATION....1202
COUNTERWEIGHT....1203
REMOVAL....1203
INSTALLATION....1204
FUEL TANK....1205
REMOVAL....1205
INSTALLATION....1206
CAB....1207
REMOVAL....1207
INSTALLATION....1209
STOP VALVE....1210
REMOVAL....1210
INSTALLATION....1210
ACCUMULATOR CHARGE VALVE....1211
REMOVAL....1211
INSTALLATION....1211
DISASSEMBLY....1212
ASSEMBLY....1213
PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH....1215
REMOVAL....1215
INSTALLATION....1215
DIVERTER VALVE....1216
REMOVAL....1216
INSTALLATION....1216
DISASSEMBLY....1217
ASSEMBLY....1218
EMERGENCY STEERING PUMP....1220
REMOVAL....1220
INSTALLATION....1220
PARKING BRAKE....1221
REMOVAL....1221
INSTALLATION....1222
PARKING BRAKE CALIPERS....1223
DISASSEMBLY....1223
ASSEMBLY....1225
PARKING BRAKE PAD....1227
REMOVAL....1227
INSTALLATION....1227
REAR TIRE....1228
REMOVAL....1228
INSTALLATION....1228
AIR CONDITIONER COMPRESSOR....1229
REMOVAL....1229
INSTALLATION....1229
AIR CONDITIONER CONDENSER....1230
REMOVAL....1230
INSTALLATION....1231
AIR CONDITIONER RECEIVER TANK....1232
REMOVAL....1232
INSTALLATION....1232
AIR CONDITIONER UNIT....1233
REMOVAL....1233
INSTALLATION....1234
MAIN MONITOR....1235
REMOVAL....1235
INSTALLATION....1236
MAINTENANCE MONITOR....1237
REMOVAL....1237
INSTALLATION....1237
ENGINE, APS CONTROLLER....1238
REMOVAL....1238
INSTALLATION....1238
40 MAINTENANCE STANDARD....1242
ENGINE AND TRANSMISSION MOUNT....1243
DAMPER....1245
TORQUE CONVERTER AND PTO....1247
TRANSMISSION CLUTCH....1249
TRANSMISSION GEAR....1251
TRANSMISSION CONTROL VALVE....1253
UPPER VALVE....1253
RELIEF VALVE....1253
LOWER VALVE....1255
SOLENOID VALVE....1257
TRANSFER....1259
DRIVE SHAFT....1261
CENTER SUPPORT....1262
DIFFERENTIAL....1263
FINAL DRIVE....1267
AXLE MOUNT....1269
CENTER HINGE PIN....1271
STEERING COLUMN....1274
STEERING DEMAND VALVE....1275
DIVERTER VALVE....1278
STEERING CYLINDER MOUNT....1279
GROUND DRIVEN STEERING PUMP....1281
BRAKE VALVE....1283
LEFT....1283
RIGHT....1285
SLACK ADJUSTER....1287
CONTROL PUMP....1288
BRAKE....1289
PARKING BRAKE....1291
MAIN CONTROL VALVE....1293
PPC VALVE....1295
PPC RELIEF VALVE....1297
HYDRAULIC CYLINDER....1299
WORK EQUIPMENT LINKAGE....1301
BUCKET POSITIONER....1303
BOOM KICK-OUT....1303
90 OTHERS....1306
SHOP MANUAL FOLDOUTS....1308
ELECTRICAL CIRCUIT DIAGRAM....1308
DIAGRAM ONE (1/6)....1308
DIAGRAM ONE (2/6)....1310
DIAGRAM ONE (3/6)....1312
DIAGRAM ONE (4/6)....1314
DIAGRAM ONE (5/6)....1316
DIAGRAM ONE (6/6)....1318
DIAGRAM TWO (1/4)....1320
DIAGRAM TWO (2/4) ....1322
DIAGRAM TWO (3/4)....1324
DIAGRAM TWO (4/4)....1326
CONNECTOR PIN ARRANGMENT....1328
CONNECTOR PIN DIGRAM (1/6)....1328
CONNECTOR PIN DIAGRAM (2/6) ....1330
CONNECTOR PIN DIAGRAM (3/6)....1332
CONNECTOR PIN DIAGRAM (4/6)....1334
CONNECTOR PIN DIAGRAM (5/6)....1336
CONNECTOR PIN DIAGRAM (6/6)....1338
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM....1340
SEAM011500 - Wheel Loader WA700-1 Operation & Maintenance Manual....1346
1. FOREWORD....1347
2. SAFETY INFORMATION....1348
3. INTRODUCTION....1349
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1350
5. CONTENTS....1351
SAFETY....1355
6. GENERAL PRECAUTIONS....1356
7. PRECAUTIONS DURING OPERATION....1361
7.1 BEFORE STARTING ENGINE....1361
7.2 OPERATING MACHINE....1363
7.3 TRANSPORTATION....1367
7.4 BATTERY....1368
7.5 TOWING....1369
8. PRECAUTIONS FOR MAINTENANCE....1370
8.1 BEFORE CARRYING OUT MAINTENANCE....1370
8.2 DURING MAINTENANCE....1372
8.3 TIRES....1376
9. POSITION FOR ATTACHING SAFETY LABELS....1378
OPERATION....1381
10. GENERAL VIEW....1382
10.1 GENERAL VIEW OF MACHINE....1382
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....1383
11. EXPLANATION OF COMPONENTS....1384
11.1 MACHINE MONITOR....1384
11.2 SWITCHES....1394
11.3 CONTROL LEVERS, PEDALS....1401
11.4 DUST INDICATOR....1406
11.5 CIRCUIT BREAKER (MAIN)....1406
11.6 SAFETY BAR....1406
11.7 STEERING COLUMN TILT LEVER....1407
11.8 DOOR-OPEN LOCK....1407
11.9 CAP WITH LOCK....1407
11.10 FUEL STOP LEVER....1408
11.11 AIR PICK-UP PORT....1408
11.12 FUSE....1409
11.13 MANUAL POCKET....1410
11.14 POWER PICKUP....1410
11.15 CAR RADIO....1411
11.16 AIR CONDITIONER....1414
11.17 CAR HEATER....1418
11.18 USING ACCUMULATOR....1420
12. OPERATION....1421
12.1 CHECK BEFORE STARTING ENGINE....1421
12.2 STARTING ENGINE....1434
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....1439
12.4 MOVING MACHINE OFF....1440
12.5 CHANGING GEAR SPEED....1441
12.6 CHANGING DIRECTION....1442
12.7 TURNING....1442
12.8 STOPPING MACHINE....1443
12.9 OPERATION OF WORK EQUIPMENT....1444
12.10 WORK POSSIBLE USING WHEEL LOADER....1445
12.11 PRECAUTIONS FOR OPERATION....1450
12.12 ADJUSTING WORK EQUIPMENT POSTURE....1452
12.13 PARKING MACHINE....1454
12.14 CHECKS AFTER COMPLETION OF OPERATION....1455
12.15 STOPPING ENGINE....1455
12.16 CHECK AFTER STOPPING ENGINE....1456
12.17 LOCKING....1456
12.18 HANDLING THE TIRES....1457
12.19 REMOVAL AND INSTALLATION OF THE BUCKET....1459
13. TRANSPORTATION....1463
13.1 LIFTING MACHINE....1463
14. COLD WEATHER OPERATION....1464
14.1 PRECAUTIONS FOR LOW TEMPERATURE....1464
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....1466
14.3 AFTER COLD WEATHER....1466
15. LONG-TERM STORAGE....1467
15.1 BEFORE STORAGE....1467
15.2 DURING STORAGE....1467
15.3 AFTER STORAGE....1467
16. TROUBLESHOOTING....1468
16.1 WHEN MACHINE RUNS OUT OF FUEL....1468
16.2 TOWING THE MACHINE....1469
16.3 IF BATTERY IS DISCHARGED....1473
16.4 OTHER TROUBLE....1477
MAINTENANCE....1485
17. GUIDES TO MAINTENANCE....1486
18. OUTLINES OF SERVICE....1489
18.1 OUTLINE OF OIL, FUEL, COOLANT....1489
18.2 OUTLINE OF ELECTRIC SYSTEM....1492
19. WEAR PARTS LIST....1493
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1494
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....1498
21.1 INTRODUCTION OF NECESSARY TOOLS....1498
21.2 TORQUE LIST....1499
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1500
23. MAINTENANCE SCHEDULE CHART....1503
23.1 MAINTENANCE SCHEDULE CHART....1503
24. SERVICE PROCEDURE....1507
24.1 INITIAL 250 HOURS SERVICE....1507
24.2 WHEN REQUIRED....1508
24.3 CHECK BEFORE STARTING....1526
24.4 EVERY 50 HOURS SERVICE....1532
24.5 EVERY 100 HOURS SERVICE....1533
24.6 EVERY 250 HOURS SERVICE....1537
24.7 EVERY 500 HOURS SERVICE....1542
24.8 EVERY 1000 HOURS SERVICE....1546
24.9 EVERY 2000 HOURS SERVICE....1552
24.10 EVERY 4000 HOURS SERVICE....1560
SPECIFICATIONS....1563
25. SPECIFICATIONS....1564
OPTIONS, ATTACHMENTS....1567
26. OPTIONAL PART AND ATTACHMENTS....1568
27. SELECTING BUCKETS AND TIRES....1569
28. EXPLANATION OF OPERATION OF JOY STICK STEERING SYSTEM....1570
28.1 FUNCTIONS AND STRUCTURE OF JOY STICK STEERING....1570
28.2 OPERATION METHOD OF JOY STICK STEERING SYSTEM....1573
28.3 PRECAUTlONS FOR STEERING WITH JOY STICK....1575
28.4 ADJUSTMENT OF JOY STICK CONSOLE....1578
28.5 ADJUSTMENT OPERATOR'S SEAT....1579
SEAM018500 - Wheel Loader WA700-3 Operation & Maintenance Manual....1582
COVER PAGE....1582
1. FOREWORD....1583
2. SAFETY INFORMATION....1584
3. INTRODUCTION....1585
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1586
5. CONTENTS....1587
SAFETY....1591
6. GENERAL PRECAUTIONS....1592
7. PRECAUTIONS DURING OPERATION....1597
7.1 BEFORE STARTING ENGINE....1597
7.2 AFTER STARTING ENGINE....1600
7.3 TRANSPORTATION....1608
7.4 BATTERY....1609
7.5 TOWING....1611
8. PRECAUTIONS FOR MAINTENANCE....1612
8.1 BEFORE CARRYING OUT MAINTENANCE....1612
8.2 DURING MAINTENANCE....1617
8.3 TIRES....1623
9. POSITION FOR ATTACHING SAFETY LABELS....1625
OPERATION....1630
10. GENERAL VIEW....1631
10.1 GENERAL VIEW OF MACHINE....1631
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....1632
11. EXPLANATION OF COMPONENTS....1633
11.1 MACHINE MONITOR....1633
11.2 SWITCHES....1643
11.3 CONTROL LEVERS, PEDALS....1652
11.4 STEERING COLUMN TILT LEVER....1657
11.5 CAP WITH LOCK....1657
11.6 ENGINE EMERGENCY STOP SWITCH AND FUEL STOP LEVER....1658
11.7 SAFETY BAR....1658
11.8 TOWING PIN....1659
11.9 GREASE PUMP....1660
11.10 BACKUP ALARM....1660
11.11 DOOR-OPEN LOCK....1660
11.12 TOOL BOX....1660
11.13 FUSE....1661
11.14 SLOW-BLOW FUSE....1662
11.15 LUNCH BOX TRAY....1663
11.16 STORAGING PLACE OF THIS MANUAL....1663
11.17 TAKING OFF POWER....1663
11.18 AM/FM CAR RADIO ....1664
11.19 AM/FM RADIO-CASSETTE STEREO....1668
11.20 CAR HEATER....1677
11.21 AIR CONDITIONER....1679
11.22 PRECAUTIONS WHEN HANDLING ACCUMULATOR....1682
12. OPERATION....1683
12.1 CHECK BEFORE STARTING ENGINE....1683
12.2 STARTING ENGINE....1697
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....1703
12.4 MOVING MACHINE OFF....1704
12.5 CHANGING GEAR SPEED....1706
12.6 CHANGING DIRECTION....1707
12.7 TURNING....1707
12.8 STOPPING MACHINE....1708
12.9 OPERATION OF WORK EQUIPMENT....1709
12.10 WORK POSSIBLE USING WHEEL LOADER....1710
12.11 PRECAUTIONS FOR OPERATION....1715
12.12 ADJUSTING WORK EQUIPMENT POSTURE....1717
12.13 PARKING MACHINE....1719
12.14 CHECKS AFTER COMPLETION OF OPERATION....1720
12.15 STOPPING ENGINE....1720
12.16 CHECK AFTER STOPPING ENGINE....1721
12.17 LOCKING....1721
12.18 HANDLING OF TIRES....1722
12.19 REMOVAL AND INSTALLATION OF THE BUCKET....1724
13. TRANSPORTATION....1728
13.1 LIFTING MACHINE....1728
14. COLD WEATHER OPERATION....1729
14.1 PRECAUTIONS FOR LOW TEMPERATURE....1729
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....1731
14.3 AFTER COLD WEATHER....1731
14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....1732
15. LONG-TERM STORAGE....1733
15.1 BEFORE STORAGE....1733
15.2 DURING STORAGE....1733
15.3 AFTER STORAGE....1733
16. TROUBLESHOOTING....1734
16.1 WHEN MACHINE RUNS OUT OF FUEL....1734
16.2 TOWING THE MACHINE....1735
16.3 IF BATTERY IS DISCHARGED....1738
16.4 OTHER TROUBLE....1742
MAINTENANCE....1749
17. GUIDES TO MAINTENANCE....1750
18. OUTLINES OF SERVICE....1753
18.1 OUTLINE OF OIL, FUEL, COOLANT....1753
18.2 OUTLINE OF ELECTRIC SYSTEM....1756
19. WEAR PARTS LIST....1757
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1758
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....1762
21.1 INTRODUCTION OF NECESSARY TOOLS....1762
21.2 TORQUE LIST....1763
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1764
23. MAINTENANCE SCHEDULE CHART....1766
23.1 MAINTENANCE SCHEDULE CHART....1766
24. SERVICE PROCEDURE....1770
24.1 INITIAL 250 HOURS SERVICE....1770
24.2 WHEN REQUIRED....1771
24.3 CHECK BEFORE STARTING....1793
24.4 EVERY 50 HOURS SERVICE....1800
24.5 EVERY 100 HOURS SERVICE....1801
24.6 EVERY 250 HOURS SERVICE....1805
24.7 EVERY 500 HOURS SERVICE....1811
24.8 EVERY 1000 HOURS SERVICE....1816
24.9 EVERY 2000 HOURS SERVICE....1822
24.10 EVERY 4000 HOURS SERVICE....1831
SPECIFICATIONS....1832
25. SPECIFICATIONS....1833
OPTIONS, ATTACHMENTS....1835
26. OPTIONAL PARTS AND ATTACHMENTS....1836
27. SELECTING BUCKETS AND TIRES....1837
28. HANDLING AUTO SHIFT SYSTEM....1838
28.1 AUTOMATIC SHIFT SYSTEM....1838
28.2 PRECAUTIONS WHEN CHANGING DIRECTION....1839
29. HANDLING JOYSTICK STEERING SYSTEM....1840
29.1 EXPLANATION OF COMPONENTS....1840
29.2 STRUCTURE AND FUNCTION OF JOYSTICK STEERING....1841
29.3 OPERATION METHOD OF JOYSTICK STEERING SYSTEM....1844
29.4 PRECAUTIONS FOR STEERING WITH JOYSTICK....1846
29.5 ADJUSTMENT OF JOYSTICK CONSOLE....1847
29.6 ADJUSTMENT OPERATOR'S SEAT....1848
30. MAIN MONITOR FAILURE DISPLAY....1850
30.1 MAIN MONITOR FAILURE DISPLAY....1850
30.2 ERROR CODES LIST INDICATED ON MAIN MONITOR....1851
31. HANDLING AUTO-GREASING SYSTEM....1853
31.1 METHOD OF OPERATING AUTO-GREASING SYSTEM....1854
31.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM....1854
31.3 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR....1860
31.4 METHOD OF SETTING TIMER....1861
SEAM018501 - Wheel Loader WA700-3 avance plus Operation & Maintenance Manual....1865
COVER....1865
1. FOREWORD....1866
2. SAFETY INFORMATION....1867
3. INTRODUCTION....1868
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1869
5. CONTENTS....1870
SAFETY....1874
6. GENERAL PRECAUTIONS....1875
7. PRECAUTIONS DURING OPERATION....1880
7.1 BEFORE STARTING ENGINE....1880
7.2 AFTER STARTING ENGINE....1883
7.3 TRANSPORTATION....1891
7.4 BATTERY....1892
7.5 TOWING....1894
8. PRECATIONS FOR MAINTENANCE....1895
8.1 BEFORE CARRYING OUT MAINTENANCE....1895
8.2 DURING MAINTENANCE....1900
8.3 TIRES....1906
9. POSITION FOR ATTATCHING SAFETY LABELS....1908
OPERATION....1914
10. GENERAL VIEW....1915
10.1 GENERAL VIEW OF MACHINE....1915
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....1916
11. EXPLANATION OF COMPONENTS....1917
11.1 MACHINE MONITOR....1917
11.2 SWITCHES....1927
11.3 CONTROL LEVERS, PEDALS....1936
11.4 STEERING COLUMN TILT LEVER....1941
11.5 CAP WITH LOCK....1941
11.6 ENGINE EMERGENCY STOP SWITCH AND FUEL STOP LEVER....1942
11.7 SAFETY BAR....1942
11.8 TOWING PIN....1943
11.9 GREASE PUMP....1944
11.10 BACKUP ALARM....1944
11.11 DOOR-OPEN LOCK....1944
11.12 TOOL BOX....1944
11.13 FUSE....1945
11.14 SLOW-BLOW FUSE....1947
11.15 LUNCH BOX TRAY....1948
11.16 STORAGING PLACE OF THIS MANUAL....1948
11.17 TAKING OFF POWER....1948
11.18 AM/FM CAR RADIO ....1949
11.19 AM/FM RADIO-CASSETTE STEREO....1953
11.20 CAR HEATER....1962
11.21 AIR CONDITIONER....1964
11.22 PRECAUTIONS WHEN HANDLING ACCUMULATOR....1967
12. OPERATION....1968
12.1 CHECK BEFORE STARTING ENGINE....1968
12.2 STARTING ENGINE....1982
12.3 OPERATIONS AND CHECK AFTER STARTING ENGINE....1988
12.4 MOVING MACHINE OFF....1989
12.5 CHANGING GEAR SPEED....1991
12.6 CHANGING DIRECTION....1992
12.7 TURNING....1992
12.8 STOPPING MACHINE....1993
12.9 OPERATION OF WORK EQUIPMENT....1994
12.10 WORK POSSIBLE USING WHEEL LOADER....1995
12.11 PRECAUTIONS FOR OPERATION....2000
12.12 ADJUSTING WORK EQUIPMENT POSTURE....2002
12.13 PARKING MACHINE....2004
12.14 CHECKS AFTER COMPLETION....2005
12.15 STOPPING ENGINE....2005
12.16 CHECK AFTER STOPPING ENGINE....2006
12.17 LOCKING....2006
12.18 HANDLING THE TIRES....2007
12.19 REMOVAL AND INSTALLATION OF THE BUCKET....2008
13. TRANSPORTATION....2013
13.1 LIFTING MACHINE....2013
14. COLD WEATHER OPERATION....2014
14.1 PRECAUTIONS FOR LOW TEMPERATURE....2014
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....2016
14.3 AFTER COLD WEATHER....2016
14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....2017
15. LONG-TERM STORAGE....2018
15.1 BEFORE STORAGE....2018
15.2 DURING STORAGE....2018
15.3 AFTER STORAGE....2018
16. TROUBLESHOOTING....2019
16.1 WHEN MACHINE RUNS OUT OF FUEL....2019
16.2 TOWING THE MACHINE....2020
16.3 IF BATTERY IS DISCHARGED....2023
16.4 OTHER TROUBLE....2027
MAINTENANCE....2035
17. GUIDES TO MAINTENANCE....2036
18. OUTLINES OF SERVICE....2039
18.1 OUTLINE OF OIL, FUEL, COOLANT....2039
18.2 OUTLINE OF ELECTRIC SYSTEM....2042
19. WEAR PARTS LIST....2043
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....2044
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....2048
21.1 INTRODUCTION OF NECESSARY TOOLS....2048
21.2 TORQUE LIST....2049
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....2050
23. MAINTENANCE SCHEDULE CHART....2052
23.1 MAINTENANCE SCHEDULE CHART....2052
24. SERVICE PROCEDURE....2056
24.1 INITIAL 250 HOURS SERVICE....2056
24.2 WHEN REQUIRED....2057
24.3 CHECK BEFORE STARTING....2079
24.4 EVERY 50 HOURS SERVICE....2086
24.5 EVERY 100 HOURS SERVICE....2087
24.6 EVERY 250 HOURS SERVICE....2091
24.7 EVERY 500 HOURS SERVICE....2097
24.8 EVERY 1000 HOURS SERVICE....2102
24.9 EVERY 2000 HOURS SERVICE....2108
24.10 EVERY 4000 HOURS SERVICE....2117
SPECIFICATIONS....2119
25. SPECIFICATIONS....2120
OPTIONS, ATTACHMENTS....2123
26. OPTIONAL PARTS AND ATTACHMENTS....2124
27. SELECTING BUCKETS AND TIRES....2125
28. HANDLING AUTO SHIFT SYSTEM....2126
28.1 AUTOMATIC SHIFT SYSTEM....2126
28.2 PRECAUTIONS WHEN CHANGING DIRECTION....2127
29. HANDLING JOYSTICK STEERING SYSTEM....2128
29.1 EXPLANANTION OF COMPONENTS....2128
29.2 STRUCTURE AND FUNCTION OF JOYSTICK STEERING....2129
29.3 OPERATION METHOD OF JOYSTICK STEERING SYSTEM....2132
29.4 PRECAUTIONS FOR STEERING WITH JOYSTICK....2134
29.5 ADJUSTMENT OF JOYSTICK CONSOLE....2135
29.6 ADJUSTMENT OPERATOR'S SEAT....2136
30. MAIN MONITOR FAILURE DISPLAY....2138
30.1 MAIN MONITOR FAILURE DISPLAY....2138
30.2 ERROR CODES LIST INDICATED ON MAIN MONITOR....2139
31. HANDLING AUTO-GREASING SYSTEM....2141
31.1 METHOD OF OPERATING AUTO-GREASING SYSTEM....2142
31.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM....2142
31.3 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR....2148
31.4 METHOD OF SETTING TIMER....2149
SEAWD01500 - Wheel Loader WA700-3 Field Assembly Instruction....2152
COVER....2152
CONTENTS....2153
1. CHART OF SEPARATED UNITS....2154
2. DIMENSIONS OF SEPARATED....2154
3. TRANSPORTATION BY LAND....2155
4. ORDER FOR ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY....2153
5. WORK SPACE LAYOUT DIAGRAM ....2156
6. TOOLS AND EQUIPMENT TO USE....2157
7. PROCEDURE FOR LOCAL ASSEMBLY....2162
A-0 POSITIONING SUPPORTS FOR FRONT & REAR AXLE, BARE MACHINE....2162
A-1 POSITIONING SUPPORTS FOR BARE MACHINE (FRAME STAND)....2163
A-2 ASSEMBLY OF REAR AXLE ASSEMBLY....2165
A-3 ASSEMBLY OF REAR DRIVE SHAFT ....2170
A-4 ASSEMBLY OF FRONT DRIVE SHAFT....2171
A-5 ASSEMBLY OF REAR TIRE, WHEEL ASSEMBLY....2173
A-6 ASSEMBLY OF REAR TIRE, WHEEL ASSEMBLY....2174
A-7 ASSEMBLY OF FRONT TIRE, WHEEL ASSEMBLY ....2175
A-8 ASSEMBLY OF BUCKET....2176
A-9 ASSEMBLY OF CAB ASSEMBLEY....2181
A-10 ASSEMBLY OF ROPS CANOPY ASSEMBLY....2187
A-11 ASSEMBLY OF FRONT LAMP ASSEMBLY....2190
A-12 ASSEMBLY OF FLOOR HANDRAIL (RIGHT)....2191
A-13 ASSEMBLY OF MUFFER STACK....2192
A-14 ASSEMBLY OF COUNTERWEIGHT....2193
A-15 ASSEMBLY OF LADDER ASSEMBLY....2195
A-16 ASSEMBLY OF FRONT FENDER....2196
A-17 ASSEMBLY OF HANDRAIL & REAR ACCESS STEP....2197
A-18 INSTALLATION OD FLOOR....2202
M-1 BLEEDING AIR FROM BRAKE LINE....2203
M-2 GREASING WORK EQUIPMENT, CHASSIS....2204
M-3 ADJUSTMENT OF BUCKET....2205
M-4 ADJUSTMENT OF BOOM KICKOUT....2206
M-5 INSPECTING ALL PARTS....2207
M-6 STARING ENGINE....2208
M-7 BLEEDING AIR FROM PISTO PUMP....2210
M-8 BLEEDING AIR FROM WORK EQUIPMENT HYRA....2211
SEBM009501 - Wheel Loader WA700-1 Shop Manual....2212
SAFETY....2218
FOREWORD....2220
GENERAL....2220
HOW TO READ THE SHOP MANUAL....2221
HOISTING INSTRUCTIONS....2222
COATING MATERIALS....2223
STANDARD TIGHTENING TORQUE....2225
ELECTRIC WIRE CODE....2228
CONVERSION TABLE ....2229
01 GENERAL....2236
GENERAL ASSEMBLY DRAWING ....2237
SPECIFICATIONS....2238
WEIGHT TABLE ....2241
LIST OF LUBRICANT AND WATER ....2243
10 STRUCTURE AND FUNCTION....2246
POWER TRAIN ....2249
RADIATOR AND COOLER ....2251
DAMPER ....2252
HYDRAULIC CIRCUIT FOR POWER TRAIN ....2253
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ....2254
TORQUE CONVERTER AND TRANSMISSION PIPING ....2255
TORQUE CONVERTER AND PTO ....2256
TORQUE CONVERTER REGULATOR VALVE ....2259
TORQUE CONVERTER OIL COOLER ....2260
TRANSMISSION ....2261
TRANSMISSION CONTROL VALVE ....2266
TRANSMISSION SOLENOID VALVE ....2269
TORQUE CONVERTER RELIEF VALVE ....2277
LUBRICATION BYPASS VALVE ....2278
TRANSMISSION SOLENOID VALVE ....2279
EMERGENCY MANUAL SPOOL ....2280
TRANSMISSION OIL FILTER ....2281
PILOT OIL FILTER ....2282
TRANSFER ....2283
DRIVE SHAFT ....2284
CENTER SUPPORT ....2285
AXLE ....2286
DIFFERENTIAL ....2288
FINAL DRIVE ....2291
AXLE MOUNT ....2293
CENTER HINGE PIN ....2295
FLOOR SUPPORT ....2296
STEERING PIPING DIAGRAM ....2297
STEERING CIRCUIT DIAGRAM ....2298
STEERING COLUMN AND LINKAGE ....2299
STEERING GEAR BOX ....2300
STEERING AND SWITCH PUMP ....2301
STEERING VALVE ....2303
ROTARY SEAL ....2305
SLOW RETURN VALVE ....2313
DIVERTER VALVE ....2314
EMERGENCY STEERING RELIEF VALVE ....2315
BRAKE AND AIR PIPING ....2319
BRAKE AND AIR CIRCUIT DIAGRAM....2321
AIR GOVERNOR....2322
AIR TANK ....2324
SAFETY VALVE ....2324
BRAKE VALVE ....2325
RELAY VALVE ....2329
DOUBLE CHECK VALVE ....2330
BRAKE CHAMBER ....2331
SLACK ADJUSTER ....2333
CHECK VALVE ....2336
HYDRAULIC TANK PRESSURIZING VALVE ....2337
PARKING BRAKE SOLENOID VALVE ....2338
SPRING CYLINDER....2339
BRAKE....2340
PARKING BRAKE....2341
HYDRAULIC PIPING ....2343
HYDRAULIC CIRCUIT SYSTEM....2345
HYDRAULIC CIRCUIT DIAGRAM....2346
WORK EQUIPMENT LEVER LINKAGE ....2347
HYDRAULIC TANK....2348
ACCUMULATOR ....2350
MAIN PUMP ....2352
PPC VALVE ....2364
PRESSURE DIFFERENTIAL VALVE....2369
MAIN CONTROL VALVE ....2371
HYDRAULIC LEVER OPERATION ....2378
LUBRICATION OF WORK EQUIPMENT ....2385
BUCKET LINKAGE ....2387
BUCKET POSITIONER AND BOOM KICK-OUT ....2389
CAB....2391
AIR CONDITIONER ....2392
ELECTRICAL WIRING DIAGRAM CIRCUIT....2398
ELECTRICAL WIRING DIAGRAM CIRCUIT....2397
ENGINE CONTROL SYSTEM ....2400
ENGINE CONTROLLER....2401
ELECTRICAL VEHICLE MONITORING SYSTEM (EVMS) ....2402
SENSORS....2408
ENGINE STARTING CIRCUIT....2415
ENGINE STOP CIRCUIT ....2416
AUTO PRIMING SYSTEM (APS) ....2417
COMBINATION SWITCH ....2422
ELECTRICAL TRANSMISSION CONTROL ....2423
ELECTRICAL PARKING BRAKE CONTROL ....2427
ELECTRICAL PARKING BRAKE....2428
KICK-DOWN SWITCH ....2436
20 TESTING AND ADJUSTING....2442
STANDARD VALUE TABLE FOR ENGINE ....2444
STANDARD VALUE TABLE FOR CHASSIS ....2445
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM....2448
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (ENGINE) ....2452
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (CHASSIS)....2453
ADJUSTING VALVE CLEARANCE ....2454
MEASURING COMPRESSION PRESSURE....2455
MEASURING BLOW-BY PRESSURE....2456
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE....2457
TESTING AND ADJUSTING FUEL INJECTION TIMING ....2458
MEASURING EXHAUST GAS COLOR....2460
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....2461
ADJUSTING ENGINE SPEED SENSOR....2462
MEASURING OPERATING EFFORT OF ACCELERATOR PEDAL....2463
ADJUSTING POTENTIOMETER, TRAVEL OF ACCELERATOR PEDAL....2464
MEASURING SHIFT LEVER....2466
MEASURING STALL SPEED....2467
MEASURING HYDRAULIC PRESSURE (TORQUE CONVERTOR, TRANSMISSION PRESSURE)....2469
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL....2471
MEASURING WHEEL LOCK RING CLEARANCE....2472
MEASURING STEERING WHEEL PLAY....2473
MEASURING OPERATING FORCE AND OPERATING TIME OF STEERING WHEEL....2474
TESTING AND ADJUSTING STEERING LINKAGE....2475
MEASURING STEERING OIL PRESSURE ....2477
MEASURING EMERGENCY STEERING PRESSURE ....2478
MEASURING BRAKE PEDAL....2480
MEASURING AIR PRESSURE....2481
TESTING BRAKE PERFORMANCE ....2483
CHECKING BRAKE PISTON LEAKAGE....2484
MEASURING WEAR OF BRAKE DISC ....2485
AIR BLEEDING FROM BRAKE LINE ....2486
TESTING PARKING BRAKE PERFORMANCE ....2487
CHECKING AND ADJUSTING PARKING BRAKE....2488
MEASURING DUMP AND LIFT CONTROL LEVERS ....2490
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT ....2492
AIR BLEEDING FROM PISTON PUMP ....2495
MEASURING WORK EQUIPMENT ....2496
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT ....2497
ADJUSTING BUCKET POSITIONER ....2498
ADJUSTING BOOM KICK-OUT ....2499
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE) ....2500
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR ....2501
TROUBLESHOOTING....2503
ELECTRICAL CIRCUIT FOR ENGINE, TRANSMISSION AND PARKING BRAKE ....2504
ELECTRICAL CIRCUIT SYSTEM....2508
VEHICLE MONITOR SYSTEM....2509
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE....2510
LOCATION OF CONNECTORS....2512
CONNECTOR TERMINAL NUMBERS....2513
POINTS TO REMEMBER WHEN TROUBLESHOOTING ....2519
SEQUENCE OF EVENTS IN TROUBLESHOOTING ....2520
PRECAUTIONS WHEN CARRYING OUT ....2521
HANDLING CONNECTORS ....2528
CHECK BEFORE TROUBLESHOOTING....2529
JUDGEMENT ON POWER TRAIN ....2530
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES ....2532
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (ENGINE, TRANSMISSION, PARKING BRAKE)....2537
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER ....2538
TROUBLESHOOTING OF APS....2540
E-1: ENGINE DOES NOT START....2542
a) Inspection of starting circuit....2542
b) Inspection of battery - battery relay - starting switch....2542
c) Check starting switch - governor cut relay....2543
E-2: ENGINE DOES NOT STOP....2544
E-3: ENGINE STOPS WHEN TRAVELING....2544
E-4: PARKING BRAKE DOES NOT WORK....2545
a) If parking brake does not work when parking brake switch is ON (applied)....2545
b) If parking brake does not work then air pressure has dropped (does not work as emergency brake)....2545
E-5: PARKING BRAKE IS NOT RELEASED....2546
E-6: PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON....2548
E-7: WHEN PARKING BRAKE IS APPLIED, TRANSMISSION DOES NOT ENTER NEUTRAL (PARKING BRAKE IS WORKNG NORMALLY)....2548
E-8: TRANSMISSION DOES NOT WORK NORMALLY....2549
a) Problem in parking brake, transmission cut-off switch, neutral relay circuit....2550
b) Defective continuity in FORWARD solenoid circuit....2552
c) Defective continuity in REVERSE solenoid circuit....2554
d) Contact in F-R circuit....2556
e) Problem in speed solenoid circuit....2560
f) Contact in speed circuit....2564
E-9: KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1 - F4 SWITCHES CORRECTLY)....2570
E-10: KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOWS NOT CARRY OUT SELF-HOLD OPERATION)....2573
E-11: KICK-DOWN OPERATION IS NOT CANCELED....2574
E-12: KICK-DOWN WORKS MISTAKE WHEN TRAVELING IN F2....2576
E-13: MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED....2576
E-14: PREHEATING IS NOT CARRIED OUT....2578
a) Does not carry out preheating automatically....2579
b) Does not carry out preheating either manually or automatically....2579
E-15: PREHEATING STAYS ON....2580
a) Automatic preheating is not canceld....2580
b) Preheating is carried out even when heater switch is turned OFF....2580
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM....2581
M-1 Brake oil level flashes when engine is stopped....2583
M-2 Engine oil level flashes when engine is stopped....2583
M-3 Radiator water level flashes when engine is stopped....2584
M-4 Battery charge flashes when engine is running....2584
M-5 Transmission oil filter clogging flashes when engine is running....2586
M-6 Fuel level flashes when engine is running....2588
M-7 Brake line failure flashes when engine is running....2588
M-8 Engine oil pressure flashes when engine is running....2590
M-9 Radiator water level flashes when engine is running....2590
M-10 Drop in air pressure flashes when engine is running....2592
M-11 Engine water temperature flashes when engine is running....2592
M-12 Torque converter oil temperature flashes when engine is running....2592
M-13 Parking brake lights up abnormally, or does not light up....2594
a) If parking brake stays lighted up....2594
b) If parking brake does not light up....2594
M-14 Working lamp lights up abnormally, or does not light up....2596
a) If working lamp stays lighted up....2596
b) If working lamp does not light up....2596
M-15 Preheating lights up, or does not light up....2598
a) Preheating lights up....2598
b) Preheating does not light up....2598
M-16 Main steering failure lights up, or does not light up....2600
a) Main steering failure lights up....2600
b) Main steering failure does not light up....2600
M-17 Transmission cut-off lights up, does not light up....2602
a) Transmission cut-off lights up....2602
b) Transmission cut-off does not light up....2602
M-18 Turn signal and Hi beam light up, or do not light up....2604
a) Turn signal (right) pilot display lights up....2604
b) Turn signal (left) pilot display lights up....2605
c) Turn signal (right) pilot display does not light up....2606
d) Turn signal (left) pilot display does not light up....2606
e) Hi beam pilot does not light up....2607
f) Hi beam pilot stays lighted up....2607
M-19 Turn signal does not flash even when hazard switch is turned on....2609
M-20 Speedometer display does not work normally....2610
M-21 Hourmeter does not work normally....2611
M-22 When starting switch is turned on, monitor panel does not work, or only part lights up....2612
a) None of monitor panel lights up....2612
b) Except for speedometer module, none of monitor panel lights up....2612
c) None of CAUTION items light up....2613
d) Some other parts do not light up....2613
M-23 When starting switch is turned ON, all monitor panel lights up, but does not go out....2613
M-24 Engine oil pressure flashes or Battery charge flashes when engine is stopped....2614
a) Engine oil pressure flashes, and alarm buzzer and warning lamp are actuated....2614
b) Battery charge flashes, and warning lamp lights up....2614
M-25 None of machine monitor panel lighting lights up, or part does not light up....2616
a) Even when combination lamp is placed at SMALL, none of panel lighting lights up....2616
b) Even when working lamp is switched ON, none of monitor panel lights up....2618
c) Even when starting switch is turned ON, none of monitor panel lights up....2620
d) Part of panel does not light up....2620
M-26 When starting switch is turned to ON position (engine stopped), buzzer does not sound for 1 sec....2622
M-27 No abnormality is shown on monitor display, but alarm buzzer sounds....2622
M-28 When starting switch is turned to ON position (engine stopped), warning lamp does not light up for 2 sec....2624
M-29 No abnormality is shown on monitor display, but warning lamp lights up....2625
M-30 Abnormality in Fuel guage system....2626
a) If nothing is displayed in display area....2626
b) If indicator remains at FULL....2626
M-31 Abnormality in Air pressure guage system....2628
a) If nothing is displayed in display area....2628
b) If indicator remains at maximum level....2628
M-32 Abnormality in Engine water temperature guage system....2630
a) If nothing is displayed in display area....2630
b) If indicator remains at minimum level....2630
M-33 Abnormality in Torque converter oil temperature guage system....2632
a) If nothing is displayed in display area....2632
b) If indicator remains at minimum level....2632
TROUBLESHOOTING CHART FOR POWER TRAIN, STEERING, AIR AND BRAKE, WORK EQUIPMENT (MECHANICAL SYSTEM)....2635
POWER TRAIN....2636
1. Machine does not move....2636
2. Machine lacks power or speed....2638
3. Excessive time lag when starting machine or shifting gear....2639
4. Torque converter oil temperature too high....2640
STEERING SYSTEM....2641
1. Steering wheel does not turn....2641
2. Steering wheel is sluggish....2642
3. Steering wheel moves unsteadily or is subjected to large shock....2643
4. Machine tends to turn naturally in one particular direction when traveling....2643
5. Left and right turning radii are different....2643
AIR AND BRAKE SYSTEM....2644
1. Air pressure does not rise at all....2644
2. Air pressure does not rise to the specified range....2645
3. Brake is ineffective or not very effective....2646
4. Brake does not release, or drags....2647
5. Parking brake does not release, or drags....2648
WORK EQUIPMENT....2649
1. Lift arm does not rise....2649
2. Lift arm moves slowly or does not have sufficient lifting power....2650
3. Lift arm movement becomes slow after it reaches a certain height....2651
4. Bucket cannot be held down with lift arm cylinder....2651
5. Lift arm has large hydraulic drift....2651
6. Lift arm movement is unsteady during work....2651
7. Lift arm lowers momentarily when control lever is shifted from "Hold" to "Raise"....2651
8. Bucket does not tilt back....2652
9. Bucket moves slowly or has insufficient tilt back power....2653
10. Bucket movement becomes slow during tilt back....2654
11. Bucket cannot be held down by the bucket cylinder....2654
12. Bucket has large hydraulic drift....2654
13. Bucket moves unsteadily when machine travels under load (Main control valve in "Hold")....2654
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"....2654
15. Control levers of lift arm and dump move stiffly and sluggishly....2655
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR)....2657
Judgement table for engine controller and engine related parts....2659
R-1 Abnormality in power source....2660
R-2 Abnormality in controller....2661
R-3 Abnormality in rack sensor system....2662
R-4 Abnormality in governor solenoid system....2663
R-5 Abnormality in governor cut relay system....2664
R-6 Abnormality in pre-stroke solenoid system....2665
R-7 Abnormality in rack sensor power source system....2666
R-8 a. Abnormality in engine speed sensor system A....2667
b. Abnormality in engine speed sensor system B....2668
R-9 Abnormality in acceleration sensor system....2669
R-10 Abnormality in governor servo system....2671
R-11 Abnormality in engine water temperature system....2672
R-12 Engine does not start....2673
Electric circuit diagram of engine controller system....2675
30 DISASSEMBLY AND ASSEMBLY....2676
STARTING MOTOR ....2679
REMOVAL AND INSTALLATION ....2679
ALTERNATOR....2680
REMOVAL AND INSTALLATION....2680
ALTERNATOR CORE ....2681
REMOVAL....2681
INSTALLATION....2684
TURBOCHARGER (TOP) ....2686
REMOVAL AND INSTALLATION....2686
FUEL INJECTION PUMP....2687
REMOVAL AND INSTALLATION....2687
TURBOCHARGER (BOTTOM) ....2689
REMOVAL AND INSTALLATION....2689
NOZZLE HOLDER....2690
REMOVAL AND INSTALLATION....2690
OIL COOLER....2691
REMOVAL AND INSTALLATION ....2691
THERMOSTAT....2692
REMOVAL AND INSTALLATION ....2692
WATER PUMP....2693
REMOVAL AND INSTALLATION....2693
CYLINDER HEAD....2694
REMOVAL....2694
INSTALLATION....2696
AIR COMPRESSOR....2700
REMOVAL AND INSTALLATION....2700
RADIATOR ....2701
REMOVAL....2701
INSTALLATION....2705
ENGINE....2709
REMOVAL....2709
INSTALLATION....2716
DAMPER....2724
REMOVAL....2724
INSTALLATION....2728
DISASSEMBLY....2733
ASSEMBLY....2735
TORQUE CONVERTER CHARGING AND PPC PUMP....2739
REMOVAL....2739
INSTALLATION....2741
TORQUE CONVERTER, PTO, TRANSMISSION....2743
REMOVAL....2743
INSTALLATION....2753
TORQUE CONVERTER....2763
DISASSEMBLY....2763
ASSEMBLY....2767
PTO....2772
DISASSEMBLY....2772
ASSEMBLY....2774
TRANSMISSION....2777
DISASSEMBLY....2777
ASSEMBLY....2789
TRANSFER....2803
DISASSEMBLY....2803
ASSEMBLY....2810
TRANSMISSION VALVE....2820
REMOVAL....2820
INSTALLATION....2821
DISASEMBLY AND ASSEMBLY....2823
CENTER SUPPORT....2828
REMOVAL....2828
INSTALLATION....2829
DISASSEMBLY....2831
ASSEMBLY....2833
DRIVE SHAFT....2836
DISASSEMBLY....2836
ASSEMBLY....2838
FRONT AXLE....2839
REMOVAL....2839
INSTALLATION....2841
REAR AXLE....2843
REMOVAL....2843
INSTALLATION....2848
DIFFERENTIAL....2853
REMOVAL....2853
INSTALLATION....2856
DISASSEMBLY....2858
ASSEMBLY....2862
FINAL DRIVE....2871
DISASSEMBLY....2871
ASSEMBLY....2875
STEERING GEAR....2879
REMOVAL....2879
INSTALLATION....2880
DISASSEMBLY....2881
ASSEMBLY....2882
STEERING, SWITCH PUMP....2885
REMOVAL....2885
INSTALLATION....2886
STEERING VALVE....2887
REMOVAL....2887
INSTALLATION....2889
DISASSEMBLY AND ASSEMBLY....2891
DIVERTER VALVE....2893
DISASSEMBLY AND ASSEMBLY....2893
STEERING CYLINDER....2895
REMOVAL....2895
INSTALLATION....2897
BRAKE VALVE....2900
REMOVAL....2900
INSTALLATION....2902
DISASSEMBLY....2904
ASSEMBLY....2906
BRAKE CHAMBER....2908
REMOVAL....2908
INSTALLATION....2909
DISASSEMBLY....2910
ASSEMBLY....2913
AIR GOVERNOR....2916
DISASSEMBLY....2916
ASSEMBLY....2917
SLACK ADJUSTER....2918
REMOVAL....2918
INSTALLATION....2919
DISASSEMBLY....2920
ASSEMBLY....2921
BRAKE....2922
REMOVAL....2922
INSTALLATION....2924
DISASSEMBLY....2926
ASSEMBLY....2930
SPRING CYLINDER....2936
REMOVAL....2936
INSTALLATION....2937
DISASSEMBLY....2938
ASSEMBLY....2939
PARKING BRAKE....2940
REMOVAL....2940
INSTALLATION....2941
DIASSEMBLY AND ASSEMBLY....2942
PARKING BRAKE PAD....2943
REMOVAL AND INSTALLATION....2943
HYDRAULIC TANK....2944
REMOVAL....2944
INSTALLATION....2946
HYDRAULIC PUMP....2948
REMOVAL....2948
INSTALLATION....2949
PISTON PUMP....2950
DISASSEMBLY....2950
ASSEMBLY....2957
PPC VALVE....2971
REMOVAL....2971
INSTALLATION....2972
DISASSEMBLY AND ASSEMBLY....2973
MAIN CONTROL VALVE....2974
REMOVAL....2974
INSTALLATION....2976
DISASSEMBLY....2979
ASSEMBLY....2981
DUMP CYLINDER....2983
REMOVAL....2983
INSTALLATION....2985
LIFT CYLINDER....2987
REMOVAL....2987
INSTALLATION....2989
STEERING, LIFT, DUMP CYLINDER....2991
DISASSEMBLY....2991
ASSEMBLY....2993
CENTER HINGE PIN....2995
REMOVAL....2995
INSTALLATION....3001
WORK EQUIPMENT....3011
REMOVAL....3011
INSTALLATION....3017
COUNTERWEIGHT....3023
REMOVAL....3023
INSTALLATION....3024
FUEL TANK....3025
REMOVAL....3025
INSTALLATION....3027
MACHINE MONITOR....3029
REMOVAL....3029
INSTALLATION....3030
40 MAINTENANCE STANDARD....3032
ENGINE AND TRANSMISSION MOUNT ....3034
DAMPER ....3035
TORQUE CONVERTER CHARGING, COOLING AND PPC PUMP ....3037
TORQUE CONVERTER AND PTO ....3039
TORQUE CONVERTER REGULATOR VALVE ....3040
TRANSMISSION....3041
TRANSMISSION CONTROL VALVE ....3045
TRANSMISSION SOLENOID VALVE ....3049
TRANSFER ....3051
DRIVE SHAFT....3053
CENTER SUPPORT ....3054
DIFFERENTIAL....3055
FINAL DRIVE ....3057
AXLE MOUNT ....3059
CENTER HINGE PIN ....3061
STEERING LINKAGE AND STEERING COLUMN ....3063
STEERING GEAR BOX ....3065
STEERING VALVE ....3067
DIVERTER VALVE ....3069
STEERING CYLINDER MOUNT ....3070
EMERGENCY STEERING PUMP ....3071
BRAKE CHAMBER ....3072
BRAKE VALVE ....3073
SLACK ADJUSTER ....3075
BRAKE....3077
PARKING BRAKE ....3079
SPRING CYLINDER ....3080
CONTROL PUMP ....3081
MAIN CONTROL VALVE ....3082
PPC VALVE ....3083
CYLINDER....3085
BUCKET LINKAGE....3087
BUCKET POSITIONER AND BOOM KICK-OUT....3089
SEBM013312 - Wheel Loader WA700-3 avance Shop Manual....3092
COVER....3092
CONTENTS....3093
01 GENERAL....3122
GENERAL ASSEMBLY DRAWING....3123
SPECIFICATIONS....3126
WEIGHT TABLE....3129
LIST OF LUBRICANT AND WATER....3131
10 STRUCTURE AND FUNCTION....3133
OUTLINE....3134
POWER TRAIN SYSTEM....3135
DAMPER....3137
RADIATOR AND OIL COOLER....3138
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....3140
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....3144
TORQUE CONVERTER AND TRANSMISSION PIPING....3146
TORQUE CONVERTER AND PTO....3148
TORQUE CONVERTER REGULATOR VALVE....3154
TRANSMISSION....3155
TRANSMISSION CONTROL VALVE....3165
TORQUE CONVERTER OIL COOLER....3189
TRANSMISSION OIL FILTER....3190
TRANSFER....3192
AXLE....3193
DIFFERENTIAL....3195
FINAL DRIVE....3197
STEERING PIPING DIAGRAM....3200
STEERING AND SWITCH PUMP....3201
STEERING UNIT (ORBIT-ROLL VALVE)....3205
STEERING DEMAND VALVE....3208
TWO-WAY RESTRICTOR VALVE....3219
STOP VALVE....3220
DIVERTER VALVE....3221
BRAKE PIPING....3225
BRAKE CIRCUIT DIAGRAM....3226
BRAKE VALVE....3227
CHARGE VALVE....3232
ACCUMULATOR (FOR BRAKE)....3235
SLACK ADJUSTER....3236
BRAKE....3239
PARKING BRAKE....3242
SPRING CYLINDER....3246
PARKING BRAKE SOLENOID VALVE....3247
HYDRAULIC PIPING....3248
HYDRAULIC CIRCUIT DIAGRAM....3249
MAIN PISTON PUMP....3251
ES VALVE (ENGINE SENSING VALVE)....3260
SERVO VALVE....3261
PRESSURE DIFFERENTIAL VALVE....3262
PPC VALVE (PROPORTIONAL PRESSURE VALVE)....3263
PPC RELIEF VALVE....3267
ACCUMULATOR (FOR PPC VALVE)....3268
MAIN CONTROL VALVE....3269
LUBRICATION OF WORK EQUIPMENT....3293
WORK EQUIPMENT LINKAGE....3295
BUCKET POSITIONER AND BOOM KICK-OUT....3297
OPERATION OF PROXIMITY SWITCH....3299
AIR CONDITIONER....3303
ELECTRIC CIRCUIT DIAGRAM....3307
MACHINE MONITOR SYSTEM....3253
MAIN MONITOR....3308
MAINTENANCE MONITOR....3312
AUTOMATIC TRANSMISSION SYSTEM (ATM)....3314
JOYSTICK STEERING SYSTEM....3327
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)....3329
TRANSMISSION AND JOYSTICK CONTROLIER....3333
ENGINE STARTING CIRCUIT....3336
ENGINE STOP CIRCUIT....3339
AUTO PRIMING SYSTEM (APS)....3341
PREHEATING CIRCUIT....3345
FUEL SYSTEM....3346
ELECTRICAL TRANSMISSION CONTROL....3347
KICK-DOWN ,HOLD SWITCH....3350
KICK-DOWN ELECTRICAL CIRCUIT....3351
ELECTRIC PARKING BRAKE CONTROL....3357
ELECTRIC CIRCUIT DIAGRAM OF ACTIVE POWER MAXIMIZING SYSTEM....3366
VHMS CONTROLLER....3372
BLOW-BY PRESSURE SENSOR....3372
ENGINE OIL TEMPERATURE SENSOR....3373
EXHAUST TEMPERATURE SENSOR/AMP....3374
AMBIENT TEMPERATURE SENSOR....3374
TRANSMISSION PUMP OIL PRESSURE SENSOR....3375
BRAKE OIL TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR....3376
BRALE OIL PRESSURE SENSOR STERING OIL PRESSURE SENSOR WORK EPUIPMENT PUMP OIL PRESSURE SENSOR....3377
COMMUNICATIONS (ORB: ORBCOMM) CONTRLOOER/ANTENNA....3378
20 TESTING AND ADJUSTING....3379
STANDARD VALUE TABLE FOR ENGINE....3380
STANDARD VALUE TABLE FOR CHASSIS....3382
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....3387
TESTING AND ADJUSTING....3404
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....3405
ADJUSTING VALVE CLEARANCE....3408
TESTING AND ADJUSTING INJECTOR LIFT....3410
MEASURING COMPRESSION PRESSURE....3412
MEASURING BLOW-BYPRESSURE....3415
TESTING AND ADJUSTING FUEL INJECTION TIMING....3416
MEASURING EXHAUST GAS COLOR....3418
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....3419
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....3420
HANDLING EQUIPMENT IN FUEL CIRCUIT....3421
MEASURING FUEL PUMP OUTLET PORT PRESSURE....3421
BLEEDING AIR FROM FUEL CIRCUIT....3422
MEASURING EXHAUST TEMPERATURE....3424
MEASURING EXHAUST TEMPERATURE (OVERALL ENGINE)....3425
MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER)....3426
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....3427
MEASURING ACCELERATOR PEDAL ....3428
ADJUSTING ACCELERATOR PEDAL TRAVEL,POTENTIOMETER ....3429
ADJUSTING ACCELERATOR PEDAL MICRO SWITCH....3431
MEASURING TORQUE CONVERTER,TRANSMISSION HYDRAULIC PRESSURE ....3432
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ....3434
TESTING AND ADJUSTING STEERING OIL PRESSURE....3436
ADJUSTING STEERING STOPPER BOLT ....3437
ADJUSTING JOYSTICK STEERING ....3438
ADJUSTING JOYSTICK LEVER EUTRAL DETECTION....3440
TESTING BRAKE OIL PRESSURE ....3441
MEASURING WEAR OF BRAKE DISC ....3442
MEASURING BRAKE PERFORMANCE ....3443
TESTING AND ADJUSTING PARKING BRAKE ....3444
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE ....3446
MEASURING PPC RELIEF VALVE HYDRAULIC PRESSURE ....3447
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE ....3449
BLEEDING AIR FROM PISTON PUMP ....3451
ADJUSTING WORK EQUIPMENT LEVER LINKAGE ....3452
TESTING AND ADJUSTING BUCKET POSITIONER ....3454
TESTING AND ADJUSTING BOOM KICK-OUT....3455
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP ....3456
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)....3457
BLEEDING AIR ....3458
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ....3459
BASIC PRECAUTIONS....3460
OUTLINE....3463
SETTING UP VHMS CONTROLLER....3469
COLLECTION, TRANSMISSION OF DATA....3471
INSPECTION AND MAINTENANCE....3476
REPLACING PARTS....3476
TROUBLESHOOTING....3477
POINTS TO REMEMBER WHEN TROUBLESHOOTING ....3478
SEQUENCE OF EVENTS IN TROUBLESHOOTING ....3479
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....3480
CHECKS BEFORE TROUBLESHOOTING ....3488
CONNECTOR TYPES AND MOUNTING LOCATIONS ....3489
CONNECTOR ARRANGEMENT DIAGRAM ....3495
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ....3505
ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM ....3528
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE ....3531
CHART OF ACTION CODES AND FAILURE CODES,AND RE-ENACTION ....3533
TRANSMISSION CONTROLLER LED DISPLAY ....3535
METHOD OF USING TROUBLESHOOTING CHARTS ....3536
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....3538
METHOD OF USING TROUBLESHOOTING CHARTS ....3539
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) ....3543
S-2 ENGINE DOES NOT START ....3545
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT ....3545
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTDE)....3546
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....3547
S-4 ENGINE STOPS DURING OPERATIONS ....3548
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....3550
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) ....3551
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....3552
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BULE) ....3553
S-9 OIL BECOMES CONTAMINATED QUICKLY ....3554
S-10 FUEL CONSUMPTION IS EXCESSIVE ....3555
S-11 OIL IS IN COOLING WATER ,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN ....3556
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) ....3557
S-13 OIL LEVEL RISES ....3558
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ....3559
S-15 ABNORMAL NOISE IS MADE ....3560
S-16 VIBRATION IS EXCESSIVE ....3562
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) ....3563
ELECTRICAL CIRCUIT DIAGAM FOR M MODE SYSTEM ....3565
M-1 MAIN MONITOR DOES NOT WORK ....3569
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP ....3570
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY ....3571
M-4 ABNORMALITY IN SHIFT INDICATOR ....3572
a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F....3572
b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R ....3572
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N,AND DISPLYS E WHEN DIRECTIONAL LEVER IS AT F....3572
d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N,AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R....3573
e) DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R)....3573
f) DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R)....3573
g) DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R)....3574
h) DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R)....3574
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP ....3576
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP ....3576
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP....3576
M-6 ABNORMALITY IN PARKING DISPLAY ....3577
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP ....3577
b) PARKING LAMP DISPLAY STAYS LIGHTED UP ....3577
M-7 NIGHT LIGHTING DOES NOT LIGHT UP ....3578
M-8 ABNORMALITY IN FRONT WORKING LAMP ....3579
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP....3579
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP....3579
c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP ....3579
M-9 ABNORMALITY IN REAR WORKING LAMP ....3581
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP ....3581
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP ....3581
c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP ....3581
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF ....3583
STANDARD SPECIFICATION....3583
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE ....3583
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED....3583
c) TRANSMISSION CUT-OFF SWITCH TURNED ON,BUT CUT-OFF FUNCTION IS NOT ACTUATED....3584
AUTO-SHIFT SPECIFICATION....3585
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE ....3585
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF,MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED ....3585
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF),CUT-OFF FUNCTION IS ALWAYS ACTUATED....3585
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)....3585
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON),BUT CUT-OFF FUNCTION IS NOT ACTUATED....3586
M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ....3587
a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N....3587
b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N....3587
M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED....3589
a) ACTUATED CONTINUOUSLY ....3589
b) NOT ACTUATED....3589
M-13 ABNORMALITY IN BUZZER....3590
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)....3590
b) BUZZER ALWAYS SOUNDS ....3590
M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY ....3591
M-15 ABNORMALITY IN FAILURE DISPLAY MODE ....3592
a) DOES NOT ENTER FAILURE DISPLAY MODE ....3592
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE ....3592
M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY....3593
a) THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED....3593
b) THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED....3593
c) PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED....3593
d) PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED....3594
M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY ....3595
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP....3595
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP....3595
M-18 ABNORMALITY IN AUTO-GREASING SYSTEM....3596
a) FORCED GREASING CANNOT BE CARRIED OUT ....3596
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)....3596
c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)....3596
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) ....3597
e) MONITOR DISPLAY GOES OUT ....3597
M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM ....3598
a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED ....3598
b) MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK ....3598
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)....3600
ELECTRICAL CIRCUIT DIAGRAM FOR K MODE SYSTEM ....3601
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 ....3603
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP ....3603
b) SOME LAMPS DO NOT LIGHT UP ....3603
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) ....3604
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS),NO LAMPS ON MAINTENANCE MONITOR GO OUT ....3605
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH ....3606
a) ENGINE OIL LEVEL DISPLAY FLASHES ....3606
b) ENGINE WATER LEVEL DISPLAY FLASHES ....3607
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH....3609
b) BATTERY CHARGE LEVEL DISPLAY FLASHES ....3611
c) BRAKE OIL PRESSURE DISPLAY FLASHES ....3612
d) AIR CLEANER [L.H.] DISPLAY FLASHES ....3613
e) AIR CLEANER [R.H.] DISPLAY FLASHES ....3614
f) AIR CLEANER DISPLAY FLASHES ....3615
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND ....3616
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS ....3617
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP,CAUTION LAMP) DOES NOT FLASH ....3618
a) CHECK LAMP ....3618
b) CAUTION LAMP ....3618
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP,CAUTION LAMP) LIGHTS UP....3619
a) CHECK LAMP ....3619
b) CAUTION LAMP ....3619
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)....3620
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF,NIGHT LIGHTING STAYS LIGHTED UP ....3621
K-12 SERVICE METER DOES NOT WORK ....3622
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED ....3622
K-14 ABNORMALITY IN GAUGE ITEMS ....3624
a) ABNORMALITY IN FUEL GAUGE ....3624
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE ....3625
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE ....3626
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....3627
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM ....3629
E-1 ENGINE DOES NOT START ....3633
a) STARTING MOTOR DOES NOT TURN ....3633
b) STARTING MOTOR TURNS ....3638
E-2 ABNORMALITY IN APS SYSTEM ....3646
a) WHEN PREHEATING SWITCH IS TURNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP....3648
b) WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20°C,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL....3649
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL....3650
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL....3651
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL ....3651
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL ....3652
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL ....3652
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL ....3653
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL ....3653
j) WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP....3654
E-3 PARKING BRAKE DOES NOT HAVE EFFECT ....3655
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON ....3655
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS ....3655
E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING....3656
E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON ....3658
E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY ....3658
E-7 TRANSMISSION DOES NOT WORK PROPERLY ....3660
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT ....3661
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT ....3664
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT ....3666
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT ....3668
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT ....3673
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT ....3676
E-8 KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS F1-F4) ....3681
E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON (KICK-DOWN SWITCH DOES NOT CARRY OUT SELF-HOLD OPERATION)....3684
E-10 KICK-DOWN ALWAYS WORKS....3685
E-11 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND....3687
E-12 BOOM KICK-OUT DOES NOT WORK....3689
E-13 DEFECTIVE BUCKET POSITIONER ....3691
E-14 POWER WINDOW DOES NOT WORK ....3693
a) WINDOW DOES NOT GO UP ....3693
b) WINDOW DOES NOT GO DOWN ....3694
E-15 ABNORMALITY IN FRONT WORKING LAMP....3696
E-16 ABNORMALITY IN REAR WORKING LAMP....3696
E-17 ABNORMALITY IN TRANSMISSION CUT-OFF....3696
E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ....3696
E-19 ABNORMALITY IN BUZZER....3696
TROUBLESHOOTING OF ELECTRIC ENGINE THROTTLE CONTROLLER & APS CONTROLLER SYSTEM SYSTEM (G MODE)....3697
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS ....3698
ACTION TAKEN BY CONTROLLER AND CODDITION OF MACHINE WHEN ABNORMALITY OCCURS....3700
ACTION TAKEN BY CONTROLLER AND CONTROLLER AND CONDITIONS FOR RESTTING WHEN ABNORMALITY OCCURS....3706
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTIN OF ENGINE CONTROLLER SYSTEM....3707
JUDGEMENT TABLE FOR ENGINE CONTROLLER ....3709
G-1 [90][OFF OR 10]ABNORMALITY IN POWER SOURCE SYSTEM ....3710
G-2 [90][11]ABNORMALITY IN CONTROLLER SYSTEM ....3710
G-3 [90][21]MISTAKEN CONNECTION OF CONNECTOR ....3711
G-4 [90][56]ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM ....3711
G-5 [90][58]ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM ....3712
G-6 [90][59]ABNORMALITY IN SWITCH POWER SOURCE SYSTEM ....3713
G-7 [91][14]ABNORMALITY IN GOVERNOR SOLENOID SYSTEM ....3714
G-8 [91][16]ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM ....3715
G-9 [91][19]ABNORMALITY IN GOVERNOR SERVO SYSTEM ....3716
G-10 [91][1d]ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM ....3717
G-11 [92][12]ABNORMALITY IN RACK SENSOR SYSTEM ....3718
G-12 [92][18]ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM ....3719
G-13 [93][1b]ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM ....3720
G-14 [94][1c]ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM ....3721
G-15 [93,94][1b,1c]ABNORMALITY IN ENGINE SPEED SENSOR A,B SYSTEM ....3722
G-16 [95][40]ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM ....3722
G-17 [97][31]ABNORMALITY IN ACCELERATOR SENSOR SYSTEM ....3723
G-18 [99][22]ENGINE OVERRUN....3725
G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY)....3725
G-20 ENGINE DOES NOT START....3726
G-21 ENGINE DOES NOT STOP ....3729
G-22 DEFECTIVE ACTUATION OF APS ....3730
a) PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE ALSO OFF)....3730
b) PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20°C WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY) PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20°C WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY) ....3732
c) NOZZLE DOES NOT INJECT FUEL WHEN STARTING SWITCH IS TURNED TO START AFTER COMPLETION OF PREHEATING WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY)....3732
d) APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY....3733
e) APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY....3733
f) APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY....3734
g) APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY....3734
h) APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) GIVES ABNORMAL DISPLAY....3735
i) APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY ....3735
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)....3737
METHOD OF USING MATRIX TROUBLESHOOTING TABLES....3739
H-1 MACHINE DOES NOT START....3741
H-2 MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES)....3742
H-3 TIME LAG IS EXCESSIVE WHEN STRATING OR SHIFTING GEAR ....3743
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ....3744
H-5 STEERING DOES NOT TURN ....3745
STEERING WHEEL SPECIFICATION....3745
H-6 STEERING DOES NOT TURN....3746
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3746
H-7 STEERING DOES NOT TURN ....3747
AJSS ( ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....3747
H-8 TURNING,RESPONSE OF STEERING IS POOR ....3748
STEERING WHEEL SPECIFICATION....3748
H-9 TURNING,RESPONSE OF STEERING IS POOR ....3749
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3749
H-10 TURNING,RESPONSE OF STEERING IS POOR ....3751
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....3751
H-11 STEERING IS HEAVY ....3752
STEERING WHEEL SPECIFICATION....3752
H-12 JOYSTICK LEVER IS HEAVY....3752
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3752
H-13 JOYSTICK LEVER IS HEAVY....3753
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....3753
H-14 STEERING WHEEL SHAKES OR JERKS....3754
STEERING WHEEL SPECIFICATION....3754
H-15 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK....3755
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3755
H-16 STEERING WHEEL SHAKES OR JERKS ....3756
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION....3756
H-17 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT....3757
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3757
H-18 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT ....3757
AJSS (ADVANCED JOYSTICK STEERING SYSTEM SPECIFICATION....3757
H-19 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR....3758
H-20 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG ....3760
H-21 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR....3761
H-22 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS....3762
H-23 NEITHER BOOM NOR BUCKET MOVE....3763
H-24 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER....3764
H-25 BOOM DOES NOT MOVE....3765
H-26 BOOM IS SLOW OR BOOM LACKS POWER....3766
H-27 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT....3767
H-28 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....3767
H-29 EXCESSIVE HYDRAULIC DRIFT BOOM....3768
H-30 BUCKET DOES NOT MOVE....3769
H-31 BUCKET IS SLOW OR LACKS POWER....3770
H-32 EXCESSIVE HYDRAULIC DRIFT OF BUCKET ....3771
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)....3772
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS ....3774
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....3778
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONIROL SYSTEM....3788
T-1 FAILURE CODE[10](SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY)IS DISPLAYED....3792
T-2 FAILURE CODE[12](SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID)IS DISPLAYED....3793
T-3 FAILURE CODE[13](SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID)IS DISPLAYED....3794
T-4 FAILURE CODE[14](SHORT CIRCUIT ,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID)IS DISPLAYED....3795
T-5 FAILURE CODE[15](SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID)IS DISPLAYED....3796
T-6 FAILURE CODE[16](SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID)IS DISPLAYED....3797
T-7 FAILURE CODE[17](SHORT CIRCUIT,DISCONNECTION,SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID)IS DISPLAYED....3798
T-8 FAILURE CODE[19](SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWICH SYSTEM)IS DISPLAYED....3799
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3799
T-9 FAILURE CODE[20](SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED....3800
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3800
T-10 FAILURE CODE[20](SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED....3803
AJSS(ADVAANCED JOYSTICK STEERING SYSTEM)SPECIFICATION....3803
T-11 FAILURE CODE[21](SHORT CIRCUIT,DISCONNECTION IN RANGE SWITCH SYSTEM)IS DISPLAYDED....3804
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3804
T-12 FAILURE CODE[21](SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM)IS DISPLAYED....3807
AJSS(ADVANCED JOYSTICK STEERING SYSTEM)SPECIFICATION....3807
T-13 FAILURE CODE[22](DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED....3809
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3809
T-14 FAILURE CODE[22](DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED....3810
AJSS(ADVANCED JOYSTICK STEERING SYSTEM)SPECIFICATION....3810
T-15 FAILURE CODE[23](SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED....3811
T-16 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM ....3815
STEERING WHEEL SPECIFICATION,AJSS(ADVANCED JOYSTICK STEERING SYSTEM)SPECIFICATION....3815
T-17 SHIFT-DOWN SWITCH SIGNAL SYSTEM AND SHIFT-UP SWITCH SIGNAL SYSTEM....3816
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3816
T-18 TRANSMISSION CUT-OFF SIGNAL SYSTEM....3817
T-19 NEUTRALIZER RELAY SIGNAL SYSTEM....3818
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3818
T-20 NEUTRALIZER RELAY SIGNAL SYSTEM ....3819
AJSS(ADVANCED JOYSTICK STEERING SYSTEM SPECIFICATION....3819
T-21 BUZZER SIGNAL SYSTEM....3821
T-22 NETWORK SYSTEM....3822
T-23 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM....3823
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3823
T-24 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM....3824
AJSS(ADVANCED JOYSTICK STEERING SYSTEM)SPECIFICATION....3824
T-25 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM....3825
STEERING WHEEL SPECIFICATION,STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION....3825
T-26 SHORT CIRCIUT IN TRAVEL SPEED SENSOR SYSTEM ....3826
AJSS(ADVANCED JOYSTICK STEERING SYSTEM)SPECIFICATION....3826
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)....3827
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS....3828
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....3829
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM....3833
J-1 FAILURE CODE[56](SHORT CIRCUIT,DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED....3834
J-2 FAILURE CODE[57](SHORT CIRCUIT IN STEERING RIGHT SOLENOID(DETECTED WHEN OUTPUT))IS DISPLAYED....3835
J-3 FAILURE CODE[58](SHORT CIRCUIT IN STEERING LEFT SOLENOID(DETECTED WHEN OUTPUT))IS DISPLAYED....3836
J-4 FAILURE CODE[59](SHORT CIRCUIT IN STEERING RIGHT SOLENOID(HOT END))IS DISPLAYED....3837
J-5 FAILURE CODE[60](SHORT CIRCUIT IN STEERING LEFT SOLENOID(HOT END))IS DISPLAYED....3838
J-6 FAILURE CODE[61](SHORT CIRCUIT,DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT)IS DISPLAYED....3839
J-7 FAILURE CODE[62](SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL)IS DISPLAYED....3840
J-8 FAILURE CODE[63](SHORT CIRCUIT,DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM)IS DISPLAYED....3841
J-9 ABNORMALITY IN POWER SOURCE,VOLTAGE....3842
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM....3843
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID ....3844
J-12 DISCONNECTION IN STEERING LEFT SOLENOID ....3845
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)....3846
JUDGEMENT TABLE FOR AJSS (ADVANCED JOSTICK STEERING SYSTEM) CONTROL SYSTEM....3847
OPERATIONS OF CONTROLLER AGINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY....3848
ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL....3852
A-1 ERROR CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM)IS IDSPLAYED....3854
A-2 ERROR CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPALYED....3855
A-3 ERROR CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENEOR SIGNALS) IS DISPLAYED....3856
A-4 ERROR CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED....3857
A-5 ERROR CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED....3858
A-6 ERROR CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED....3859
A-7 ERROR CODE [63] (DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND,OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED....3860
A-8 STEERING SPEEDS IN BOTH DIRECTIOND ARE DIFFERENT....3861
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SERSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)....3862
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE....3863
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE)....3864
MTHOD OF ERROR CODE DISPLAY....3866
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED....3868
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROL SYSTEM....3876
EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)....3878
EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)....3878
EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)....3879
EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)....3880
EA-5 ERROR CODE [116] (ABNORMALITY [HIGH LEVEL] IN TIMING RAIL PRESSURE SENSOR SYSTEM)....3882
EA-6 ERROR CODE [117] (ABNORMALITY [LOW LEVEL] IN TIMING RAIL PRESSURE SENSOR SYSTEM)....3883
EA-7 ERROR CODE [118] (ABNORMALITY [HIGH LEVEL] IN FUEL PUMP PRESSURE SENSOR SYSTEM)....3884
EA-8 ERROR CODE [119] (ABNORMALITY [LOW LEVEL] IN FUEL PUMP PRESSURE SENSOR SYSTEM)....3885
EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)....3886
EA-10 ERROR CODE [122] (ABNORMALITY [HIGH LEVEL] IN BOOST PRESSURE SENSOR SYSTEM)....3887
EA-11 ERROR CODE [123] (ABNORMALITY [LOW LEVEL] IN BOOST PRESSURE SENSOR SYSTEM)....3888
EA-12 ERROR CODE [131] (ABNORMALITY [HIGH LEVEL] IN ACCELERATOR PRESSURE SENSOR SYSTEM)....3889
EA-13 ERROR CODE [132] (ABNORMALITY [LOW LEVEL] IN ACCELERATOR PRESSURE SENSOR SYSTEM)....3890
EA-14 ERROR CODE [135] (ABNORMALITY [HIGH LEVEL] IN OIL PRESSURE SENSOR SYSTEM)....3891
EA-15 ERROR CODE [141] (ABNORMALITY [LOW LEVEL] IN OIL PRESSURE SENSOR SYSTEM)....3892
EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))....3893
EA-17 ERROR CODE [144] (ABNORMALITY [HIGH LEVEL] IN WATER TEMPERATUER SENSOR SYSTEM)....3894
EA-18 ERROR CODE [145] (ABNORMALITY [LOW LEVEL] IN WATER TEMPERATUER SENSOR SYSTEM)....3895
EA-19 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)....3895
EA-20 ERROR CODE [153] (ABNORMALITY [HIGH LEVEL] IN INTAKE AIR TEMPERATUER SENSOR SYSTEM)....3896
EA-21 ERROR CODE [154] (ABNORMALITY [LOW LEVEL] IN INTAKE AIR TEMPERATUER SENSOR SYSTEM)....3896
EA-22 ERROR CODE [221] (ABNORMALITY [HIGH LEVEL] IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)....3897
EA-23 ERROR CODE [222] (ABNORMALITY [LOW LEVEL] IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)....3898
EA-24 ERROR CODE [234] (OVERSPEED)....3900
EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF CALVE SYSTEM VOLTAGE)....3901
EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)....3902
EA-27 ERROR CODE [261] (ABNORMALITY RISE IN DUEL TEMPERATURE)....3902
EA-28 ERROR CODE [263] (ABNORMALITY [HIGH LEVEL] IN FUEL TEMPERATURE SENSOR SYSTEM)....3903
EA-29 ERROR CODE [265] (ABNORMALITY [LOW LEVEL] IN FUEL TEMPERATURE SENSOR SYSTEM)....3903
EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)....3904
EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR....3905
EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)....3905
EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)....3906
EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)....3907
EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2)....3908
EA-36 ERROR CODE [423] (ABNORMALITY [IN RANGE] IN TIMING RAIL PRESSURE SENSOR SYSTEM)....3908
EA-37 ERROR CODE [431] (ABNORMALITY [1] IN IDING VALIDATION SWITCH SYSTEM)....3910
EA-38 ERROR CODE [432] (LDING VALIDATION PROCESS REEOR)....3912
EA-39 ERROR CODE [441] (ABNORMALITY [LOW LEVEL] IN BATTERY VOLTAGE)....3914
EA-40 ERROR CODE [442] (ABNORMALITY [HIGH LEVEL] IN BATTERY VOLTAGE)....3914
EA-41 ERROR CODE [451] (ABNORMALITY [HIGH LEVEL] IN FUEL RAIL PRESSURE SENSOR SYSTEM)....3915
EA-42 ERROR CODE [452] (ABNORMALITY [LOW LEVEL] IN FUEL RAIL PRESSURE SENSOR SYSTEM)....3916
EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)....3917
EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)....3918
EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)....3918
EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)....3918
EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)....3919
EA-48 ERROR CODE [551] (ABNORMALITY [2] IN IDING VALIDATION SWITCH SYSTEM)....3919
EA-49 ERROR CODE [554] (ABNORMALITY [IN RANGE] IN FUEL RAIL PRESSURE SENSOR)....3920
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)....3922
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER....3924
INFORMATION GIVEN IN TROUBLESHOOTING CHART....3926
PHENOMENON TYPE CODE LIST....3927
[DBB0KK] (OR VHMS_LED INDICATES [N901] ABNORMALITY IN SOURCE VOLTAGE....3928
[DBB5KP] (OR VHMS_LED INDICATES [N904]) ABNORMALITY IN SENSOR POWER SOURCE (5 V) SYSTEM ....3930
[DBB6KP] (OR VHMS_LED INDICATES [N902]) ABNORMALITY IN SENSOR POWER SOURCE (24 V) SYSTEM ....3932
[DBBRKR] (OR VHMS_LED DISPLAYS [N801]) DEFECTIVE CAN COMMUNICATIONS :DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)....3934
[DGE1KB] (OR VHMS_LED DISPLAYS [N242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN.(AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}....3936
[DGE1KY] (OR VHMS_LED DISPLAYS [N242]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY) ....3937
[DGE5KX] (OR VHMS_LED DISPLAYS [N401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM:INPUT SIGNAL OUTSIDE RANGE (KX)....3938
[DGT4KA] (OR VHMS_LED DISPLAYS [N312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.1,2,3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)....3939
[DGT4KB] (OR VHMS_LED DISPLAYS [N311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO.1,2,3 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)....3941
[DGT5KA] (OR VHMS_LED DISPLAYS [N322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO.4,5,6(FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)....3943
[DGT5KB] (OR VHMS_LED DISPLAYS [N321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO.4,5,6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB) ....3945
[DHE5KB] (OR VHMS_LED DISPLAYS [N332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SSYSTEM (KA) ....3947
[DHE5KY] (OR VHMS_LED DISPLAYS [N331]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY) ....3949
[DHT3KX] (OR VHMS_LED DISPLAYS [N614]) TROUBLE IN TRANSMISSION OIL PRESSURE SENSOR SYSTEM:OUT OF INPUT SIGNAL RANGE (KX) ....3950
[DHP2KX] (OR VHMS_LED DISPLAYS [N531]) TROUBLE IN MAIN PUMP OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SINGNAL RANGE (KX) ....3952
[DHT8KX] (OR VHMS_LED DISPLAYS [N533]) TROUBLE IN STEERING OIL PRESSURE SENSOR SYSTEM:OUT OF INPUT SINGNAL RANGE (KX) ....3954
[DGH2KX] (OR VHMS_LED DISPLAYS [N537]) TROUBLE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SINGNAL RANGE (KX)....3956
[DHU2KX] (OR VHMS_LED DISPLAYS [N711]) TROUBLE IN FRONT BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SINGNAL RANGE (KX)....3957
[DHU3KX] (OR VHMS_LED DISPLAYS [N712]) TROUBLE IN REAR BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SINGNAL RANGE (KX)....3959
[DGR4KX] (OR VHMS_LED DISPLAYS [N717]) TROUBLE IN FRONT BRAKE OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SINGNAL RANGE (KX)....3961
[F@BBZL] (OR VHMS_LED DISPLAYS [N338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)....3962
[F@BYNR] (OR VHMS_LED DISPLAYS [N362]) NO.1,2,3 (REAR) EXHAUST TEMPERATURE IS HIGH (2): (NR)....3963
[F@BYNS] (OR VHMS_LED DISPLAYS [N361]) NO.1,2,3 (REAR) EXHAUST TEMPERATURE IS HIGH (1): (NS)....3964
[F@BZNR] (OR VHMS_LED DISPLAYS [N372]) NO.4,5,6 (FRONT) EXHAUST TEMPERATURE IS HIGH (2): (NR)....3965
[F@BZNS] (OR VHMS_LED DISPLAYS [N371]) NO.4,5,6 (FRONT) EXHAUST TEMPERATURE IS HIGH (1): (NS)....3966
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION....3967
a) SATELLOTE COMMUNICATION DATA ARE NOT TRANSMITTED....3967
b) ABNORMALITY IN DOWNLOADING INTO PC OR SETTING OF PC....3971
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)....3973
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL)....3975
30 DISASSEMBLY AND ASSEMBLY....3976
METHOD OF USING MANUAL....3979
PRECAUTIONS WHEN CARRYING OUT OPERATION....3981
SPECIAL TOOL LIST....3984
SKETCHES OF SPCIAL TOOLS....3989
STARTING MOTOR....3993
REMOVAL ＆ INSTALLATION....3993
ALTERNATOR....3994
REMOVAL ＆ INSTALLATION....3994
ENGINE OIL COOLER....3996
REMOVAL ＆ INSTALLATION....3996
FUEL INJECTION PUMP....3998
REMOVAL....3998
INSTALLATION....3999
WATER PUMP....4000
REMOVAL ＆ INSTALLATION....4000
NOZZLE HOLDER....4001
REMOVAL ＆ INSTALLATION....4001
TURBOCHARGER....4002
REMOVAL....4002
INSTALLATION....4003
REPLACEMENT ENGINE....4004
FRONT SEAL....4004
REAR SEAL....4006
CYLINDER HEAD....4008
REMOVAL....4008
INSTALLATION....4011
THERMOSTAT....4013
REMOVAL ＆ INSTALLATION....4013
HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER....4014
REMOVAL....4014
INSTALLATION....4015
HYDRAULIC OIL COOLER, RADIATOR AFTERCOOLER,FUEL COOLER....4016
REMOVAL....4016
INSTALLATION....4018
ENGINE, DAMPER....4019
REMOVAL....4019
INSTALLATION....4021
DAMPER....4025
REMOVAL ＆ INSTALLATION....4025
DISASSEMBLY....4026
ASSEMBLY....4028
PTO....4032
DISASSEMBLY....4032
ASSEMBLY....4034
TORQUE CONVERTER, TRANSMISSION....4037
REMOVAL....4037
INSTALLATION....4041
TORQUE CONVERTER....4042
DISASSEMBLY....4042
ASSEMBLY....4046
TRANSMISSION....4051
DISASSEMBLY....4051
ASSEMBLY....4065
TRANSMISSION VALVE....4080
REMOVAL ＆ INSTALLATION....4080
TRANSMISSION CONTROL VALVE....4081
DISASSEMBLY ＆ ASSEMBLY....4081
TRANSFER....4086
DISASSEMBLY....4086
ASSEMBLY....4093
CENTER SUPPORT....4102
REMOVAL....4102
INSTALLATION....4103
DISASSEMBLY....4104
ASSEMBLY....4106
DRIVE SHAFT....4109
DISASSEMBLY....4109
ASSEMBLY....4111
FRONT AXLE....4113
REMOVAL....4113
INSTALLATION....4114
FRONT DIFFERENTIAL....4115
REMOVAL....4115
INSTALLATION....4116
REAR AXLE....4119
REMOVAL....4119
INSTALLATION....4123
REAR DIFFERENTIAL....4124
REMOVAL....4124
INSTALLATION....4125
DISASSEMBLY....4126
ASSEMBLY....4130
FINAL DRIVE....4139
DISASSEMBLY....4139
ASSEMBLY....4143
ORBIT ROLL....4147
REMOVAL ＆ INSTALLATION....4147
STEERING CYLINDER....4148
REMOVAL....4148
INSTALLATION....4150
STEERING DAMAND VALVE....4151
REMOVAL....4151
INSTALLATION....4152
BRAKE VALVE....4153
REMOVAL ＆ INSTALLATION....4153
BRAKE VALVE (R.H.)....4154
DISASSEMBLY....4154
ASSEMBLY....4156
BRAKE VALVE (L.H.)....4158
DISASSEMBLY....4158
ASSEMBLY....4160
SLACK ADJUSTER....4162
REMOVAL AND INSTALLATION....4162
DISASSEMBLY....4163
ASSEMBLY....4164
BRAKE....4165
REMOVAL....4165
INSTALLATION....4166
DISASSEMBLY....4167
ASSEMBLY....4171
HYDRAULIC PUMP....4177
REMOVAL....4177
INSTALLATION....4178
PISTON PUMP....4179
DISASSEMBLY....4179
ASSEMBLY....4185
HYDRAULIC TANK....4200
REMOVAL....4200
INSTALLATION....4201
PPC VALVE....4202
REMOVAL....4202
INSTALLATION....4203
DISASSEMBLY ＆ ASSEMBLY....4204
WORK EQUIPMENT VALVE....4205
REMOVAL....4205
INSTALLATION....4206
WORK EQUIPMENT CONTROL VALVE....4207
DISASSEMBLY....4207
ASSEMBLY....4209
DUMP CYLINDER....4211
REMOVAL ＆ INSTALLATION....4211
LIFT CYLINDER....4212
REMOVAL....4212
INSTALLATION....4213
STEERING LIFT, DUMP CYLINDER....4214
DISASSEMBLY....4214
ASSEMBLY....4216
GENTER HINGE PIN....4218
REMOVAL....4218
INSTALLATION....4224
WORK EUIPMENT....4228
REMOVAL....4228
INSTALLATION....4231
BULKHAD....4233
REMOVAL....4233
INSTALLATION....4234
FLOOR FRAME....4238
REMOVAL....4238
INSTALLATION....4240
COUNTERWEIGHT....4241
REMOVAL ＆ INSTALLATION....4241
FUEL TAKE....4242
REMOVAL....4242
INSTALLATION....4243
CAB....4246
REMOVAL....4246
INSTALLATION....4248
STOP VALVE....4249
REMOVAL ＆ INSTALLATION....4249
ACCUMULATOR CHARGR VALVE....4250
REMOVAL ＆ INSTALLATION....4250
DISASSEMBLY....4251
ASSEMBLY....4252
PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH....4254
REMOVAL ＆ INSTALLTION....4254
DIVERTER VALVE....4255
REMOVAL ＆ INSTALLATION....4255
DISASSEMBLY....4256
ASSEMBLY....4257
EMERGENCY STEERING PUMP....4259
REMOVAL ＆ INSTALLATION....4259
PARKING BRAKE....4260
REMOVAL ＆ INSTALLATION....4260
PARKING BRAKE CALIPERS....4261
DISASSEMBLY....4261
ASSEMBLY....4263
PARKING BRAKE PAD....4265
REMOVAL ＆ INSTALLATION....4265
REAR TIRE....4268
REMOVAL AND INSTALLATAION....4268
AIR CONDITIONER COMPRESSOR....4269
REMOVAL ＆ INSTALLATION....4269
CONDITIONER CONDENSER....4272
REMOVAL AND INSTALLATION....4272
RECEIVER TAKE....4274
REMOVAL ＆ INSTALLATAION....4274
AIR CONDITIONER UNIT....4275
REMOVAL....4275
INSTALLATION....4276
MAIN MONITOR....4277
REMOVAL....4277
INSTALLATION....4278
MAINTENANCE MONITOR....4279
REMOVAL ＆ INSTALLATION....4279
ENGINE, APS CONTROLLER....4280
REMOVAL ＆ INSTALLATION....4280
40 MAINTENANCE STANDARD....4281
ENGINE AND TRANSMISSION MOUNT....4282
DAMPER....4283
TORQUE CONVERTER AND PTO....4285
TORQUE CONVERTER REGULATOR VALVE....4286
TRANSMISSION....4287
TRANSIMISSION CONTROL VALVE....4290
TRANSFER....4295
DRIVE SHAFT....4297
CENTER SUPPORT....4298
DIFFERENTIAL....4299
FINAL DRIVE....4301
AXLE MOUNT....4303
CENTER HINGE PIN....4305
STEERING COLUMN....4307
STEERING DEMAND VALVE....4308
DIVERTER VALVE....4310
STEERING CYLIDER MOUNT....4311
EMERGENCY STEERING PUMP....4312
BRAKE VALVE....4313
SLACK ADJUSTER....4319
BRAKE....4320
PARKING BRAKE....4324
CONTROL PUMP....4325
STEERING AND SWITCH PUMP....4326
MAIN PISTON PUMP....4327
MAIN CONTROL VALVE....4328
PPC VALVE....4332
PPC RELIEF VALVE....4334
HYDRAULIC CYLINDER....4335
WORK EQUIPMENT LINKAGE....4336
BUCKET....4338
BUCKET POSITIONER AND BOOM KICK-OUT....4339
90 OTHERS....4340
ELECTRIC CIRCUIT DIAGRAM (1/5) (SERIAL.:500001-51000)....4341
ELECTRIC CIRCUIT DIAGRAM (2/5) (SERIAL.:500001-51000)....4342
ELECTRIC CIRCUIT DIAGRAM (3/5) (SERIAL.:500001-51000)....4343
ELECTRIC CIRCUIT DIAGRAM (4/5) (SERIAL.:500001-51000)....4344
ELECTRIC CIRCUIT DIAGRAM (5/5) (SERIAL.:500001-51000)....4345
ELECTRIC CIRCUIT DIAGRAM (1/6) (SERIAL.:51001 AND UP)....4346
ELECTRIC CIRCUIT DIAGRAM (2/6) (SERIAL.:51001 AND UP)....4347
ELECTRIC CIRCUIT DIAGRAM (3/6) (SERIAL.:51001 AND UP)....4348
ELECTRIC CIRCUIT DIAGRAM (4/6) (SERIAL.:51001 AND UP)....4349
ELECTRIC CIRCUIT DIAGRAM (5/6) (SERIAL.:51001 AND UP)....4350
ELECTRIC CIRCUIT DIAGRAM (6/6) (SERIAL.:51001 AND UP)....4351
ELECTRIC CIRCUIT DIAGRAM (1/3) (WITH AUTO SHIFT AND JOYSTICK STEERING) (SERIAL NO.:50001-51000)....4352
ELECTRIC CIRCUIT DIAGRAM (2/3) (WITH AUTO SHIFT AND JOYSTICK STEERING) (SERIAL NO.:50001-51000)....4353
ELECTRIC CIRCUIT DIAGRAM (3/3) (WITH AUTO SHIFT AND JOYSTICK STEERING) (SERIAL NO.:50001-51000)....4354
ELECTRIC CIRCUIT DIAGRAM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION) (1/3) (SERIAL NO.:51001 AND UP)....4355
ELECTRIC CIRCUIT DIAGRAM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION) (2/3) (SERIAL NO.:51001 AND UP)....4356
ELECTRIC CIRCUIT DIAGRAM (AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION) (3/3) (SERIAL NO.:51001 AND UP)....4357
SEBM032802 - Wheel Loader WA700-3 (KA Spec.) Shop Manual....4358
COVER....4358
CONTENTS....4359
SAFETY....4365
SAFETY NOTICE....4365
FOREWORD....4367
GENERAL....4367
HOW TO READ THE SHOP MANUAL....4368
HOISTING INSTRUCTIONS....4369
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER....4370
COATING MATERIALS....4372
STANDARD TIGHTENING TORQUE....4374
ELECTRIC WIRE CODE....4377
CONVERSION TABLE....4378
UNITS....4384
01 GENERAL....4385
GENERAL ASSEMBLY DRAWING....4386
SPECIFICATIONS....4387
WEIGHT TABLE....4390
LIST OF LUBRICANT AND WATER....4392
10 STRUCTURE AND FUNCTION....4395
OUTLINE....4396
POWER TRAIN SYSTEM....4398
DAMPER....4400
RADIATOR AND OIL COOLER....4401
TORQUE CONVERTER AND TRANSMISSION PIPING....4402
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....4404
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....4406
TORQUE CONVERTER AND PTO....4408
TORQUE CONVERTER REGULATOR VALVE....4411
TRANSMISSION....4413
TRANSMISSION CONTROL VALVE....4422
TORQUE CONVERTER OIL COOLER....4442
TRANSMISSION OIL FILTER....4443
TRANSFER....4445
AXLE....4446
DIFFERENTIAL....4448
FINAL DRIVE....4451
AXLE MOUNT....4454
CENTER HINGE PIN....4456
JOYSTICK STEERING LINKAGE....4457
STEERING AND SWITCH PUMP....4458
SWITCH PUMP CUT-OFF SOLENOID....4460
STEERING DEMAND VALVE....4461
EPC VALVE....4472
ROTARY VALVE....4473
TWO WAY RESTRICTOR VALVE....4476
DIVERTER VALVE....4477
BRAKE PIPING....4481
BRAKE CIRCUIT DIAGRAM....4482
BRAKE VALVE....4484
CHARGE VALVE....4490
ACCUMULATOR (FOR BRAKE)....4494
SLACK ADJUSTER....4495
BRAKE....4498
PARKING BRAKE....4500
SPRING CYLINDER....4502
PARKING BRAKE SOLENOID VALVE....4503
HYDRAULIC PIPING....4504
HYDRAULIC CIRCUIT DIAGRAM....4506
MAIN PISTON PUMP....4509
ES • CO VALVE....4517
SERVO VALVE....4518
PRESSURE DIFFERENTIAL VALVE....4519
PPC VALVE (PROPORTIONAL PRESSURE VALVE)....4520
PPC RELIEF VALVE....4524
ACCUMULATOR (FOR PPC VALVE)....4525
MAIN CONTROL VALVE....4526
LUBRICATION OF WORK EQUIPMENT....4540
WORK EQUIPMENT LINKAGE....4542
BUCKET POSITIONER AND BOOM KICK-OUT....4544
OPERATION OF PROXIMITY SWITCH....4546
AIR CONDITIONER....4550
ELECTRIC CIRCUIT DIAGRAM....4553
MACHINE MONITOR SYSTEM....4553
MAIN MONITOR....4554
MAINTENANCE MONITOR....4558
AUTOMATIC TRANSMISSION SYSTEM (ATM)....4560
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)....4571
TRANSMISSION AND JOYSTICK CONTROLLER....4576
ENGINE STARTING CIRCUIT....4578
ENGINE STOP CIRCUIT....4579
PREHEATING CIRCUIT....4580
FUEL SYSTEM....4581
KICK-DOWN, HOLD SWITCH....4582
ELECTRIC PARKING BRAKE CONTROL....4583
ELECTRIC CIRCUIT OF ACTIVE POWER MAXIMIZING FUNCITON....4592
[RELATED TO VHMS CONTROLLER]....4598
VHMS CONTROLLER....4598
BLOW-BY PRESSURE SENSOR....4598
ENGINE OIL TEMPERATURE SENSOR....4599
EXHAUST TEMPERATURE SENSOR/AMP....4600
AMBIENT TEMPERATURE SENSOR....4600
TRANSMISSION PUMP OIL PRESSURE SENSOR....4601
BRAKE OIL TEMPERATURE SENSOR AND HYDRAULIC OIL TEMPERATURE SENSOR....4602
BRAKE OIL PRESSURE SENSOR, STEERING OIL PRESSURE SENSOR AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR....4603
COMMUNICATIONS (ORB: ORBCOMM) CONTROLLER/ANTENNA....4604
20 TESTING AND ADJUSTING....4606
STANDARD VALUE TABLE FOR ENGINE....4607
STANDARD VALUE TABLE FOR CHASSIS....4608
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....4613
TESTING AND ADJUSTING....4622
TABLE OF TOOLS FOR TESING, ADJUSTING, AND TROUBLESHOOTING....4623
ADJUSTING VALVE CLEARANCE....4625
MEASURING COMPRESSION PRESSURE....4626
MEASURING BLOW-BY PRESSURE....4628
MEASURING EXHAUST GAS COLOR....4629
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....4630
MEASURING EXHAUST TEMPERATURE....4631
MEASURING ENGINE SPEED....4633
ADJUSTING SET LOAD OF INJECTOR....4635
TROUBLESHOOTING OF INJECTOR....4637
MEASURING FUEL CIRCUIT PRESSURE....4638
HANDLING EQUIPMENT IN FUEL CIRCUIT....4640
BLEEDING AIR FROM FUEL CIRCUIT....4641
ADJUSTING SPEED SENSORS....4643
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....4644
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....4645
MEASURING ACCELERATOR PEDAL....4646
ADJUSTING ACCELERATOR PEDAL TRAVEL, POTENTIOMETER....4647
ADJUSTING ACCELERATOR PEDAL MICRO SWITCH....4649
MEASURING TORQUE CONVERTER, TRANSMISSION HYDRAULIC PRESSURE....4650
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL....4652
TESTING AND ADJUSTING STEERING OIL PRESSURE....4654
ADJUSTING STEERING STOPPER BOLT....4655
ADJUSTING JOYSTICK STEERING....4656
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH....4657
TESTING BRAKE OIL PRESSURE....4658
MEASURING WEAR OF BRAKE DISC....4659
MEASURING BRAKE PERFORMANCE....4660
TESTING AND ADJUSTING PARKING BRAKE....4661
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE....4663
MEASURING PPC RELIEF VALVE HYDRAULIC PRESSURE....4664
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE....4666
BLEEDING AIR FROM THE PISTON PUMP....4668
ADJUSTING WORK EQUIPMENT LEVER LINKAGE....4669
TESTING AND ADJUSTING BUCKET POSITIONER....4671
TESTING AND ADJUSTING BOOM KICK-OUT....4672
TESTING AND ADJUSTING PROXIMITY SWITCH FOR ACTIVE POWER MAXIMIZING FUNCTION....4673
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP....4674
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)....4675
BLEEDING AIR....4676
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....4677
PM CLINIC INSPECTION TABLE....4678
BASIC PRECAUTIONS....4680
OUTLINE....4683
SETTING UP VHMS CONTROLLER....4689
COLLECTION, TRANSMISSION OF DATA....4691
INSPECTION AND MAINTENANCE....4696
REPLACING PARTS....4696
TROUBLESHOOTING....4697
POINTS TO REMEMBER WHEN TROUBLESHOOTING ....4698
SEQUENCE OF EVENTS IN TROUBLESHOOTING....4699
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....4700
CHECKS BEFORE TROUBLESHOOTING....4708
CONNECTOR TYPES AND MOUNTING LOCATIONS....4709
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....4713
T-BRANCH BOX AND T-BRANCH TABLE....4736
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE....4738
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION....4740
TRANSMISSION CONTROLLER LED DISPLAY....4742
METHOD OF USING TROUBLESHOOTING CHARTS....4743
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....4745
METHOD OF USING TROUBLESHOOTING CHARTS....4746
S-1 Starting performance is poor (starting always takes time)....4750
S-2 Engine does not start....4752
a) Engine does not turn....4752
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)....4754
c) Exhaust smoke comes out but engine does not start (fuel is being injected)....4756
S-3 Engine does not pick up smoothly (follow-up is poor)....4758
S-4 Engine stops during operations....4760
S-5 Engine does not rotate smoothly (hunting)....4762
S-6 Engine lacks output (or lacks power)....4764
S-7 Exhaust smoke is black (incomplete combustion)....4766
S-8 Oil consumption is excessive (or exhaust smoke is blue)....4768
S-9 Oil becomes contaminated quickly....4769
S-10 Fuel consumption is excessive....4770
S-11 Oil is in cooling water, or water spurts back, or water level goes down....4771
S-12 Oil pressure caution lamp lights up (drop in oil pressure)....4772
S-13 Oil level rises....4773
S-14 Water temperature becomes too high (overheating)....4774
S-15 Abnormal noise is made....4775
S-16 Vibration is excessive....4776
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)....4777
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....4780
M-1 Main monitor does not work....4782
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up....4783
M-3 Speedometer display does not work properly....4784
M-4 Abnormality in shift indicator....4785
a) displays N even when directional lever is at F....4785
b) Displays N even when directional lever is at R....4785
c) Does not display N even when directional lever is at N, and displays R when directional lever is at F....4785
d) Does not display N even when directional lever is at N, and displays F when directional lever is at R....4786
e) Does not display 1st even when speed lever is at 1 (directional lever at F or R)....4786
f) Does not display 2nd even when speed lever is at 2 (directional lever at F or R)....4786
g) Does not display 3rd even when speed lever is at 3 (directional lever at F or R)....4787
h) Does not display 4th even when speed lever is at 4 (directional lever at F or R)....4787
M-5 Turn signal display does not light up....4789
a) L.H. turn signal display does not light up....4789
b) R.H. turn signal display does not light up....4789
M-6 Abnormality in parking display....4790
a) Parking lamp display does not light up....4790
b) Parking lamp display stays lighted up....4790
M-7 Night lighting does not light up....4791
M-8 Abnormality in front working lamp....4792
a) Neither monitor display nor front working lamp light up....4792
b) Working lamp lights up but monitor display does not light up....4792
c) Monitor display lights up but working lamp does not light up....4792
M-9 Abnormality in rear working lamp....4794
a) Neither monitor display nor rear working lamp light up....4794
b) Working lamp lights up but monitor display does not light up....4794
c) Monitor display lights up but working lamp does not light up....4794
M-10 Abnormality in transmission cut-off....4795
a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not change....4795
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated....4795
c) Transmission cut-off switch turned ON, but cut-off function is not actuated....4796
Auto-shift specification....4797
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change....4797
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off funciton is actuated when pedal is depressed....4797
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated....4797
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF)....4797
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated....4798
M-11 Abnormality in parking brake dragging warning....4799
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N....4799
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at position other than N....4799
M-12 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated....4801
a) Actuated continuously ....4801
b) Not actuated....4801
M-13 Abnormality in buzzer....4802
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)....4802
b) Buzzer always sounds....4802
M-14 Condition of monitor switched is not stored in memory....4803
M-15 Abnormality in failure display mode....4804
a) Does not enter failure display mode....4804
b) Count for time elapsed since failure display mode does not advance....4804
M-16 Abnormality in emergency steering actuation display....4805
a) Emergency steering actuation display does not light up....4805
b) Emergency steering actuation display stays lighted up....4805
M-17 Abnormality in auto-greasing system....4806
a) Forced greasing cannot be carried out....4806
b) Monitor display flashes rapidly (2 times/sec.)....4806
c) When no more grease remains, monitor display flashes rapidly (2 times/sec.)....4806
d) Monitor display flashes slowly (1 time/sec.)....4807
e) Monitor display goes out....4807
M-18 Abnormality in low idling select system....4808
a) Display does not change when switch is pressed....4808
b) Monitor display lights up but low idling select function does not work....4808
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)....4809
ELECTRICAL CIRCUIT DIAGRAM FOR K MODE SYSTEM....4810
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....4811
a) No lamps on maintenance monitor light up....4811
b) Some lamps do not light up....4811
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds)....4812
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out....4813
K-4 When starting switch is turned ON (engine stopped), CHECK items flash....4814
a) Engine oil level display flashes....4814
b) Engine water level display flashes....4815
K-5 When starting switch is turned ON (engine started), CAUTION items flash....4816
a) Engine oil pressure display flashes (Check that the engine oil pressure is correct.)....4816
b) Battery charge level display flashes....4817
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct)....4818
d) Air cleaner display flashes (Check that there is no clogging of the air cleaner)....4819
K-6 CAUTION items are flashing but caution buzzer does not sound....4820
K-7 There is no abnormality in monitor display but caution buzzer sounds....4821
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash....4822
a) CHECK lamp....4822
b) CAUTION lamp....4822
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up....4823
a) CHECK lamp....4823
b) CAUTION lamp....4823
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)....4824
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up....4825
K-12 Service meter does not work....4826
K-13 Service meter is running even when engine is stopped....4826
K-14 Abnormality is gauge items....4828
a) Abnormality is fuel gauge....4828
b) Abnormality in engine water temperature gauge....4829
c) Abnormality in torque converter oil temperature gauge....4830
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....4831
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM....4832
ELECTRICAL CIRCUIT DIAGRAM FOR ACTIVE POWER UP SYSTEM....4834
E-1 Engine does not start....4836
E-2 Defective preheating....4841
E-3 Parking brake does not have effect....4843
a) Parking brake has no effect when parking brake switch is turned ON....4843
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure drops....4843
E-4 Parking brake is applied when machine is traveling....4844
E-5 Parking brake is released when starting switch is turned ON....4846
E-6 Transmission does not change to neutral when parking brake is applied, but parking brake works normally....4846
E-7 Transmission does not work properly....4849
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit....4850
b) No continuity in travel FORWARD solenoid circuit....4854
c) No continuity in travel REVERSE solenoid circuit....4856
d) Short circuit to chassis ground in directional solenoid circuit....4858
e) Abnormality in shift solenoid circuit....4864
f) Short circuit to chassis ground in shift solenoid circuit....4867
E-8 Kick-down switch does not work (shift works correctly during normal gear shift operations F1 - F4)....4872
E-9 Kick-down works only when kick-down switch is being turned ON (kick-down switch does not carry out self-hold operation)....4875
E-10 Kick-down always works....4876
E-11 Kick-down switch works even when traveling FORWARD in 2nd....4878
E-12 Boom Kick-out does not work....4880
E-13 Defective bucket positioner....4882
E-14 Power window does not work....4884
a) Window does not go up....4884
b) Window does not go down....4885
E-15 Defective operation of solenoid for power maximizing function....4888
a) Inspection of timer 1 and no-load relay system....4888
b) Inspection of neutral relay 1 and neutral relay 2 (Power supply system)....4890
c) Inspection of solenoid (U11) drive system)....4892
E-16 Abnormality in front working lamp....4897
E-17 Abnormality in rear working lamp....4897
E-18 Abnormality in transmission cut-off....4897
E-19 Abnormality in parking brake dragging warning....4897
E-20 Abnormality in buzzer....4897
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)....4899
METHOD OF USING MATRIX TROUBLESHOOTING TABLES....4900
H-1 Machine does not start....4902
H-2 Machine lacks power or speed when traveling (all speed ranges)....4903
H-3 Time lag is excessive when starting or shifting gear....4904
H-4 Torque converter oil temperature is high....4905
H-5 Steering does not turn....4906
H-6 Steering does not turn (machine with joystick)....4907
H-7 Turning, response of steering is poor....4908
H-8 Turning, response of steering is poor (machine with joystick)....4910
H-9 Steering is heavy....4912
H-10 Steering wheel shakes or jerks....4913
H-11 Steering shakes or there is excessive shock (machine with joystick)....4914
H-12 Turning radius is different between left and right at maximum steering....4914
H-13 Wheel brakes do not work or braking effect is poor....4916
H-14 Wheel brakes are not released or brakes drag....4918
H-15 Parking brake does not work or braking effect is poor....4919
H-16 Parking brake is not released or brake drags....4920
H-17 Neither boom nor bucket move....4921
H-18 Both boom and bucket are slow or lack power....4922
H-19 Boom does not move....4923
H-20 Boom is slow or boom lacks power....4924
H-21 Boom cannot be set to FLOAT or cannot be released from FLOAT....4925
H-22 Boom drops momentarily when control lever is operated from HOLD to RAISE....4925
H-23 Excessive hydraulic drift of boom....4926
H-24 Bucket does not move....4927
H-25 Bucket is slow or lacks power....4928
H-26 Excessive hydraulic drift of bucket....4929
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)....4931
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS....4932
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....4934
ELECTRICAL CIRCUIT DIAGRAM FOR T MODE SYSTEM....4940
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed....4942
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed....4943
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed....4944
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed....4945
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed....4946
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed....4947
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed....4948
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed....4949
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed....4950
T-10 Failure code [21] (Short circuit, disconnection in range switch system) is displayed....4954
T-11 Failure code [22] (Disconnection in travelspeed sensor system) is displayed....4957
T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed....4958
T-13 Hold switch system....4959
T-14 Kick-down switch system....4959
T-15 Transmission cut-off signal system....4960
T-16 Neutralizer relay signal system....4961
T-17 Buzzer signal system....4962
T-18 Network system....4963
T-19 Transmission controller power source system....4964
T-20 Short circuit in travel speed sensor system....4965
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM CONTROL SYSTEM) (J MODE)....4967
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM....4968
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY....4970
ELECTRIC CIRCUIT DIAGRAM RELATED TO AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL....4974
J-1 Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed....4976
J-2 Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed....4977
J-3 Error code [58] (Deviation of steering lever angle sensor and frame sensor signals) is displayed....4978
J-4 Error code [59] (Disconnection or short circuit with chassis ground in frame angle sensor system) is displayed....4979
J-5 Error code [60] (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed....4980
J-6 Error code [62] (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed....4981
J-7 Error code [63] (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed....4982
J-8 Steering speeds in both directions are different....4983
J-9 Abnormality in console switch (adjustment of steering lever angle sensor and frame angle sensor is impossible)....4984
J-10 Abnormality in power source and voltage....4985
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (EA MODE)....4987
METHOD OF ERROR CODE DISPLAY....4989
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED....4992
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROL SYSTEM....5000
EA-1 Error code [111] (Abnormality in controller memory)....5002
EA-2 Error code [112] (Abnormality in timing rail actuator)....5002
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)....5003
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system)....5004
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)....5006
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system)....5007
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system)....5008
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)....5009
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system)....5010
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system)....5011
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system)....5012
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system)....5013
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system)....5014
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system)....5015
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)....5016
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))....5017
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)....5018
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system)....5019
EA-19 Error code [151] (Abnormal rise in water temperature)....5019
EA-20 Error code [153] (Abnormality [high level] in intake air temperature sensor system)....5020
EA-21 Error code [154] (Abnormality [low level] in intake air temperature sensor system)....5020
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure sensor system)....5021
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure sensor system)....5022
EA-24 Error code [234] (Overspeed)....5024
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)....5025
EA-26 Error code [259] (Abnormality in fuel shut-off valve)....5026
EA-27 Error code [261] (Abnormal rise in fuel temperature)....5026
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)....5027
EA-29 Error code [265] (Abnormality [low level] in fuel temperature sensor system)....5027
EA-30 Error code [316] (Abnormality in fuel pump actuator system current)....5028
EA-31 Error code [318] (Abnormality in fuel pump actuator)....5029
EA-32 Error code [343] (Abnormality in controller internal communication)....5029
EA-33 Error code [346] (Abnormality in controller power down)....5030
EA-34 Error code [384] (Abnormality in preheating heater control system)....5031
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))....5032
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system)....5032
EA-37 Error code [431] (Abnormality [1] in idling validation switch system)....5034
EA-38 Error code [432] (Idling validation process error)....5036
EA-39 Error code [441] (Abnormality [low level] in battery voltage)....5038
EA-40 Error code [442] (Abnormality [high level] in battery voltage)....5038
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system)....5039
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)....5040
EA-43 Error code [455] (Abnormality in fuel rail actuator system current)....5041
EA-44 Error code [467] (Abnormality in timing rail actuator control)....5042
EA-45 Error code [468] (Abnormality in fuel rail actuator control)....5042
EA-46 Error code [514] (Abnormality in fuel rail actuator)....5042
EA-47 Error code [527] (Abnormality in dual output solenoid A system)....5043
EA-48 Error code [551] (Abnormality [2] in idling validation switch system)....5043
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor)....5044
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (VHMS MODE)....5046
ELECTRICAL SYSTEM DIAGRAM RELATED TO VHMS CONTROLLER....5049
INFORMATION GIVEN IN TROUBLESHOOTING CHART....5051
PHENOMENON TYPE CODE LIST....5052
[DBB0KK] (OR VHMS_LED INDICATES [N901]) ABNORMALITY IN SOURCE VOLTAGE....5053
[DBB5KP] (OR VHMS_LED INDICATES [N904]) ABNORMALITY IN SENSOR POWER SOURCE (5V) SYSTEM....5055
[DBB6KP] (OR VHMS_LED INDICATES [N902]) ABNORMALITY IN SENSOR POWER SOURCE (24V) SYSTEM....5057
[DBBRKR] (OR VHMS_LED DISPLAYS [N801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)....5059
[DGE1KB] (OR VHMS_LED DISPLAYS [N242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KB) {30 MIN. (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE)....5061
[DGE1KY] (OR VHMS_LED DISPLAYS [N242]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)....5062
[DGE5KX] (OR VHMS_LED DISPLAYS [N401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)....5063
[DGT4KA] (OR VHMS_LED DISPLAYS [N312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2 , 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)....5065
[DGT4KB] (OR VHMS_LED DISPLAYS [N311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)....5067
[DGT5KA] (OR VHMS_LED DISPLAYS [N322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) ....5069
[DGT5KB] (OR VHMS_LED DISPLAYS [N321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)....5071
[DHE5KB] (OR VHMS_LED DISPLAYS [N332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA)....5073
[DHE5KY] (OR VHMS_LED DISPLAYS [N331]) SHORT CIRCUIT WIRTH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)....5075
[DHT3KX] (OR VHMS_LED DISPLAYS [N614]) TROUBLE IN TRANSMISSION OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....5077
[DHP2KX] (OR VHMS_LED DISPLAYS [N531]) TROUBLE IN MAIN PUMP OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....5079
[DHT8KX] (OR VHMS_LED DISPLAYS [N533]) TROUBLE IN STEERING OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIIGNAL RANGE (KX)....5081
[DGH2KX] (OR VHMS_LED DISPLAYS [N537]) TROUBLE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....5083
[DHU2KX] (OR VHMS_LED DISPLAYS [N711]) TROUBLE IN FRONT BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....5085
[DHU3KX] (OR VHMS_LED DISPLAYS [N712]) TROUBLE IN REAR BRAKE OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....5087
[DGR4KX] OR VHMS_LED DISPLAYS [N717]) TROUBLE IN FRONT BRAKE OIL TEMPERATURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE (KX)....5089
[F@BBZL] (OR VHMS_LED DISPLAYS [N338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL) ....5090
[F@BYNR] (OR VHMS_LED DISPLAYS [N362]) NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (2): (NR)....5091
[F@BYNS] (OR VHMS_LED DISPLAYS [N361]) NO. 1, 2, 3 (REAR) EXHAUST TEMPERATURE IS HIGH (1): (NS)....5092
[F@BZNR] (OR VHMS_LED DISPLAYS {N372]) NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (2): (NR)....5093
[F@BZNS] (OR VHMS_LED DISPLAYS [N371]) NO. 4, 5, 6 (FRONT) EXHAUST TEMPERATURE IS HIGH (1): (NS)....5094
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION....5095
A SATELLITE COMMUNICATION DATA ARE NOT TRANSMITTED....5095
B ABNORMALITY IN DOWNLOADING INTO PC OR SETTING PC....5099
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED)....5101
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRTUMENT IS NORMAL)....5103
40 MAINTENANCE STANDARD....5104
ENGINE AND TRANSMISSION MOUNT....5106
DAMPER....5107
TORQUE CONVERTER AND PTO....5109
TORQUE CONVERTER REGULATOR VALVE....5110
TRANSMISSION....5111
TRANSMISSION CONTROL VALVE....5115
TRANSFER....5121
DRIVE SHAFT....5123
CENTER SUPPORT....5124
DIFFERENTIAL....5125
FINAL DRIVE....5127
AXLE MOUNT....5129
CENTER HINGE PIN....5131
STEERING DEMAND VALVE....5133
DIVERTER VALVE....5135
STEERING CYLINDER MOUNT....5136
EMERGENCY STEERING PUMP....5137
BRAKE VALVE....5138
SLACK ADJUSTER....5140
BRAKE....5141
PARKING BRAKE....5143
CONTROL PUMP....5144
STEERING AND SWITCH PUMP....5145
MAIN PISTON PUMP....5146
MAIN CONTROL VALVE....5147
PPC VALVE....5149
PPC RELIEF VALVE....5151
HYDRAULIC CYLINDER....5152
WORK EQUIPMENT LINKAGE....5153
BUCKET....5155
BUCKET POSITIONER AND BOOM KICK-OUT....5156
90 OTHERS....5158
ELECTRIC CIRCUIT DIAGRAM (1/7)....5159
ELECTRIC CIRCUIT DIAGRAM (2/7)....5160
ELECTRIC CIRCUIT DIAGRAM (3/7)....5161
ELECTRIC CIRCUIT DIAGRAM (4/7)....5162
ELECTRIC CIRCUIT DIAGRAM (5/7)....5163
ELECTRIC CIRCUIT DIAGRAM (6/7)....5164
ELECTRIC CIRCUIT DIAGRAM (7/7)....5165
SEBM04270104 - Wheel Loader WA700-1 Shop Manual....5167
COVER....5167
CONTENTS....5168
10 STRUCTURE AND FUNCTION....5192
GENERAL....5194
ENGINE SPEED CONTROL....5196
SERVO CYLINDER....5198
RADIATOR AND COOLER....5201
DAMPER....5202
HYDRAULIC CIRCUIT FOR POWER TRAIN....5203
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN....5204
TORQUE CONVERTER AND TRANSMISSION PIPING....5205
TORQUE CONVERTER AND PTO....5206
TORQUE CONVERTER OIL COOLER....5209
TORQUE CONVERTER REGULATOR VALVE....5210
TRANSMISSION....5211
TRANSMISSION CONTROL VALVE....5216
TRANSMISSION SOLENOID VALVE....5219
TORQUE CONVERTER RELIEF VALVE....5227
LUBRICATION BYPASS VALVE....5228
TRANSMISSION SOLENOID VALVE....5229
EMERGENCY MANUAL SPOOL....5230
TRANSMISSION OIL FILTER....5231
PILOT OIL FILTER....5232
TRANSFER....5233
DRIVE SHAFT....5234
CENTER SUPPORT....5235
AXLE....5236
DIFFERENTIAL....5238
FINAL DRIVE....5241
AXLE MOUNT....5242
TIRE AND WHEEL....5244
CENTER HINGE PIN....5245
FLOOR SUPPORT....5246
STEERING PIPING DIAGRAM....5247
STEERING CIRCUIT DIAGRAM....5248
STEERING COLUMN AND LINKAGE....5249
STEERING GEAR BOX....5250
STEERING AND SWITCH PUMP....5251
STEERING VALVE....5253
ROTARY SEAL....5255
SLOW RETURN VALVE....5263
DIVERTER VALVE....5264
EMERGENCY STEERING RELIEF VALVE....5265
STEERING DEMAND VALVE (MACHINE WITH JOYSTICK STEERING)....5268
STEERING UNIT (ORBIT-ROLL VALVE) (MACHINE WITH JOYSTICK STEERING)....5279
BRAKE AND AIR PIPING....5282
BRAKE AND AIR CIRCUIT DIAGRAM....5284
AIR GOVERNOR....5285
AIR TANK....5289
BRAKE VALVE....5290
RELAY VALVE....5294
DOUBLE CHECK VALVE....5295
BRAKE CHAMBER....5296
SLACK ADJUSTER....5298
CHECK VALVE....5301
HYDRAULIC TANK PRESSURIZING VALVE....5302
PARKING BRAKE SOLENOID VALVE....5303
SPRING CYLINDER....5304
BRAKE....5305
PARKING BRAKE....5306
HYDRAULIC PIPING....5308
HYDRAULIC CIRCUIT SYSTEM....5310
HYDRAULIC CIRCUIT DIAGRAM....5311
HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH JOYSTICK STEERING)....5312
WORK EQUIPMENT LEVER LINKAGE....5313
HYDRAULIC TANK....5314
ACCUMULATOR....5316
MAIN PUMP....5317
PPC VALVE....5329
PRESSURE DIFFERENTIAL VALVE....5334
MAIN CONTROL VALVE....5335
HYDRAULIC LEVER OPERATION....5342
LUBRICATION OF WORK EQUIPMENT....5348
BUCKET LINKAGE....5350
BUCKET POSITIONER AND BOOM KICK-OUT....5352
CAB....5354
AIR CONDITIONER....5355
ELECTRICAL WIRING DIAGRAM CIRCUIT....5360
ELECTRICAL WIRING DIAGRAM CIRCUIT (MACHINE WITH JOYSTICK STEERING)....5362
ELECTRICAL VEHICLE MONITORING SYSTEM (EVMS)....5363
SENSORS....5369
ENGINE STARTING CIRCUIT....5376
ENGINE STOP CIRCUIT....5377
AUTO PRIMING SYSTEM (APS)....5378
COMBINATION SWITCH....5383
ELECTRICAL TRANSMISSION CONTROL....5384
ELECTRICAL PARKING BRAKE CONTROL....5388
ELECTRICAL PARKING BRAKE....5389
KICK-DOWN SWITCH....5397
20 TESTING AND ADJUSTING....5403
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....5405
STANDARD VALUE TABLE FOR CHASSIS....5406
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM....5409
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (ENGINE)....5412
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (CHASSIS)....5413
ADJUSTING VALVE CLEARANCE....5414
MEASURING COMPRESSION PRESSURE....5415
MEASURING BLOW-BY PRESSURE....5416
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE....5417
TESTING AND ADJUSTING FUEL INJECTION TIMING....5418
MEASURING EXHAUST GAS COLOR....5419
TESTING AND ADJUSTING ALTERNATOR DRIVE BELT TENSION....5420
ADJUSTING AUTO TENSIONER....5421
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE....5422
MEASURING SHIFT LEVER....5426
MEASURING STALL SPEED....5427
MEASURING HYDRAULIC PRESSURE (TORQUE CONVERTER, TRANSMISSION PRESSURE)....5429
METHOD OF OPERATION OF EMERGENCY MANUAL SPOOL....5431
MEASURING WHEEL LOCK RING CLEARANCE....5432
MEASURING STEERING WHEEL PLAY....5433
MEASURING OPERATING FORCE AND OPERATING TIME OF STEERING WHEEL....5434
TESTING AND ADJUSTING STEERING LINKAGE....5435
MEASURING STEERING OIL PRESSURE....5437
MEASURING EMERGENCY STEERING PRESSURE....5438
ADJUSTING JOYSTICK STEERING....5440
MEASURING BRAKE PEDAL....5443
MEASURING AIR PRESSURE....5444
TESTING BRAKE PERFORMANCE....5447
CHECKING BRAKE PISTON LEAKAGE....5448
MEASURING WEAR OF BRAKE DISC....5449
AIR BLEEDING FROM BRAKE LINE ....5450
TESTING PARKING BRAKE PERFORMANCE....5451
CHECKING AND ADJUSTING PARKING BRAKE....5452
MEASURING DUMP AND LIFT CONTROL LEVERS....5454
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT....5456
AIR BLEEDING FROM PISTON PUMP....5459
MEASURING WORK EQUIPMENT....5460
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT....5461
ADJUSTING BUCKET POSITIONER....5462
ADJUSTING BOOM KICK-OUT....5463
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)....5464
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR....5465
TROUBLESHOOTING....5466
ELECTRICAL CIRCUIT FOR ENGINE, TRANSMISSION AND PARKING BRAKE....5467
ELECTRICAL CIRCUIT SYSTEM....5471
VEHICLE MONITOR SYSTEM....5472
LOCATION OF CONNECTORS....5473
CONNECTOR TERMINAL NUMBERS....5474
POINTS TO REMEMBER WHEN TROUBLESHOOTING....5478
SEQUENCE OF EVENTS IN TROUBLESHOOTING....5479
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....5480
HANDLING CONNECTORS....5487
CHECK BEFORE TROUBLESHOOTING....5488
JUDGEMENT OF POWER TRAIN....5489
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES....5491
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (ENGINE, TRANSMISSION, PARKING BRAKE)....5495
CONNECTOR TYPE AND POSITION OF DEVICE....5496
TROUBLESHOOTING CHART....5503
E-1. ENGINE DOES NOT START....5503
a) INSPECTION OF STARTING CIRCUIT....5503
b) INSPECTION OF BATTERY - BATTERY RELAY - STARTING SWITCH....5503
c) INSPECTION OF STARTING SWITCH - ENGINE STOP MOTOR....5504
E-2. ENGINE DOES NOT STOP....5506
E-3. ENGINE STOPS WHEN TRAVELING....5506
E-4. PARKING BRAKE DOES NOT WORK....5507
a) IF PARKING BRAKE DOES NOT WORK WHEN PARKING SWITCH IS ON (APPLIED)....5507
b) IF PARKING BRAKE DOES NOT WORK THEN AIR PRESSURE HAS DROPPED. (DOES NOT WORK AS EMERGENCY BRAKE)....5507
E-5. PARKING BRAKE IS NOT RELEASED....5508
E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON....5510
E-7. WHEN PARKING BRAKE IS APPLIED, TRANSMISSION DOES NOT ENTER NEUTRAL. (PARKING BRAKE IS WORKING NORMALLY.)....5510
E-8. TRANSMISSION DOES NOT WORK NORMALLY....5511
a) PROBLEM IN PARKING BRAKE, TRANSMISSION CUT-OFF SWITCH, NEUTRAL RELAY CIRCUIT....5512
b) DEFECTIVE CONTINUITY IN FORWARD SOLENOID CIRCUIT....5514
c) DEFECTIVE CONTINUITY IN REVERSE SOLENOID CIRCUIT....5516
d) CONTACT IN F-R CIRCUIT....5518
e) PROBLEM IN SPEED SOLENOID CIRCUIT....5522
f) CONTACT IN SPEED CIRCUIT....5525
E-9. KICK-DOWN SWITCH DOES NOT WORK (NORMAL F-1 - F-4 SWITCHES CORRECTLY)....5531
E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)....5534
E-11. KICK-DOWN OPERATION IS NOT CANCELED....5535
E-12. KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2....5537
E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED....5537
E-14. PREHEATING IS NOT CARRIED OUT....5539
a) PREHEATING IS NOT CARRIED OUT AUTOMATICALLY....5540
b) PREHEATING IS NOT CARRIED OUT NORMALLY OR AUTOMATICALLY....5541
E-15. PREHEATING STAYS ON....5543
a) AUTOMATIC PREHEATING IS NOT CANCELED....5543
b) PREHEATING CONTINUES EVEN WHEN HEATER SWITCH IS TURNED OFF....5544
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM....5546
CONNECTOR TYPE AND POSITION OF DEVICE....5548
M-1. (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED....5558
M-2. (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED....5558
M-3. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED....5560
M-4. (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING....5560
M-5. (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING....5562
M-6. (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING....5563
M-7. (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING....5563
M-8. (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING....5565
M-9. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING....5565
M-10. (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING....5567
M-11. (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING....5567
M-12. (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING....5567
M-13. (PARKING BRAKE) LIGHTS UP ABNORMALLY , OR DOES NOT LIGHT UP....5569
a) IF PARKING BRAKE STAYS LIGHTED UP....5569
b) IF PARKING BRAKE DOES NOT LIGHT UP....5569
M-14. (WORKING LAMP) LIGHTS UP....5571
a) IF WORKING LAMP STAYS LIGHTED UP....5571
b) IF WORKING LAMP DOES NOT LIGHT UP....5571
M-15. (PREHEATING) LIGHTS UP, OR DOES NOT LIGHT UP....5573
a) PREHEATING LIGHTS UP....5573
b) PREHEATING DOES NOT LIGHT UP....5573
M-16. (MAIN STEERING FAILURE) LIGHTS UP OR DOES NOT LIGHT UP....5574
a) MAIN STEERING FAILURE LIGHTS UP....5574
b) MAIN STEERING FAILURE DOES NOT LIGHT UP....5574
M-17. (TRANSMISSION CUT-OFF) LIGHTS UP , OR DOES NOT LIGHT UP....5576
a) TRANSMISSION CUT-OFF LIGHTS UP....5576
b) TRANSMISSION CUT-OFF DOES NOT LIGHT UP....5576
M-18. TURN SIGNAL AND HI BEAM LIGHT UP, OR DO NOT LIGHT UP....5578
a) TURN SIGNAL (RIGHT) PILOT DISPLAY LIGHTS UP....5578
b) TURN SIGNAL (LEFT) PILOT DISPLAY LIGHTS UP....5579
c) TURN SIGNAL (RIGHT) PILOT DISPLAY DOES NOT LIGHT UP....5580
d) TURN SIGNAL (LEFT) PILOT DISPLAY DOES NOT LIGHT UP....5580
e) HI BEAM PILOT DOES NOT LIGHT UP....5581
f) HI BEAM PILOT STAYS LIGHTED UP....5581
M-19. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON....5583
M-20. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY....5584
M-21. HOURMETER DOES NOT WORK NORMALLY....5585
M-22. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART LIGHTS UP....5586
a) NONE OF MONITOR PANEL LIGHTS UP....5586
b) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHTS UP....5586
c) NONE OF CAUTION ITEMS LIGHT UP....5587
d) SOME OTHER PARTS DO NOT LIGHT UP....5587
M-23. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT....5587
M-24. (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED....5588
a) (ENGINE OIL PRESSURE) FLASHES, AND ALARM BUZZER AND WARNING LAMP ARE ACTUATED....5588
b) (BATTERY CHARGE) FLASHES, AND WARNING LAMP LIGHTS UP....5588
M-25. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP....5590
a) EVEN WHEN COMBINATION LAMP IS PLACED AT SMALL, NONE OF PANEL LIGHTING LIGHTS UP....5590
b) EVEN WHEN WORKING LAMP SWITCHED ON, NONE OF MONITOR PANEL LIGHTS UP ....5591
c) EVEN WHEN STARTING SWITCH IS TURNED ON, NONE OF MONITOR PANEL LIGHTS UP....5593
d) PART OF PANEL DOES NOT LIGHT UP....5593
M-26. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND....5595
M-27. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS....5595
M-28. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH....5597
M-29. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP....5598
M-30. ABNORMALITY IN FUEL GAUGE....5599
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....5599
b) IF INDICATOR REMAINS AT FULL....5599
M-31. ABNORMALITY IN AIR PRESSURE GAUGE....5601
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....5601
b) IF INDICATOR REMAINS AT MAXIMUM LEVEL....5601
M-32. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE....5603
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....5603
b) IF INDICATOR REMAINS AT MINIMUM LEVEL....5603
M-33. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE....5605
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....5605
b) IF INDICATOR REMAINS AT MINIMUM LEVEL....5605
TROUBLESHOOTING CHART FOR POWER TRAIN ,STEERING , AIR AND BRAKE , WORK EQUIPMENT (MECHANICAL SYSTEM)....5607
POWER TRAIN....5608
1. MACHINE DOES NOT MOVE....5608
2. MACHINE LACKS POWER OR SPEED....5610
3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....5611
4. TORQUE CONVERTER AIR TEMPERATURE TOO HIGH....5612
STEERING SYSTEM....5613
1. STEERING WHEEL DOES NOT TURN....5613
2. STEERING WHEEL IS SLUGGISH....5614
3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK....5615
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING....5615
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT....5615
AIR AND BRAKE SYSTEM....5616
1. AIR PRESSURE DOES NOT RISE AT ALL....5616
2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE....5617
3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE....5618
4. BRAKE DOES NOT RELEASE, OR DRAGS....5619
5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS....5620
WORK EQUIPMENT....5621
1. LIFT ARM DOES NOT RISE....5621
2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER....5622
3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT....5623
4. BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER....5623
5. LIFT ARM HAS LARGE HYDRAULIC DRIFT....5623
6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK....5623
7. LIFT ARM LOWERS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE" ....5623
8. BUCKET DOES NOT TILT BACK....5624
9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER....5625
10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK....5626
11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER....5626
12. BUCKET HAS LARGE HYDRAULIC DRIFT....5626
13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN "HOLD")....5626
14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"....5626
15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY....5627
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)....5628
1. FUNCTION....5630
2. TROUBLESHOOTING....5630
3. TABLE OF FAILURE CODES....5630
4. TABLE OF FAILURE MODES AND CAUSES ....5631
J-1 FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY SYSTEM....5632
J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM....5633
J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION N RELAY SYSTEM....5634
J-4 FAILURE CODE [19] ABNORMALITY IN CAUTION LAMP SYSTEM....5635
J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F, N, R SIGNAL SYSTEM....5636
J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R. H. STEERING SOLENOID....5637
J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R. H. STEERING SOLENOID....5638
J-8 FAILURE CODE [32] DISCONNECTION IN STEERING L. H. STEERING SOLENOID....5639
J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L. H. STEERING SOLENOID....5640
J-10 FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM....5641
J-11 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM....5642
J-12 FAILURE CODE [37] ABNORMALITY IN JOYSTICK STEERING LEVER POTENTIOMETER ....5643
J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING HARNESS....5644
J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE....5645
J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM....5646
J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM....5647
J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM....5648
J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM....5649
J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM....5650
J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM....5651
J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM....5652
30 DISASSEMBLY AND ASSEMBLY....5653
STARTING MOTOR....5656
REMOVAL AND INSTALLATION....5656
ALTERNATOR....5657
REMOVAL AND INSTALLATION....5657
AFTERCOOLER CORE....5658
REMOVAL AND INSTALLATION....5658
FUEL INJECTION PUMP....5659
REMOVAL AND INSTALLATION....5659
TURBOCHARGER (TOP)....5660
REMOVAL AND INSTALLATION....5660
TURBOCHARGER (BOTTOM)....5661
REMOVAL AND INSTALLATION....5661
NOZZLE HOLDER....5662
REMOVAL AND INSTALLATION....5662
OIL COOLER....5663
REMOVAL AND INSTALLATION....5663
THERMOSTAT....5664
REMOVAL AND INSTALLATION....5664
WATER PUMP....5665
REMOVAL AND INSTALLATION....5665
CYLINDER HEAD....5666
REMOVAL....5666
INSTALLATION....5668
AIR COMPRESSOR....5672
REMOVAL AND INSTALLATION....5672
RADIATOR....5673
REMOVAL....5673
INSTALLATION....5676
ENGINE....5679
REMOVAL....5679
INSTALLATION....5686
DAMPER....5695
REMOVAL....5695
INSTALLATION....5699
DISASSEMBLY....5704
ASSEMBLY....5706
TORQUE CONVERTER CHARGING AND PPC PUMP....5710
REMOVAL....5710
INSTALLATION....5712
TORQUE CONVERTER, PTO, TRANSMISSION....5714
REMOVAL....5714
INSTALLATION....5724
TORQUE CONVERTER....5735
DISASSEMBLY....5735
ASSEMBLY....5739
PTO....5744
DISASSEMBLY....5744
ASSEMBLY....5746
TRANSMISSION....5749
DISASSEMBLY....5749
ASSEMBLY....5761
TRANSFER....5775
DISASSEMBLY....5775
ASSEMBLY....5782
TRANSMISSION VALVE....5792
REMOVAL ....5792
INSTALLATION....5793
DISASSEMBLY AND ASSEMBLY....5794
CENTER SUPPORT....5799
REMOVAL....5799
INSTALLATION....5800
DISASSEMBLY....5802
ASSEMBLY....5804
DRIVE SHAFT....5807
DISASSEMBLY....5807
ASSEMBLY....5809
FRONT AXLE....5810
REMOVAL....5810
INSTALLATION....5812
REAR AXLE ....5814
REMOVAL....5814
INSTALLATION....5819
DIFFERENTIAL....5824
REMOVAL....5824
INSTALLATION....5827
DISASSEMBLY....5829
ASSEMBLY....5833
FINAL DRIVE....5842
DISASSEMBLY....5842
ASSEMBLY....5846
STEERING GEAR....5850
REMOVAL....5850
INSTALLATION....5851
DISASSEMBLY....5852
ASSEMBLY....5853
STEERING, SWITCH PUMP....5856
REMOVAL....5856
INSTALLATION....5857
STEERING VALVE....5858
REMOVAL....5858
INSTALLATION....5860
DISASSEMBLY AND ASSEMBLY....5862
DIVERTER VALVE....5864
DISASSEMBLY AND ASSEMBLY....5864
STEERING CYLINDER....5866
REMOVAL....5866
INSTALLATION....5868
BRAKE VALVE....5871
REMOVAL....5871
INSTALLATION....5873
DISASSEMBLY....5875
ASSEMBLY....5877
BRAKE CHAMBER....5879
REMOVAL....5879
INSTALLATION....5880
DISASSEMBLY....5881
ASSEMBLY....5884
AIR GOVERNOR (SERIAL NO. 10062 AND UP)....5887
DISASSEMBLY....5887
ASSEMBLY....5888
SLACK ADJUSTER....5889
REMOVAL....5889
INSTALLATION....5890
DISASSEMBLY....5891
ASSEMBLY....5892
BRAKE....5893
REMOVAL....5893
INSTALLATION....5895
DISASSEMBLY....5897
ASSEMBLY....5901
SPRING CYLINDER....5907
REMOVAL....5907
INSTALLATION....5908
DISASSEMBLY....5909
ASSEMBLY....5910
PARKING BRAKE....5911
REMOVAL....5911
INSTALLATION....5912
DISASSEMBLY AND ASSEMBLY....5913
PARKING BRAKE PAD....5914
REMOVAL AND INSTALLATION....5914
HYDRAULIC TANK....5915
REMOVAL....5915
INSTALLATION....5917
HYDRAULIC PUMP....5919
REMOVAL....5919
INSTALLATION....5920
PISTON PUMP....5921
DISASSEMBLY....5921
ASSEMBLY....5928
PPC VALVE....5942
REMOVAL....5942
INSTALLATION....5943
DISASSEMBLY AND ASSEMBLY....5944
MAIN CONTROL VALVE....5945
REMOVAL....5945
INSTALLATION....5947
DISASSEMBLY....5949
ASSEMBLY....5951
DUMP CYLINDER....5953
REMOVAL....5953
INSTALLATION....5955
LIFT CYLINDER....5957
REMOVAL....5957
INSTALLATION....5959
STEERING, LIFT, DUMP CYLINDER....5961
DISASSEMBLY....5961
ASSEMBLY....5963
CENTER HINGE PIN....5965
REMOVAL....5965
INSTALLATION....5971
WORK EQUIPMENT....5981
REMOVAL....5981
INSTALLATION....5987
COUNTERWEIGHT....5996
REMOVAL....5996
INSTALLATION....5997
FUEL TANK....5998
REMOVAL....5998
INSTALLATION....6000
MACHINE MONITOR....6002
REMOVAL....6002
INSTALLATION....6003
40 MAINTENANCE STANDARD....6004
ENGINE AND TRANSMISSION MOUNT....6005
DAMPER....6006
TORQUE CONVERTER CHARGING, COOLING AND PPC PUMP....6008
TORQUE CONVERTER AND PTO....6010
TORQUE CONVERTER REGULATOR VALVE....6011
TRANSMISSION....6012
TRANSMISSION CONTROL VALVE....6015
TRANSMISSION SOLENOID VALVE....6019
TRANSFER....6020
DRIVE SHAFT....6022
CENTER SUPPORT....6023
DIFFERENTIAL....6024
FINAL DRIVE....6026
AXLE MOUNT....6028
CENTER HINGE PIN....6030
STEERING LINKAGE AND STEERING COLUMN....6032
STEERING GEAR BOX....6034
STEERING VALVE....6035
DIVERTER VALVE....6037
STEERING CYLINDER MOUNT....6038
EMERGENCY STEERING PUMP....6039
BRAKE CHAMBER....6040
BRAKE VALVE....6041
SLACK ADJUSTER....6043
BRAKE....6044
PARKING BRAKE....6046
SPRING CYLINDER....6047
CONTROL PUMP....6048
MAIN CONTROL VALVE....6049
PPC VALVE....6050
CYLINDER....6052
BUCKET LINKAGE....6053
BUCKET POSITIONER AND BOOM KICK-OUT....6055
TEN00001-03 - Wheel Loader GALEO WA700-3 Operation & Maintenance Manual....6056
COVER....6056
FOREWORD....6057
FOREWORD....6058
SAFETY INFORMATION....6061
INTRODUCTION....6063
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....6063
VISIBILITY FROM OPERATOR'S SEAT....6064
NECESSARY INFORMATION....6065
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....6065
ENGINE SERIAL NO. PLATE AND POSITION....6065
POSITION OF SERVICE METER....6066
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....6066
CONTENTS....6067
SAFETY....6070
SAFETY....6071
SAFETY LABELS....6073
LOCATION OF SAFETY LABELS....6074
GENERAL PRECAUTIONS....6080
SAFETY RULES....6080
IF ABNORMALITIES ARE FOUND....6080
CLOTHING AND PERSONAL PROTECTIVE ITEMS....6080
FIRE EXTINGUISHER AND FIRST AID KIT....6080
SAFETY FEATURES....6080
KEEP MACHINE CLEAN....6081
INSIDE OPERATOR'S COMPARTMENT....6081
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT....6081
HANDRAILS AND STEPS....6082
MOUNTING AND DISMOUNTING....6082
NO PEOPLE ON ATTACHMENTS....6082
DO NOT GET CAUGHT IN ARTICULATED PORTION....6083
PREVENTION OF BURNS....6083
FIRE PREVENTION....6084
ACTION IF FIRE OCCURS....6085
WINDOW WASHER LIQUID....6085
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)....6085
PRECAUTIONS FOR ATTACHMENTS, OPTIONS....6085
UNAUTHORIZED MODIFICATION....6085
SAFETY AT WORKSITE....6086
WORKING ON LOOSE GROUND....6086
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES....6087
ENSURE GOOD VISIBILITY....6087
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS....6088
CHECKING SIGNALMAN'S SIGNALS AND SIGNS....6088
EMERGENCY EXIT FROM OPERATOR'S CAB....6088
BE CAREFUL ABOUT ASBESTOS DUST....6088
PRECAUTIONS FOR OPERATION....6089
STARTING ENGINE....6089
CHECKS BEFORE STARTING ENGINE....6089
PRECAUTIONS WHEN STARTING....6089
PRECAUTIONS IN COLD AREAS....6090
OPERATION....6091
CHECKS BEFORE OPERATION....6091
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE....6091
PRECAUTIONS WHEN TRAVELING....6092
TRAVELING ON SLOPES....6093
PROHIBITED OPERATIONS....6094
PRECAUTIONS WHEN OPERATING....6095
METHODS OF USING BRAKE....6095
OPERATE CAREFULLY ON SNOW....6096
PARKING MACHINE ....6097
TRANSPORTATION....6098
LOADING AND UNLOADING....6098
SHIPPING....6098
BATTERY....6099
BATTERY HAZARD PREVENTION....6099
STARTING WITH BOOSTER CABLES....6100
TOWING....6101
PRECAUTIONS FOR MAINTENANCE....6102
WARNING TAG ....6102
KEEP WORK PLACE CLEAN AND TIDY....6102
APPOINT LEADER WHEN WORKING WITH OTHERS....6102
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....6103
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....6104
PROPER TOOLS....6105
WORK EQUIPMENT SUPPORT....6105
ACCUMULATOR....6105
PERSONNEL....6105
ATTACHMENTS ....6106
NOISE....6106
PRECAUTIONS WHEN USING HAMMER ....6106
REPAIR WELDING ....6106
REMOVING BATTERY TERMINAL ....6106
PRECAUTIONS WITH HIGH-PRESSURE OIL....6107
HANDLING HIGH-PRESSURE HOSES....6107
WASTE MATERIALS ....6107
MAINTENANCE OF AIR CONDITIONER....6107
COMPRESSED AIR....6108
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ....6108
PRECAUTIONS WITH TIRES....6109
HANDLING TIRES....6109
PRECAUTIONS WHEN STORING TIRES....6109
OPERATION....6110
GENERAL VIEW....6111
GENERAL VIEW OF MACHINE....6111
GENERAL VIEW OF CONTROLS AND GAUGES....6112
EXPLANATION OF COMPONENTS....6114
MACHINE MONITOR....6114
SWITCHES....6127
CONTROL LEVERS, PEDALS....6136
STEERING COLUMN TILT LEVER....6140
CAP WITH LOCK....6141
FUEL STOP LEVER FOR EMERGENCY ENGINE STOP....6142
SAFETY BAR....6142
TOWING PIN....6143
GREASE PUMP....6143
BACKUP ALARM....6143
CAB DOOR OPEN LOCK....6144
TOOL BOX....6144
DUST INDICATOR....6144
FUSE....6144
SLOW BLOW FUSE....6146
LUNCH BOX TRAY....6146
POWER OUTLET....6146
PRECAUTIONS WHEN HANDLING ACCUMULATOR....6147
OPERATION....6149
CHECK BEFORE STARTING ENGINE, ADJUST....6149
STARTING ENGINE....6166
OPERATIONS AND CHECKS AFTER STARTING ENGINE....6168
STOPPING ENGINE....6170
CHECK AFTER STOPPING ENGINE....6170
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....6171
TURNING....6176
OPERATION OF WORK EQUIPMENT....6177
WORK POSSIBLE USING WHEEL LOADER....6179
PRECAUTIONS FOR OPERATION....6185
ADJUSTING WORK EQUIPMENT POSTURE....6187
REMOVAL AND INSTALLATION OF THE BUCKET....6189
PARKING MACHINE....6193
CHECKS AFTER COMPLETION OF OPERATION....6195
LOCKING....6195
HANDLING THE TIRES....6196
TRANSPORTATION....6198
TRANSPORTATION PROCEDURE....6198
LOADING, UNLOADING WORK....6198
METHOD OF SECURING MACHINE....6198
METHOD OF LIFTING MACHINE....6200
COLD WEATHER OPERATION....6203
PRECAUTIONS FOR LOW TEMPERATURE....6203
PRECAUTIONS AFTER COMPLETION OF WORK....6204
AFTER COLD WEATHER....6205
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....6205
LONG-TERM STORAGE....6206
BEFORE STORAGE....6206
DURING STORAGE....6206
AFTER STORAGE....6206
TROUBLESHOOTING....6207
WHEN MACHINE RUNS OUT OF FUEL....6207
METHOD OF TOWING MACHINE....6209
IF BATTERY IS DISCHARGED....6213
OTHER TROUBLE....6217
MAINTENANCE....6221
GUIDES TO MAINTENANCE....6222
OUTLINES OF SERVICE....6224
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....6224
OUTLINE OF ELECTRIC SYSTEM....6227
WEAR PARTS....6228
WEAR PARTS LIST....6228
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....6229
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....6230
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....6231
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....6232
TORQUE LIST....6232
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....6233
SAFETY CRITICAL PARTS....6233
MAINTENANCE SCHEDULE CHART....6234
MAINTENANCE SCHEDULE CHART....6234
SERVICE PROCEDURE....6236
INITIAL 250 HOURS SERVICE....6236
INITIAL 2000 HOURS SERVICE....6236
CHECK INJECTOR SETTING LOAD, ADJUST....6236
WHEN REQUIRED....6237
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT....6237
CLEAN INSIDE OF COOLING SYSTEM....6240
CHECK TRANSMISSION OIL LEVEL, ADD OIL....6243
CHECK AXLE OIL LEVEL, ADD OIL....6245
CLEAN AXLE CASE BREATHER....6246
CLEAN AIR CONDITIONER CONDENSER....6246
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID....6247
CLEAN RADIATOR FINS AND OIL COOLER FINS....6247
CHECK ELECTRICAL INTAKE AIR HEATER....6248
REPLACE BUCKET TEETH....6248
LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES)....6249
CHECK AIR CONDITIONER....6249
REPLACE SLOW BLOW FUSE....6250
BLEEDING AIR FROM HYDRAULIC TANK....6251
REPLACE FAN BELT, ADJUST AUTO-TENSIONER....6253
BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT....6255
BLEEDING AIR FROM PPC CIRCUIT....6255
SELECTION AND INSPECTION OF TIRES....6256
CHECK BEFORE STARTING....6258
EVERY 50 HOURS SERVICE....6259
DRAIN WATER, SEDIMENT FROM FUEL TANK....6259
EVERY 100 HOURS SERVICE....6260
LUBRICATING....6260
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....6262
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER....6263
EVERY 250 HOURS SERVICE....6264
CHECK BATTERY ELECTROLYTE LEVEL....6264
CHECK PARKING BRAKE....6265
CHECK ALTERNATOR BELT TENSION, ADJUST....6266
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....6267
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN....6267
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....6268
EVERY 500 HOURS SERVICE....6269
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....6269
REPLACE FUEL FILTER CARTRIDGE....6271
REPLACE TRANSMISSION OIL FILTER ELEMENT....6272
LUBRICATE CENTER DRIVE SHAFT....6273
CHECK FAN BELT FOR WEAR ....6273
EVERY 1000 HOURS SERVICE....6274
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER....6274
CLEAN TRANSMISSION CASE BREATHER....6275
LUBRICATING....6276
CHECK TIGHTENING PARTS OF TURBOCHARGER....6278
CLEAN FUEL STRAINER....6278
REPLACE CORROSION RESISTOR CARTRIDGE....6278
TIGHTEN ROPS CANOPY....6279
EVERY 2000 HOURS SERVICE....6280
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT....6280
REPLACE HYDRAULIC TANK BREATHER ELEMENT....6282
CLEAN HYDRAULIC TANK STRAINER....6283
CHANGE AXLE OIL....6284
REPLACE FILTER ELEMENT IN BRAKE OIL TANK....6285
REPLACE BRAKE OIL TANK BREATHER....6286
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER....6286
CLEAN PPC CIRCUIT STRAINER....6286
CLEAN ENGINE BREATHER ELEMENT....6287
CHECK ALTERNATOR, STARTING MOTOR....6287
CHECK ENGINE VALVE CLEARANCE, ADJUST....6287
CHECK BRAKE DISC WEAR....6287
CLEAN AND CHECK TURBOCHARGER....6287
CHECK ACCUMULATOR FUNCTION....6288
CHECK ACCUMULATOR GAS PRESSURE....6288
EVERY 4000 HOURS SERVICE....6289
CHECK WATER PUMP....6289
CHECK VIBRATION DAMPER....6289
CHECK FAN PULLEY AND TENSION PULLEY....6289
CHECK AIR CONDITIONER COMPRESSOR, ADJUST....6289
SPECIFICATIONS....6290
SPECIFICATIONS....6291
ATTACHMENTS, OPTIONS....6293
SELECTING BUCKET AND TIRES....6294
HANDLING AUTO-GREASING SYSTEM....6295
METHOD OF OPERATING AUTO-GREASING SYSTEM....6296
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM....6297
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR....6304
METHOD OF SETTING TIMER....6305
HANDLING AUTOMATIC SHIFT SYSTEM....6308
METHOD OF OPERATION....6308
PRECAUTION WHEN CHANGING DIRECTION....6309
HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM)....6310
EXPLANATION OF COMPONENTS....6310
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....6311
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....6314
ADJUSTMENT OF JOYSTICK CONSOLE....6317
ADJUSTMENT OF AIR SUSPENSION SEAT....6318
FAILURE DISPLAY ON MAIN MONITOR....6320
FAILURE CODE ON MAIN MONITOR....6320
CAR RADIO....6321
EXPLANATION OF COMPONENTS....6321
METHOD OF USE....6324
PRECAUTIONS WHEN USING....6326
AM/FM RADIO-CASSETTE STEREO....6327
EXPLANATION OF COMPONENTS....6327
METHOD OF OPERATION....6332
PRECAUTIONS FOR USE....6334
AIR CONDITIONER....6335
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL....6335
METHOD OF OPERATION....6337
INDEX....6339
TEN00066-02 - Wheel Loader GALEO WA700-3 Operation & Maintenance Manual....6343
COVER....6343
FOREWORD....6345
FOREWORD....6346
SAFETY INFORMATION....6349
INTRODUCTION....6351
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....6351
VISIBILITY FROM OPERATOR'S SEAT....6352
NECESSARY INFORMATION....6353
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....6353
ENGINE SERIAL NO. PLATE AND POSITION....6353
POSITION OF SERVICE METER....6354
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....6354
CONTENTS....6355
SAFETY....6359
SAFETY....6360
SAFETY LABELS....6362
LOCATION OF SAFETY LABELS....6363
GENERAL PRECAUTIONS....6369
PRECAUTIONS FOR OPERATION....6379
STARTING ENGINE....6379
OPERATION....6381
TRANSPORTATION....6389
BATTERY....6390
TOWING....6392
PRECAUTIONS FOR MAINTENANCE....6393
PRECAUTIONS WITH TIRES....6401
OPERATION....6403
GENERAL VIEW....6404
GENERAL VIEW OF MACHINE....6404
GENERAL VIEW OF CONTROLS AND GAUGES....6405
EXPLANATION OF COMPONENTS....6407
MACHINE MONITOR....6407
SWITCHES....6420
CONTROL LEVERS, PEDALS....6430
MAIN MONITOR TILT LEVER....6434
CAP WITH LOCK....6435
FUEL STOP LEVER FOR EMERGENCY ENGINE STOP....6436
SAFETY BAR....6436
TOWING PIN....6437
GREASE PUMP....6437
BACKUP ALARM....6437
CAB DOOR OPEN LOCK....6438
TOOL BOX....6438
DUST INDICATOR....6438
FUSE....6438
SLOW BLOW FUSE....6440
LUNCH BOX TRAY....6440
POWER OUTLET....6440
AIR CONDITIONER....6441
PRECAUTIONS WHEN HANDLING ACCUMULATOR....6446
OPERATION....6448
CHECK BEFORE STARTING ENGINE, ADJUST....6448
STARTING ENGINE....6465
OPERATIONS AND CHECKS AFTER STARTING ENGINE....6467
STOPPING ENGINE....6469
CHECK AFTER STOPPING ENGINE....6469
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....6470
TURNING....6477
OPERATION OF WORK EQUIPMENT....6478
WORK POSSIBLE USING WHEEL LOADER....6480
ADJUSTING WORK EQUIPMENT POSTURE....6488
REMOVAL AND INSTALLATION OF THE BUCKET....6490
PARKING MACHINE....6494
CHECKS AFTER COMPLETION OF OPERATION....6496
LOCKING....6496
HANDLING THE TIRES....6497
TRANSPORTATION....6499
TRANSPORTATION PROCEDURE....6499
LOADING, UNLOADING WORK....6499
METHOD OF SECURING MACHINE....6499
METHOD OF LIFTING MACHINE....6501
COLD WEATHER OPERATION....6505
PRECAUTIONS FOR LOW TEMPERATURE....6505
PRECAUTIONS AFTER COMPLETION OF WORK....6506
AFTER COLD WEATHER....6507
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....6507
LONG-TERM STORAGE....6508
BEFORE STORAGE....6508
DURING STORAGE....6508
AFTER STORAGE....6508
TROUBLESHOOTING....6509
WHEN MACHINE RUNS OUT OF FUEL....6509
METHOD OF TOWING MACHINE....6511
IF BATTERY IS DISCHARGED....6515
OTHER TROUBLE....6519
MAINTENANCE....6525
GUIDES TO MAINTENANCE....6526
OUTLINES OF SERVICE....6528
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....6528
OUTLINE OF ELECTRIC SYSTEM....6531
WEAR PARTS....6532
WEAR PARTS LIST....6532
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....6533
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS....6533
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....6537
TORQUE LIST....6537
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....6538
SAFETY CRITICAL PARTS....6538
MAINTENANCE SCHEDULE CHART....6539
MAINTENANCE SCHEDULE CHART....6539
SERVICE PROCEDURE....6541
INITIAL 250 HOURS SERVICE....6541
INITIAL 2000 HOURS SERVICE....6541
WHEN REQUIRED....6542
CHECK BEFORE STARTING....6561
EVERY 50 HOURS SERVICE....6562
EVERY 100 HOURS SERVICE....6563
EVERY 250 HOURS SERVICE....6567
EVERY 500 HOURS SERVICE....6572
EVERY 1000 HOURS SERVICE....6578
EVERY 2000 HOURS SERVICE....6584
EVERY 4000 HOURS SERVICE....6593
SPECIFICATIONS....6595
SPECIFICATIONS....6596
ATTACHMENTS, OPTIONS....6599
SELECTING BUCKET AND TIRES....6600
HANDLING AUTO-GREASING SYSTEM....6601
METHOD OF OPERATING AUTO-GREASING SYSTEM....6602
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM....6603
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR....6610
METHOD OF SETTING TIMER....6611
CAR RADIO....6614
EXPLANATION OF COMPONENTS....6614
METHOD OF USE....6617
PRECAUTIONS WHEN USING....6619
AM/FM RADIO-CASSETTE STEREO....6620
EXPLANATION OF COMPONENTS....6620
METHOD OF OPERATION....6625
PRECAUTIONS FOR USE....6627
INDEX....6629
Komatsu WA700 Loader Factory Service & Shop Manuals
