WHEELLOADER
MachinemodelSerialnumber
WA200-672001andup
00Indexandforeword
Indexandforeword.................................................................................................................................00-2
Foreword,safetyandgeneralinformation.............................................................................................00-11
Importantsafetynotice......................................................................................................................00-11
Howtoreadtheshopmanual............................................................................................................00-18
Explanationoftermsformaintenancestandard................................................................................00-20
Handlingequipmentoffuelsystemdevices......................................................................................00-22
Handlingofintakesystemparts........................................................................................................00-23
Handlingofhydraulicequipment.......................................................................................................00-24
Methodofdisconnectingandconnectingofpush-pulltypecoupler..................................................00-26
Handlingofelectricalequipment.......................................................................................................00-29
Howtoreadelectricwirecode..........................................................................................................00-37
Precautionswhenperformingoperation............................................................................................00-40
PracticaluseofKOMTRAX...............................................................................................................00-45
Standardtighteningtorquetable.......................................................................................................00-46
ListofAbbreviation............................................................................................................................00-52 Conversiontable................................................................................................................................00-56
01Specifications
Specification............................................................................................................................................01-3
Specificationdimensiondrawing.........................................................................................................01-3
Specifications......................................................................................................................................01-4
Weighttable.........................................................................................................................................01-8
Tableoffuel,coolantandlubricants..................................................................................................01-10
10Structure,functionandmaintenancestandard
Engineandcoolingsystem.....................................................................................................................10-4
Enginemountandtransfermount.......................................................................................................10-4
Damper................................................................................................................................................10-5
Coolingsystem....................................................................................................................................10-6
Coolingsystemhydraulicpipingdiagram............................................................................................10-7
Coolingfanmotor................................................................................................................................10-9
Powertrain............................................................................................................................................10-17
Powertrain........................................................................................................................................10-17
Powertrainsystemdiagram..............................................................................................................10-18
Driveshaft.........................................................................................................................................10-20
HSThydraulicpipingdiagram...........................................................................................................10-21
HSTpump.........................................................................................................................................10-22
HSTmotor.........................................................................................................................................10-30 Transfer.............................................................................................................................................10-36
Clutchsolenoidvalve.........................................................................................................................10-47
Axle....................................................................................................................................................10-48 Differential.........................................................................................................................................10-50
Torqueproportioningdifferential........................................................................................................10-55
Limitedslipdifferential.......................................................................................................................10-58
Finaldrive..........................................................................................................................................10-62
Steeringsystem....................................................................................................................................10-67
Steeringpipingdiagram.....................................................................................................................10-67
Steeringcolumn.................................................................................................................................10-68
Priorityvalve......................................................................................................................................10-69
Orbit-rollvalve...................................................................................................................................10-72
2-wayrestrictorvalve........................................................................................................................10-80
Cushionvalve....................................................................................................................................10-81
Steeringcylinder................................................................................................................................10-82
Emergencysteeringpipingdiagram..................................................................................................10-84
Emergencysteeringvalve.................................................................................................................10-85
Steeringreliefvalve...........................................................................................................................10-88
Brakesystem........................................................................................................................................10-89
Brakepipingdiagram........................................................................................................................10-89
Chargevalve.....................................................................................................................................10-90
Brakevalve........................................................................................................................................10-94
Inchingvalve.....................................................................................................................................10-98
Accumulator(forbrake).....................................................................................................................10-99
Slackadjuster..................................................................................................................................10-100
Brake...............................................................................................................................................10-102
Parkingbrakecontrol......................................................................................................................10-107
Parkingbrake..................................................................................................................................10-108
Undercarriageandframe....................................................................................................................10-110
Axlemountandcenterhingepin.....................................................................................................10-110
Hydraulicsystem.................................................................................................................................10-116
Workequipmenthydraulicpipingdiagram......................................................................................10-116
Workequipmentcontrolleverlinkage.............................................................................................10-118
Hydraulictank..................................................................................................................................10-120
Quadruplegearpump.....................................................................................................................10-122
Workequipmentcontrolvalve.........................................................................................................10-125 PPCvalve........................................................................................................................................10-142
Lockvalve.......................................................................................................................................10-150
Accumulator(forPPCcircuit)..........................................................................................................10-151
Workequipment..................................................................................................................................10-152
Workequipmentlinkage..................................................................................................................10-152
30Testingandadjusting
Relatedinformationontestingandadjusting..........................................................................................30-4
Toolsfortesting,adjusting,andtroubleshooting.................................................................................30-4
Sketchesofspecialtools.....................................................................................................................30-9
Engineandcoolingsystem...................................................................................................................30-10
Measuringenginespeed...................................................................................................................30-10
Measuringexhaustgascolor.............................................................................................................30-12
Adjustingvalveclearance..................................................................................................................30-13
Measuringcompressionpressure.....................................................................................................30-15
Measuringblowbypressure...............................................................................................................30-18
Testingengineoilpressure...............................................................................................................30-19
Measuringintakeair(boost)pressure...............................................................................................30-20
Handlingfuelsystemequipment.......................................................................................................30-21
Releasingresidualpressureinfuelsystem.......................................................................................30-21
Measuringfuelpressure....................................................................................................................30-22
Measuringfuelreturnrateandleakage.............................................................................................30-24
Bleedingairfromfuelcircuit..............................................................................................................30-28
Checkingleakageinfuelsystem.......................................................................................................30-29
Handlingcylindercut-outmodeoperation.........................................................................................30-30
Handlingno-injectioncrankingoperation..........................................................................................30-30
Handlingcontrollervoltagecircuit......................................................................................................30-31
Checkofmufflerandmufflerstackforloosenessanddamage.........................................................30-31
Checkofmufflerfunction...................................................................................................................30-32
Checkofinstalledconditionofcylinderheadandmanifolds.............................................................30-32
Checkofenginepipingfordamageandlooseness...........................................................................30-33
Testingandadjustingairconditionercompressorbelttension..........................................................30-33
Replacingalternatorbelt....................................................................................................................30-34
Powertrain............................................................................................................................................30-35
TestingandadjustingHSToilpressure.............................................................................................30-35
Testingclutchcontrolpressure..........................................................................................................30-39
Steeringsystem....................................................................................................................................30-40
Testingsteeringwheel.......................................................................................................................30-40
Testingandadjustingsteeringoilpressure.......................................................................................30-42
Bleedingairfromsteeringcircuit.......................................................................................................30-44
Brakesystem........................................................................................................................................30-45
Measuringbrakepedal......................................................................................................................30-45
Testingandadjustingbrakepedallinkage........................................................................................30-46
Measuringbrakeperformance...........................................................................................................30-47
Testingandadjustingaccumulatorchargepressure.........................................................................30-48
Testingwheelbrakeoilpressure.......................................................................................................30-50
Testingwearofbrakedisc.................................................................................................................30-53
Bleedingairfromwheelbrakecircuit.................................................................................................30-54
Releasingresidualpressureinbrakeaccumulatorcircuit.................................................................30-55
Testingparkingbrakeperformance...................................................................................................30-56
Testingandadjustingparkingbrakecontrolcable............................................................................30-57
Hydraulicsystem...................................................................................................................................30-58
Testinghydraulicfan.........................................................................................................................30-58
Testingandadjustingworkequipmenthydraulicpressure................................................................30-60
TestingworkequipmentPPCoilpressure........................................................................................30-62
Bleedingairfromhydrauliccircuit......................................................................................................30-64
Releasingremainingpressureinhydrauliccircuit.............................................................................30-65
Workequipment....................................................................................................................................30-66
Testingandadjustingbucketpositioner............................................................................................30-66
Testingandadjustingboomkick-outswitch......................................................................................30-68
Checkingproximityswitchoperationpilotlamp.................................................................................30-69
Cabanditsattachments.......................................................................................................................30-70
Checkingoperatingforceofacceleratorpedal..................................................................................30-70
Checkingdirectionallever.................................................................................................................30-71
Measuringworkequipmentcontrollever...........................................................................................30-72
Electricalsystem...................................................................................................................................30-73
Procedurefortestingdiodes.............................................................................................................30-73
Preparationworkfortroubleshootingforelectricsystem..................................................................30-75
StartingKOMTRAXterminaloperations............................................................................................30-79
IndicatorlampsofKOMTRAXterminal.............................................................................................30-86
Adjustingmachinemonitor................................................................................................................30-92
Adjustingreplaced,reassembledoraddedsensor,controller,etc.withmachinemonitor................30-93
Specialfunctionsofmachinemonitor(EMMS).................................................................................30-95
Pmclinic..............................................................................................................................................30-146
Pmclinicinspectionchart................................................................................................................30-146
40Troubleshooting
Relatedinformationontroubleshooting..................................................................................................40-7
Pointstorememberwhenperformingtroubleshooting........................................................................40-7
Howtoproceedintroubleshooting......................................................................................................40-9
Testingbeforetroubleshooting..........................................................................................................40-11
Classificationandproceduresoftroubleshooting..............................................................................40-12
PhenomenalookingliketroublesandtroubleshootingNos..............................................................40-16
Informationintroubleshootingtable..................................................................................................40-18
Troubleshootingmethodforopencircuitinwiringharnessofpressuresensorsystem....................40-20
Connectiontableforconnectorpinnumbers.....................................................................................40-23
T-branchboxandT-branchadaptertable.......................................................................................40-59 Fuselocation.....................................................................................................................................40-63
Failurecodestable............................................................................................................................40-67
Troubleshootingbyfailurecode(Displayofcode)................................................................................40-74
Failurecode[2G40ZG]Brake:Lowoilpressure..............................................................................40-74
Failurecode[6091NX]HSTfilter:Clogging.....................................................................................40-76
Failurecode[989FN1]Travelspeed:Overrunalarm.......................................................................40-78
Failurecode[AB00L6]AlternatorRsystem:Hotshort.....................................................................40-80
Failurecode[AB00MA]AlternatorRsystem:Groundfault/Opencircuit/Lowchargelevel..........40-82
Failurecode[B@BAZG]Engine:Lowoilpressure..........................................................................40-84
Failurecode[B@BCNS]Engine:Overheat......................................................................................40-85
Failurecode[B@BCZK]Engine:Lowcoolantlevel.........................................................................40-86
Failurecode[B@C6NS]Frontbrake:Oiltemperatureoverheat......................................................40-88
Failurecode[B@CRNS]HST:Oiltemperatureoverheat................................................................40-89
Failurecode[CA111]Enginecontroller:Internalfailure...................................................................40-90
Failurecode[CA115]EngineNeandBkupspeedsensor:Error.....................................................40-91
Failurecode[CA122]Chargeairpressuresensor:Higherror.........................................................40-92
Failurecode[CA123]Chargeairpressuresensor:Lowerror..........................................................40-94
Failurecode[CA131]Throttlesensor:Higherror.............................................................................40-96
Failurecode[CA132]Throttlesensor:Lowerror.............................................................................40-98
Failurecode[CA144]Coolanttemperaturesensor:Higherror......................................................40-100
Failurecode[CA145]Coolanttemperaturesensor:Lowerror.......................................................40-102
Failurecode[CA153]Chargeairtemperaturesensor:Higherror..................................................40-104
Failurecode[CA154]Chargeairtemperaturesensor:Lowerror..................................................40-106
Failurecode[CA155]Chargeairtemperature:Highspeedderate................................................40-108
Failurecode[CA187]Sensorpowersupply2voltage:Lowerror..................................................40-110
Failurecode[CA221]Ambientpressuresensor:Higherror...........................................................40-112
Failurecode[CA222]Ambientpressuresensor:Lowerror...........................................................40-114
Failurecode[CA227]Sensorpowersupply2voltage:Higherror.................................................40-116
Failurecode[CA234]Engine:Overspeed......................................................................................40-116
WA200-600-5
Failurecode[CA238]NeSpeedsensor:Powersupplyvoltageerror............................................40-117 Failurecode[CA271]IMV(IMA):Shortcircuit.................................................................................40-118 Failurecode[CA272]IMV(IMA):Opencircuit................................................................................40-120
Failurecode[CA322]Injector#1system:Open/Shortcircuit.........................................................40-122 Failurecode[CA324]Injector#3system:Open/Shortcircuit.........................................................40-124 Failurecode[CA331]Injector#2system:Open/Shortcircuit.........................................................40-126 Failurecode[CA332]Injector#4system:Open/Shortcircuit.........................................................40-128 Failurecode[CA342]Enginecontroller:Datamismatching...........................................................40-130 Failurecode[CA351]InjectorsDriveCircuit:Error.........................................................................40-131 Failurecode[CA352]Sensorpowersupply1voltage:Lowerror..................................................40-132 Failurecode[CA386]Sensorpowersupplyvoltage1:Higherror..................................................40-134 Failurecode[CA428]Water-in-fuelsensor:Higherror..................................................................40-136 Failurecode[CA429]Water-in-fuelsensor:Lowerror...................................................................40-138 Failurecode[CA431]Idlevalidationswitch:Error..........................................................................40-140 Failurecode[CA432]Idlevalidationswitch:Actionerror...............................................................40-143 Failurecode[CA435]Engineoilpressureswitch:Error.................................................................40-146 Failurecode[CA441]Powersupplyvoltage:Lowerror.................................................................40-148 Failurecode[CA442]Powersupplyvoltage:Higherror.................................................................40-151 Failurecode[CA449]Commonrailpressure:Higherror2............................................................40-152 Failurecode[CA451]Commonrailpressuresensor:Higherror....................................................40-154 Failurecode[CA452]Commonrailpressuresensor:Lowerror....................................................40-156 Failurecode[CA488]Chargetemperature:Hightorquederate.....................................................40-158 Failurecode[CA553]Commonrailpressure:Higherror...............................................................40-159 Failurecode[CA559]SupplyPump:Lowrailpressure1...............................................................40-160 Failurecode[CA689]EngineNespeedsensor:Error...................................................................40-162 Failurecode[CA731]EngineBkupspeedsensor:Phaseerror.....................................................40-164 Failurecode[CA757]Enginecontroller:Lostofalldata................................................................40-165 Failurecode[CA778]EngineBkupspeedsensor:Error................................................................40-166 Failurecode[CA1633]KOMNET:Error.........................................................................................40-169 Failurecode[CA2185]Throttlesensorpowersupplyvoltage:Higherror......................................40-170 Failurecode[CA2186]Throttlesensorpowersupplyvoltage:Lowerror.......................................40-172 Failurecode[CA2249]Supplypump:Lowrailpressure2.............................................................40-174 Failurecode[CA2311]IMV(IMA)Solenoid:Error..........................................................................40-175 Failurecode[CA2555]Intakeheaterrelay:Opencircuit................................................................40-176 Failurecode[CA2556]Intakeheaterrelay:Shortcircuit................................................................40-179 Failurecode[D160KY]Backupalarm/lamprelay1circuit:Hotshort..............................................40-182 Failurecode[D1B0KA]HSTsafetyrelay:Disconnection................................................................40-184 Failurecode[D1B0KB]HSTsafetyrelay:Groundfault...................................................................40-186 Failurecode[D1B0KY]HSTsafetyrelay:Hotshort........................................................................40-188 Failurecode[D5ZHL6]IGNCsystem:Groundfault/Disconnection...............................................40-190 Failurecode[DAF3KK]UNSWpowersupply:Groundfault/Disconnection...................................40-194 Failurecode[DAFRKR]MachinemonitorCAN-NETSignal:Disconnection...................................40-197 Failurecode[DAJ0KK]HSTcontrollerpowersupply:Lowvoltage.................................................40-198 Failurecode[DAJ0KT]HSTcontrollermemory(EEPROM):Abnormality......................................40-201
Failurecode[DAJ1L4]HSTcontrollermainpowersupplyline:Disconnection/Groundfault..........40-202
Failurecode[DAJ1L6]HSTcontrollermainpowersupplyline:Hotshort.......................................40-205
Failurecode[DAJ2KK]Controllersolenoidpowersupply:Lowvoltage..........................................40-208
Failurecode[DAJ2L3]HSTcontrollerloadpowersupplyholdingline:Hotshort................................40-211
Failurecode[DAJ2L4]HSTcontrollerloadpowersupplyholdingline:Disconnection/Groundfault ..................................................................................................................................................40-214
Failurecode[DAJ5KX]Sensor5Vpowersupply:Outofinputrange.............................................40-217
Failurecode[DAJ9KQ]HSTcontroller:Disagreementinmodelselection.....................................40-219
Failurecode[DAJRKR]HSTcontrollerCAN-NETsignal:Disconnection.......................................40-220
Failurecode[DAJRMA]HSTcontroller:Disagreementinoptionselection.....................................40-227
Failurecode[DB2RKR]EnginecontrollerCAN-NETsignal:Disconnection...................................40-228
Failurecode[DD1NL4]FanAutoReverseSwitchSignal:Abnormality.........................................40-234
00-6WA200-6
Failurecode[DD1NLD]FanReverseSwitchSignal:Abnormal......................................................40-237
Failurecode[DDB6KA]Parkingbrakeremindersignal:Disconnection/Hotshort..........................40-240
Failurecode[DDB6KB]Parkingbrakeindicatorsignal:Groundfault.............................................40-244
Failurecode[DDB6KZ]Parkingbrakeindicatorsignalorparkingbrakeremindersignal:Failure.40-247
Failurecode[DDB6L0]Parkingbrakeremindersignal:Groundfault.............................................40-250
Failurecode[DDB6L4]Parkingbrakeindicatorsignal:Disconnection/Hotshort............................40-253
Failurecode[DDD7KX]Travelspeedcontroldialsignal:Disconnection/Groundfault...................40-258
Failurecode[DDD7KY]Travelspeedcontroldialsignal:Hotshort................................................40-260
Failurecode[DDE5MA]Emergencysteeringoperationswitch:Disconnection..............................40-262
Failurecode[DDK6KA]FNRlever:Disconnection/Groundfault.....................................................40-264
Failurecode[DDK6KY]FNRlever:Hotshort.................................................................................40-268
Failurecode[DDS5L6]Steering:Lowoilpressure(Operationofemergencysteering)..................40-270
Failurecode[DF10KA]Travelspeedrangeselectorswitch:Disconnection/Groundfault..............40-272
Failurecode[DF10KB]Travelspeedrangeselectorswitch:Hotshort...........................................40-277
Failurecode[DGH1KX]HSToiltemperaturesensor:Groundfault................................................40-282
Failurecode[DGR2KB]Brakeoiltemperaturesensor:Groundfault..............................................40-284
Failurecode[DGR2KZ]Brakeoiltemperaturesensor:Disconnection/Hotshort...........................40-286
Failurecode[DHH1KX]HSToilpressuresensor:Disconnection/Groundfault..............................40-288
Failurecode[DHH1KY]HSToilpressuresensor:Hotshort...........................................................40-290
Failurecode[DHTCL6]HSTfiltercloggingsensor:Functionaldefect............................................40-292
Failurecode[DJF1KA]Fuellevelsensor:Disconnection/Hotshort................................................40-294 Failurecode[DLT3KX]TravelspeedsensorB:Abnormality..........................................................40-296 Failurecode[DLT4KX]TravelspeedsensorA:Abnormality..........................................................40-302 Failurecode[DLT4LC]TravelspeedsensorA&B:Abnormality...................................................40-304 Failurecode[DV00KY]Alarmbuzzer:Hotshort.............................................................................40-306 Failurecode[DW26KA]Motor2solenoid:Disconnection/Groundfault..........................................40-308 Failurecode[DW26KY]Motor2solenoid:Hotshort.......................................................................40-310 Failurecode[DW7BKY]Fanreversesolenoidcircuit:Hotshort.....................................................40-312 Failurecode[DW7BKZ]Fanreversesolenoidcircuit:Disconnection/Groundfault........................40-314 Failurecode[DX16KA]FanEPCsolenoid:Disconnection.............................................................40-316 Failurecode[DX16KB]FanEPCsolenoid:Groundfault................................................................40-317 Failurecode[DX16KY]FanEPCsolenoid:Hotshort.....................................................................40-318 Failurecode[DX19KA]Motor1solenoid:Disconnection................................................................40-320 Failurecode[DX19KB]Motor1solenoid:Groundfault..................................................................40-322 Failurecode[DX19KY]Motor1solenoid:Hotshort........................................................................40-324 Failurecode[DX20KA]ClutchEPCsolenoid:Disconnection.........................................................40-326 Failurecode[DX20KB]ClutchEPCsolenoid:Groundfault............................................................40-328 Failurecode[DX20KY]ClutchEPCsolenoid:Hotshort.................................................................40-330 Failurecode[DXH7KB]Reversesolenoid:Groundfault................................................................40-332 Failurecode[DXH7KZ]Reversesolenoid:Disconnection/Hotshort..............................................40-334 Failurecode[DXH8KB]Forwardsolenoid:Groundfault................................................................40-336 Failurecode[DXH8KZ]Forwardsolenoid:Disconnection/Hotshort...............................................40-338
Failurecode[J141N1]Steeringpump:Overrunalarm....................................................................40-340
Failurecode[M100N1]HSTpump:Overrunalarm.........................................................................40-340
Failurecode[M400N1]Motor1:Overrunalarm..............................................................................40-341
Troubleshootingofelectricalsystem(E-mode)...................................................................................40-342
E-1Enginedoesnotstart................................................................................................................40-342
E-2Preheaterdoesnotoperatenormally.......................................................................................40-350
E-3WhenstartingswitchisturnedtoONposition,nothingisdisplayedonmachinemonitor........40-355
E-4Travelspeedisnotdisplayedcorrectly.....................................................................................40-359
E-5Travelspeedisloworhigh.......................................................................................................40-360
E-6Boomkick-outdoesnotworkorisnotreset.............................................................................40-363
E-7Bucketpositionerdoesnotworkorisnotreset........................................................................40-367
E-8BoomFLOATholdingdoesnotworkorisnotreset.................................................................40-371
E-9Directionalselectiondoesnotworknormally............................................................................40-377
E-10Wipersdonotoperate............................................................................................................40-382
E-11Windowwasherdoesnotoperate...........................................................................................40-388
E-12Headlamp,clearancelamp,taillamporlicense-platelampdoesnotlightupordoesnotgoout ..................................................................................................................................................40-392
E-13Workinglampdoesnotlightupordoesnotgoout.................................................................40-402
E-14Turnsignalandhazardlampdonotlightupordonotgoout.................................................40-408
E-15Stoplampdoesnotlightuporremainslightingup.................................................................40-418
E-16Backuplampdoesnotlightoritkeepslightingup..................................................................40-421
E-17Backupalarmdoesnotsoundordoesnotstopsounding......................................................40-424
E-18Horndoesnotsoundordoesnotstopsounding....................................................................40-426
E-19Alarmbuzzerdoesnotsoundordoesnotstopsounding.......................................................40-428
E-20Troubleshootingofairconditioner...........................................................................................40-430
E-21KOMTRAXsystemdoesnotoperatenormally.......................................................................40-452
Troubleshootingofhydraulicandmechanicalsystem(H-mode)........................................................40-456
Methodofusingtroubleshootingchart............................................................................................40-456
Failurecodeandcausetable..........................................................................................................40-458
H-1Themachinedoesnotstart......................................................................................................40-460
H-2Thetravelspeedisslow...........................................................................................................40-461
H-3Thetractionforceisweak.........................................................................................................40-462
H-4Enginestallswhentravelingorenginespeeddropsexcessively.............................................40-463
H-5Speedrangeisnotshifted........................................................................................................40-464
H-6Thesteeringwheeldoesnotturn.............................................................................................40-465
H-7Thesteeringwheelisheavy.....................................................................................................40-466
H-8Steeringwheelshakesorjerks.................................................................................................40-467
H-9Machinedeviatesnaturallytoonesidewhentraveling............................................................40-467
H-10Thebrakedoesnotworkordoesnotworkwell.....................................................................40-468
H-11Thebrakeisnotreleasedorisdragged.................................................................................40-469
H-12Theboomdoesnotriseorlower............................................................................................40-470
H-13Theboommovesslowlyortheliftarmrisingforceisinsufficient...........................................40-471
H-14Whenrising,theboomcomestomoveslowlyatspecificheight............................................40-472
H-15Theliftcylindercannotholddownthebucket(Thebucketrisesintheair)............................40-472
H-16Hydraulicdriftsoftheboomarelarge.....................................................................................40-472 H-17Theboomwobblesduringoperation......................................................................................40-472 H-18Whenthecontrolleverisswitchedfrom“HOLD”to“RAISE,”theboomfallstemporarily......40-473 H-19Thebucketdoesnottiltback..................................................................................................40-474 H-20Thebucketmovesslowlyorthetilting-backforceisinsufficient.............................................40-475 H-21Thebucketcomestooperateslowlyinthemidstoftilting-back.............................................40-476
H-22Thebucketcylindercannotholddownthebucket..................................................................40-476
H-23Hydraulicdriftsofthebucketoccuroften................................................................................40-476
H-24Thebucketwobblesduringtravelwithload(Theworkequipmentvalveissetto“HOLD”)....40-476
H-25Whenthecontrolleverisswitchedfrom“HOLD”to“TILT,”thebucketfallstemporarily........40-477
H-26Thecontrolleversoftheboomandbucketdonotmovesmoothlyandheavy.......................40-477
H-27Fanrevolutionisabnormal(Fansound/vibrationisabnormallylargeorengineoverheats)..40-478
Troubleshootingofengine(S-mode)...................................................................................................40-479
Methodofusingtroubleshootingcharts...........................................................................................40-479
S-1Startingperformanceispoor.....................................................................................................40-482
S-2Enginedoesnotstart................................................................................................................40-483
S-3Enginedoesnotpickupsmoothly............................................................................................40-486
S-4Enginestopsduringoperations................................................................................................40-487
S-5Enginedoesnotrotatesmoothly..............................................................................................40-488
S-6Enginelacksoutput(orlackspower)........................................................................................40-489
S-7Exhaustsmokeisblack(incompletecombustion)....................................................................40-490
S-8Oilconsumptionisexcessive(orexhaustsmokeisblue).........................................................40-491
S-9Oilbecomescontaminatedquickly...........................................................................................40-492
S-10Fuelconsumptionisexcessive...............................................................................................40-493
S-11Oilisincoolant(orcoolantspurtsbackorcoolantlevelgoesdown).....................................40-494
S-12Oilpressuredrops...................................................................................................................40-495
S-13Oillevelrises(Entryofcoolantorfuel)...................................................................................40-496
S-14Coolanttemperaturebecomestoohigh(overheating)...........................................................40-497
S-15Abnormalnoiseismade.........................................................................................................40-498
S-16Vibrationisexcessive.............................................................................................................40-499
50Disassemblyandassembly
Generalinformationondisassemblyandassembly...............................................................................50-3
Howtoreadthismanual......................................................................................................................50-3
Coatingmaterialslist...........................................................................................................................50-5
Specialtoollist....................................................................................................................................50-9
Sketchesofspecialtools...................................................................................................................50-13
Engineandcoolingsystem...................................................................................................................50-22
Removalandinstallationoffuelsupplypumpassembly...................................................................50-22
Removalandinstallationoffuelinjectorassembly............................................................................50-26
Removalandinstallationofcylinderheadassembly.........................................................................50-34
Removalandinstallationenginehoodassembly..............................................................................50-48
Removalandinstallationofradiator..................................................................................................50-52
Removalandinstallationofairaftercooler........................................................................................50-55
Removalandinstallationofhydraulicoilcoolerassembly................................................................50-57
Removalandinstallationofengineassembly...................................................................................50-59
Removalandinstallationofenginefrontoilsealassembly...............................................................50-66
Removalandinstallationofenginerearoilsealassembly................................................................50-70
Removalandinstallationofcoolingfanandfanmotorassembly.....................................................50-73
Removalandinstallationoffueltankassembly................................................................................50-76
Powertrain............................................................................................................................................50-78
Removalandinstallationoftransferassembly..................................................................................50-78
Disassemblyandassemblyoftransferassembly.............................................................................50-82
Removalandinstallationofparkingbrakeassembly......................................................................50-101
Disassemblyandassemblyofparkingbrakeassembly..................................................................50-103
Removalandinstallationoffrontaxleassembly.............................................................................50-108
Removalandinstallationofrearaxleassembly..............................................................................50-110
Disassemblyandassemblyofaxlehousingassembly...................................................................50-113
Disassemblyandassemblyofdifferentialassembly.......................................................................50-121
Undercarriageandframe....................................................................................................................50-148
Removalandinstallationofcenterhingepin...................................................................................50-148
Removalandinstallationofcounterweightassembly......................................................................50-157
Hydraulicsystem.................................................................................................................................50-159
RemovalandinstallationofHSTpumpandquadruplegearpumpassembly.................................50-159
RemovalandinstallationofHSTmotor1assembly........................................................................50-163
RemovalandinstallationofHSTmotor2assembly........................................................................50-165
Removalandinstallationofworkequipmentcontrolvalveassembly.............................................50-167
Removalandinstallationofhydraulictank......................................................................................50-169
Disassemblyandassemblyofhydrauliccylinderassembly............................................................50-171
Workequipment..................................................................................................................................50-175
Removalandinstallationofworkequipmentassembly...................................................................50-175
Cabanditsattachments.....................................................................................................................50-182
Removalandinstallationofoperator'scabandfloorframeassembly............................................50-182
Removalandinstallationofoperator'scabglass(Stuckglass)......................................................50-187
Removalandinstallationofoperator'sseatassembly....................................................................50-195
Removalandinstallationofairconditionerunit...............................................................................50-196
Electricalsystem.................................................................................................................................50-201
Removalandinstallationofmonitorpanel......................................................................................50-201
Removalandinstallationofenginecontrollerassembly.................................................................50-203
RemovalandinstallationofHSTcontrollerassembly.....................................................................50-205
RemovalandinstallationofKOMTRAXterminal(ORBCOMM)assembly......................................50-206
RemovalandinstallationofKOMTRAXterminal(GPRS)assembly...............................................50-207
90Diagramsanddrawings
Hydraulicdiagramsanddrawings...........................................................................................................90-3
Symbolsusedinhydrauliccircuitdiagrams.........................................................................................90-3
Hydrauliccircuitdiagram.....................................................................................................................90-5
Electricaldiagramsanddrawings...........................................................................................................90-7
Symbolsusedinelectriccircuitdiagrams............................................................................................90-7
Electricalcircuitdiagram..................................................................................................................90-11
ElectricalcircuitdiagramforCIS.....................................................................................................90-27
ElectricalcircuitdiagramofengineandHST...................................................................................90-37
Connectorlistandstereogram........................................................................................................90-39
Connectorlistandstereogram(CISspecification)..........................................................................90-41
Index...........................................................................................................................................................1
1.Winduptheropeslowlyuntilthewirerope tensions.Whenputtingyourhandsonthe wireropes,donotgraspthembutpressthem downfromabove.Ifyougraspthem,your fingersmaybecaught.