CEBM004402
Shop Manual
WA700-3L WHEEL LOADER
SERIAL NUMBERS
WA700-3L
A50001
and UP
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
November 2002 2
WA900-3LC
Copyright 2002 Komatsu DataKom Publishing Division
FOREWORD
CONTENTS
12 00
CONTENTS
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
WA700-3L
PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages. The Publications listed below are available for this particular machine(s). DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB006400 OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM004401 SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM004402 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEBES6161000 SAFETY MANUAL Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WTL70-1
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS) or the Extranet Literature Ordering System. If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.
700-3L pubinfokrev2.fm
11/8/02
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO
DataKom Publishing Division 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME PURCHASE ORDER NO.
SHIP TO ATTN.
TYPE or PRINT ONLY
STREET ADDRESS
ORDER DATE
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY.
PUBLICATION FORM NO.
➥
PARTS BOOK P-Paper M-Microfiche
KDC91E 040202
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
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WA700-3L
FOREWORD
SAFETY
12 00
00
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 00
GENERAL PRECAUTIONS
00
PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4.
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
• •
3.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.
When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.
5.
6.
Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
WA700-3L
00
PRECAUTIONS DURING WORK
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
00-3
FOREWORD
SAFETY
12 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
9. •
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-4
WA700-3L
FOREWORD
GENERAL
12 00
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
WA700-3L
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12 00
00
HOW TO READ THE SHOP MANUAL VOLUMES
00
REVISIONS
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Chassis volume: Engine volume:
00
Issued for every machine model Issued for each engine series
Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available. 00
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Symbol
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example:
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
10 - 3
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. 00
SYMBOLS
FILING METHOD
1. 2.
★
Item number (10. Structure and Function) Consecutive page number for each item 3.
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
10-4 10-4-1 10-4-2
Added pages
10-5 00
REVISED EDITION MARK
When a manual is revised, an edition mark (123‌) is recorded on the bottom outside corner of the pages.
00-6
WA700-3L
FOREWORD
HOISTING INSTRUCTIONS
12 00
00
HOISTING INSTRUCTIONS HOISTING
can result. Hooks have maximum strength at the middle portion.
WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
• 1. 2.
00
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
3.
WARNING! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident
WIRE ROPES
1.
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°
★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident
WA700-3L
00-7
FOREWORD
COATING MATERIALS
12 00
COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below. Category
Code LT-1A
Adhesives
LT-1B
790-129-9030
790-129-9050
Quantity
Container
150 g
Tube
20 g (2 pes.)
Polyethylene container
50 g
Polyethylene container
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-2
09940-00030
LT-3
790-129-9060 (Set of adhesive and hardening agent)
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
2g
Polyethylene container
Three bond 1735
Gasket sealant
Part No.
179-129-9140
Aronalpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-3
790-129-9070
50 g
1 kg
Polyethylene container
Main applications, features •
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and nonmetal.
•
• •
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
•
Used as adhesive or sealant for metal, glass or plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals.
• • •
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
• •
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
Can •
00-8
WA700-3L
FOREWORD Category
Code
LG-4
COATING MATERIALS Part No.
790-129-9020
Quantity
200 g
Container
Tube
Main applications, features • • • • •
LG-5
790-129-9080
1 kg
Polyethylene container
Gasket sealant
• •
LG-6
09940-00011
250 g
Tube
• •
Molybdenum disulphide lubricant
• 09920-00150
150 g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2160CNCA
Various
Various
400 g (10 per case)
Belows type
Molybdenum disulphide lubricant
Grease
LG-7
00-9
SYG2-400M
•
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
•
Used as heat-resisting sealant for repairing engines.
•
Used as lubricant for sliding parts (to prevent squeaking).
• •
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load.
WA700-3L
FOREWORD
STANDARD TIGHTENING TORQUE
12 00
00
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6
10
13.2 ±1.4
1.35 ±0.15
8
13
31.4 ±2.9
3.20 ±0.3
10
17
65.7 ±6.8
6.70 ±0.7
12
19
112 ±9.8
11.5 ±1.0
14
22
177 ±19
18 ±2.0
16
24
279 ±29
28.5 ±3
18
27
383 ±39
39 ±4
20
30
549 ±58
56 ±6
22
32
745 ±78
76 ±8
24
36
927 ±98
94.5 ±10
27
41
1320 ±140
135 ±15
30
46
1720 ±190
175 ±20
33
50
2210 ±240
225 ±25
36
55
2750 ±290
280 ±30
39
60
3280 ±340
335 ±35
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6
10
7.85 ± 1.95
0.8 ± 0.2
8
13
18.6 ± 4.9
1.9 ± 0.5
10
14
40.2 ± 5.9
4.1 ± 0.6
12
27
82.35 ± 7.85
8.4 ± 0.8
00-10
WA700-3L
FOREWORD 12 TIGHTENING 00
STANDARD TIGHTENING TORQUE
TORQUE OF HOSE NUTS
Use these torques for hose nuts. Thread diameter
Width across flat
mm
mm
Nm
kgm
02
14
19
24.5 ± 4.9
2.5 ± 0.5
03
18
24
49 ± 19.6
5±2
04
22
27
78.5 ± 19.6
8±2
05
24
32
137.3 ± 29.4
14 ± 3
06
30
36
176.5 ± 29.4
18 ± 3
10
33
41
196.1 ± 49
20 ± 5
12
36
46
245.2 ± 49
25 ± 5
14
42
55
294.2 ± 49
30 ± 5
Nominal No.
00
Tightening torque
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
00
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
14
65.7 ± 6.8
6.7 ± 0.7
12
17
112 ± 9.8
11.5 ± 1
16
22
279 ± 29
28.5 ± 3
TIGHTENING TORQUE FOR FLARED NUTS
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
Nm
kgm
14
19
24.5 ±4.9
2.5 ±0.5
18
24
49 ±19.6
5 ±2
22
27
78.5 ±19.6
8 ±2
24
32
137.3 ±29.4
14 ±3
30
36
176.5 ±29.4
18 ±3
33
41
196.1 ±49
20 ±5
36
46
245.2 ±49
25 ±5
42
55
294.2 ±49
30 ±5
00-11
Tightening torque
WA700-3L
FOREWORD
ELECTRIC WIRE CODE
12 00
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. 00
CLASSIFICATION BY THICKNESS Copper wire Nominal numNumber of Dia. Of strand Cross section ber strands (mm) (mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
2
26
0.32
2.09
3.1
20
Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
CLASSIFICATION BY COLOR AND CODE Priority
1
Circuits Classification Primary
00
Cable O.D. (mm)
2
4
5
6
00-12
Auxiliary
3
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
Black & White
Red & White
Yellow & Red
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Yellow & Black
Green & Red
Blue & Red
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
Black & YelRed & Black low
WA700-3L
FOREWORD
CONVERSION TABLES
12 00
00
CONVERSION TABLES METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1. B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2. C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2.
Convert 550 mm into inches. A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. B. Carry out the same procedure as above to convert 55 mm to 2.165 inches. C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. 2
Millimeters to inches
1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
3 1
00-13
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
WA700-3L
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
00-14
1 kg = 2.2046 lb 0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
WA700-3L
FOREWORD
CONVERSION TABLES
12
Liter to U.S. Gallon
1 L = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
00-15
1 L = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
WA700-3L
FOREWORD
CONVERSION TABLES
12
kgm to ft. lb.
00-16
1 kgm = 7.233 ft. lb. 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.63 1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1439.4
1432.1
WA700-3L
FOREWORD
CONVERSION TABLES
12
kg/cm2 to lb/in2
00-17
1 kg/cm2 = 14.2233lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
WA700-3L
FOREWORD
CONVERSION TABLES
12 Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C °F °C °F °C °F °C °F -40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8 -37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6 -34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4 -31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2 -28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0 -28.3 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-18
WA700-3L
01
GENERAL
GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 3 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LIST OF LUBRICANT AND WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WA700-3L
01-1
GENERAL
GENERAL ASSEMBLY DRAWING
12
GENERAL ASSEMBLY DRAWING Unit: mm
01-2
WA700-3L
GENERAL
SPECIFICATIONS
12
SPECIFICATIONS
Weight
Machine model
WA700-3L
Serial No.
A50001 and up
Operating weight
kg
70,800
Distribution (front)
kg
38,100
Distribution (rear)
kg
32,700
Bucket capacity (piled)
m3
8.7
kN {lbf}
153 {34395.8}
FORWARD 1st
km/h
6.4
FORWARD 2nd
km/h
11.1
FORWARD 3rd
km/h
18.7
FORWARD 4th
km/h
30.0
REVERSE 1st
km/h
7.1
REVERSE 2nd
km/h
12.3
REVERSE 3rd
km/h
20.5
REVERSE 4th
km/h
32.2
kN {lbf}
470.7{105818}
deg
25
Center of outside wheel
mm
8,095
Outside portion of chassis (with tooth)
mm
9,615
Overall length (with tooth)
mm
12,500
Overall width (chassis)
mm
4,040
cutting edge
mm
4,330
tire guard
mm
4,570
top of ROPS canopy
mm
4,790
bucket raised
mm
8,165
Wheel base
mm
4,800
Tread
mm
3,000
Min. ground clearance
mm
540
Height of bucket hinge pin
mm
5,990
Dumping clearance (tip of edge)
mm
4,380
Dumping reach (tip of edge)
mm
1.910
Bucket dump angle
deg
61.5
Rated load
Performance
Travel speed
Max. rimpull
FORWARD
Gradeability Min. turning radius
Bucket width
Dimensions
Overall height
01-3
WA700-3L
GENERAL
SPECIFICATIONS
Cont.
Machine model
WA700-3L
Serial No.
A50001 and up
Bucket tilt angle (travel poster)
deg
50
Digging depth (10° dump) (with tooth)
mm
410
Model
SAA6D170E 4-cycle, water-cooled, in-line 6-cylinder, direct injection, with 2-turbocharger, after-cooler
Type
No. of cylinders - bore x stroke
mm
6 - 170 x 170
Liter [cc]
23.15 [23,150]
Flywheel horsepower
kW/rpm [HP/rpm]
478/2,000 [641/2,000]
Maximum torque
Nm/rpm [kgm/rpm]
2,810/1,400 [286.5/1,400]
g/kW•h
207
High idling speed
rpm
2,240
Low idling speed
rpm
650
Performance
Engine
Piston displacement
Fuel consumption ratio
Starting motor
24 V 7.5 kW x 2
Alternator
24 V 75 A
Battery
12 V 200 Ah x 2
Torque converter
3-element, 1-stage, single-phase Planetary gear, constant-mesh multiple-disc, hydraulically actuated, pressure lubrication, modulation type
Axle, wheel
Power train
Transmission
Differential
Straight bevel gear
Final drive
Planetary gear single stage, splash lubrication
Drive type
Front / rear wheel drive
Front axle
Fixed frame, full floating
Rear axle
Center pin support type, full floating
Tire
45/65-39-36PR(L-5)
Wheel rim Inflation pressure
01-4
Spiral bevel gear, splash lubrication
Reduction gear
32.00 x 39-4WTB Front tire
kPa [kg/cm2]
441 [4.5]
Rear tire
kPa [kg/cm2]
441 [4.5]
WA700-3L
GENERAL Machine model
SPECIFICATIONS WA700-3L
Serial No.
Parking brake
Drive shaft, dry caliper type disc brake, hydraulically released spring type
Brakes
Main brake
Front/rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated
Hydraulic system
Hydraulic pump delivery
Control valve set pressure
Work equipment
Cylinder
01-5
A50001 and up
Link type bucket edge type
Torque converter, transmission pump
Liter / m
317 [Gear type: SAR(4)160]
Steering pump
Liter / m
203 (Fixed capacity piston pump: HP90)
Switch pump
Liter / m
203 (Fixed capacity piston pump: HP90)
PPC pump
Liter / m
43 [Gear type: SAR(1)20]
Cooling pump
Liter / m
55 [Gear type: SAR(1)28]
Work equipment pump
Liter / m
405 (Variable capacity piston pump: HPV90 + Fixed capacity piston pump: HPF90)
Transmission valve
MPa [kg/cm2]
2.9 [30] (Spool type, electric control)
Steering demand valve
MPa [kg/cm2]
31.4 [320] (Fully hydraulic type)
PPC valve
MPa [kg/cm2]
3.7 [38] (2-lever type)
Main control valve
MPa [kg/cm2]
31.4 [320] (2-spool type)
Steering cylinder No. - bore x stroke
mm
Reciprocating piston 2 - 130 x 532
Boom cylinder No. - bore x stroke
mm
Reciprocating piston 2 - 225 x 1,196
Bucket cylinder No. - bore x stroke
mm
Reciprocating piston 1 - 280 x 729 Single Z bar link Spade nose with teeth
WA700-3L
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE WARNING! This weight table is a guide for use when transporting or handling components. Unit: kg/lb Machine model
WA700-3L
Serial number
A50001 and up
Engine (dry)
2900 / 6393
Radiator (dry)
644 / 1420
Torque converter (dry)
574 / 1265
Transmission (dry)
1720 / 3792
Damper
170 / 375
Upper drive shaft
52 / 128
Center drive shaft
90 / 198
Front drive shaft
112 / 247
Rear drive shaft
83 / 183
Center support
67 / 148
Front axle
5532 / 14822
Rear axle
5454 / 14613
Front differential
826 / 1821
Rear differential
854 / 1883
Planetary carrier assembly (each)
358 / 788
Planetary hub (each)
298 / 657
Axle support (Rear axle)
331 / 730
Wheel (each)
617 / 1361
Tire (each)
1870 / 4123
Steering demand valve
66 / 146
Steering cylinder (each)
159 / 351
Hydraulic tank (dry)
665 / 1466
Work equipment pump
150 / 331
Torque converter charging + cooling + PPC + brake pump Steering + Switch pump PPC valve
01-6
37 / 82 145 / 320 6 / 12
WA700-3L
GENERAL
Main control valve
WEIGHT TABLE Machine model
WA700-3L
Serial number
A50001 and up 95 / 210
Boom cylinder (each)
674 / 1486
Bucket cylinder
945 / 2083
Engine hood
Top 62 / 137 Side 50 / 111
Front frame
4960 / 10935
Rear frame
5761 / 12701
Bucket link (with bushing)
340 / 750
Bellcrank (with bushing)
1460 / 3219
Boom (with bushing)
5714 / 12597
Bucket (with teeth)
7090 / 15631
Counterweight
2510 / 5534
Fuel tank
568 / 1252
Battery (each)
64 / 141
Cab
449 / 989
Air conditioner unit
55 / 122
Operator’s seat
55 / 120
Floor board
348 / 767
Fender, ladder assembly
01-7
1354 / 2985
WA700-3L
GENERAL
LIST OF LUBRICANT AND WATER
12
LIST OF LUBRICANT AND WATER Ambient Temperature Reservoir
Kind of fluid
-22 -30
-4 -20
14 -10
32 0
50 10
68 20
Capacity 86 30
104 40
122°F 50°C
Specified
Refill
SAE 30 SAE 10W
Engine oil pan
63 L 16.6 gal
54 L 14.2 gal
38 L 10 gal
27 L 15 gal
120 L 31.7 gal
105 L 27.7 gal
SAE 10W
780 L 206 gal
490 L 129.4 gal
See Note 1
245 L 64.7 gal
245 L 64.7 gal
SAE 10W-30 SAE 15W-40
SAE 10W
Brake Engine oil Transmission case
SAE 10W SAE 10W
Hydraulic system
Axle (front & rear) (each)
Axle oil
Pins
Grease
Fuel tank
Diesel fuel
Cooling system
Coolant
NLGI No. 2
ASTM D975 No. 2
* Add Anti-freeze Coolant
---
---
1100 L 290.5 gal
---
200 L 52.8 gal
190 L 50.2 gal
* ASTM D975 No. 1
01-8
WA700-3L
GENERAL
LIST OF LUBRICANT AND WATER
Other equipment will be necessary, when operating the machine at temperatures below -20oC (-4oF), therefore consult your Komatsu distributor for your needs. Note 1:For axle oil, use only the recommended oil as follows. SHELL: DONAX TT or TD CALTEX:RPM TRACTOR HYDRAULIC FLUID CHEVRON:TRACTOR HYDRAULIC FLUID TEXACO:TDH OIL MOBIL: MOBIL 424 It is possible to substitute engine oil SAE 30 API classification CD for axle oil. Although increased brake noise may result, durability is not affected.
REMARKS •
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur content
Change interval of oil in engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
•
When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time.
•
Use API classification CD as engine oil and if API classification CC is used, reduce the engine oil change interval to half.
•
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table.
•
We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: SAE: API:
01-9
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
WA700-3L
GENERAL
LIST OF LUBRICANT AND WATER
12
MEMORANDUM
01-10
WA700-3L
10
STRUCTURE AND FUNCTION
POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 TORQUE CONVERTER AND TRANSMISSION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 OPERATION OF CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 FORWARD 4TH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 PILOT REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 MODULATING VALVE AND QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 QUICK FILL VALVE (FOR 2ND CLUTCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 LUBRICATING RELIEF VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 EMERGENCY MANUAL SPOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 LUBRICATION BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 HYDRAULIC CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47 FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47 REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 STEERING PIPING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 STEERING AND SWITCH PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 STEERING UNIT (ORBIT-ROLL VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 STEERING DEMAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57 OVERLOAD RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
WA700-3L
10-1 2
STRUCTURE AND FUNCTION
TABLE OF CONTENTS
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 OPERATION OF DEMAND VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 WHEN STEERING SPOOL IS OPERATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63 OPERATION OF STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65 TWO-WAY RESTRICTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68 STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69 DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70 GROUND DRIVEN STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 BRAKE CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75 BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 BRAKE VALVE (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 BRAKE VALVE (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77 CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 ACCUMULATOR (FOR BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86 SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91 PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92 SPRING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93 PARKING BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98 MAIN PISTON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101 PISTON PUMP (HPV90 + HPF90) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102 CONTROL PUMP (BAR025) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107 CONTROL PUMP RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 ES VALVE (ENGINE SENSING VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109 SERVO VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 PRESSURE DIFFERENTIAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 PPC VALVE (PROPORTIONAL PRESSURE VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116 ACCUMULATOR (FOR PPC VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117 MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120 WORK EQUIPMENT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120 WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122 BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124 BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125 BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125 PROXIMITY SWITCH - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126 BOOM RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126 BUCKET TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130 AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130 AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131 AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 DRY RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133 MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134 MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135 MAIN MONITOR DISPLAY FUNCTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136 MAIN MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138 TROUBLE DATA DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139 MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140 MAINTENANCE MONITOR DISPLAY FUNCTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
10-2 2
WA700-3L
STRUCTURE AND FUNCTION
TABLE OF CONTENTS
AUTOMATIC TRANSMISSION SYSTEM (ATM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143 SYSTEM STRUCTURE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157 JOYSTICK TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157 TRANSMISSION AND JOYSTICK CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161 ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161 ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163 AUTO PRIMING SYSTEM (APS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164 APS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165 APS ASSISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165 ELECTRICAL TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168 COMBINATION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170 KICK-DOWN, HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172 KICK-DOWN ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173 PARKING BRAKE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180 PARKING BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181 PARKING SAFETY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181 NEUTRALIZER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181 EMERGENCY BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (1 0F 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
WA700-3L
10-3 2
STRUCTURE AND FUNCTION
POWER TRAIN SYSTEM
12
POWER TRAIN SYSTEM
10-4 2
WA700-3L
STRUCTURE AND FUNCTION
POWER TRAIN SYSTEM
12
1. Engine 2. Damper 3. Upper drive shaft 4. Four tandem pump (T/C charging + cooling + PPC + brake pump) 5. Piston pump (Steering + Switch pump) 6. Piston pump (work equipment pump x 2) 7. Torque converter 8. Transmission 9. Transfer 10. Ground driven steering pump 11. Center drive shaft 12. Center support 13. Front drive shaft 14. Parking brake 15. Front axle 16. Front differential 17. Front brake 18. Front final drive 19. Front wheel 20. Rear drive shaft 21. Rear differential 22. Rear axle 23. Rear brake 24. Rear final drive 25. Rear wheel
WA700-3L
10-5 2
STRUCTURE AND FUNCTION
DAMPER
12
DAMPER
1. Shaft 2. Rubber cushion 3. Inner body 4. Outer body
OPERATION The motive force from the engine is transmitted from the flywheel to outer body (4), and the torsional vibration of the engine is absorbed by rubber cushion (2). The power then passes through inner body (3) to shaft (1), and is transmitted to the upper drive shaft.
10-6 2
WA700-3L
STRUCTURE AND FUNCTION
DAMPER
12
MEMORANDUM
WA700-3L
10-7 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
TORQUE CONVERTER AND TRANSMISSION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
10-8 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
1. Transmission case
18. Reducing valve
2. Strainer
19. Reverse spool
3. Torque converter charging pump
20. Forward spool
4. Oil filter (x 4)
21. 4th spool
5. Transmission main relief valve
22. 3rd spool
6. Torque converter relief valve
23. 2nd spool
7. Torque converter
24. 1st spool
8. Oil cooler
25. Ground driven manual spool
9. PTO case
26. Solenoid valve
10. Lubrication valve
27. Reverse clutch
11. Transmission lubrication
28. Forward clutch
12. Lubrication bypass valve
29. 4th clutch
13. Priority valve
30. 3rd clutch
14. Modulating valve
31. 2nd clutch
15. Quick return valve
32. 1st clutch
16. Pilot reducing valve
33. Quick fill valve
17. Pilot filter
34. PTO lubrication
WA700-3L
10-9 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 TRANSMISSION
HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case
12. Torque converter
23. 2nd spool
2. Strainer
13. Oil cooler
24. 1st spool
3. Torque converter charging pump
14. Lubrication valve
25. Ground driven manual spool
4. Oil filter (x4)
15. Transmission lubrication
26. Solenoid valve
5. Transmission main relief valve
16. Torque converter relief valve
27. Reverse clutch
6. Pilot filter
17. Lubrication bypass valve
28. Forward clutch
7. Pilot reducing valve
18. Reverse spool
29. 4th clutch
8. Priority valve
19. Forward spool
30. 3rd clutch
9. Modulating valve
20. 4th spool
31. 2nd clutch
10. Quick fill valve
21. 3rd spool
32. 1st clutch
11. Quick return valve
22. Reducing valve
10-10 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
TORQUE CONVERTER AND TRANSMISSION PIPING
1. Transfer 2. Transmission control valve 3. Torque converter 4. Torque converter oil cooler 5. Torque converter charging pump 6. Transmission 7. Torque converter oil filter 8. Transmission oil sight gauge
WA700-3L
10-11 2
STRUCTURE AND FUNCTION 12 TORQUE
TORQUE CONVERTER AND TRANSMISSION
CONVERTER AND PTO
SPECIFICATIONS Type: 3-element, single stage, single phase Stall torque ratio: 2.84
1. Torque converter outlet oil pressure pick-up
A. Torque converter outlet port
2. Torque converter inlet oil pressure pick-up
B. Torque converter oil temperature sensor mounting port
3. Steering and switch pump mount
C. Torque converter inlet port
4. Main pump mount
D. Drain port (to transmission)
5. Coupling 6. Torque converter charging, cooling, PPC and brake pump mount
10-12 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
7. Turbine 8. Drive case 9. Pump 10. Transmission input shaft 11. Rear housing 12. Front housing 13. PTO gear (Teeth 86) 14. Stator 15. Gear (Teeth 81) 16. Gear (Teeth 81)
WA700-3L
10-13 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 Flow of motive force • The torque converter is installed between the damper and transmission. The motive force from the damper passes through the drive shaft and enters coupling (1). Coupling (1), drive case (8), pump (2) and PTO gear (drive) (3) are fixed with bolts. They are rotated directly by the rotation of the engine. The motive force of pump (2) uses oil to rotate turbine (4). This transmits motive force to transmission input shaft (5). •
The motive force of coupling (1) passes through PTO gear (drive) (3) and is also used as the motive force to drive the pump.
Flow of oil • The oil enters torque converter inlet port A, passes through the oil hole in housing (6), and flows to pump (2). The oil is given centrifugal force by pump (2), enters turbine (4), and transmits the energy of the oil to the turbine. Turbine (4) is fixed to transmission input shaft (5), so the power is transmitted to the transmission. The oil from turbine (4) is sent to stator (7), and enters the pump again. However, part of the oil is sent from the stator through torque converter outlet port B of housing (6) to the oil cooler.
10-14 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 TRANSMISSION
WA700-3L
1. Transmission control valve
5. Coupling
2. Lubrication bypass valve
6. Oil filter
3. Transmission
7. Drain plug
4. Transfer
8. Strainer
10-15 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
10-16 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION 12
1. Input shaft 2. Sun gear (Teeth 32) 3. Planetary gear (Teeth 29) 4. Reverse clutch 5. Ring gear (Teeth 112) 6. Ring gear (Teeth 90) 7. Sun gear (Teeth 45) 8. Forward clutch 9. Ring gear (Teeth 95) 10. Planetary gear (Teeth 25) 11. Planetary gear (Teeth 25) 12. Sun gear (Teeth 45) 13. 4th clutch 14. Ring gear (Teeth 124) 15. 2nd clutch 16. Hub (Teeth 90) 17. 3rd clutch 18. Ring gear (Teeth 95) 19. Planetary gear (Teeth 21) 20. Sun gear (Teeth 53) 21. 1st clutch 22. Ring gear (Teeth 95) 23. Planetary gear (Teeth 21) 24. Sun gear (Teeth 53) 25. Output shaft 26. Carrier (1st) 27. Carrier (3rd) 28. Carrier (Forward and 4th) 29. Carrier (Reverse)
WA700-3L
10-17 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
OUTLINE • The transmission consists of a 4-FORWARD, 4-REVERSE speed planetary gear transmission, transfer, and transmission control valve. •
In the transmission, the motive force of the input shaft is changed by the combination of Forward or Reverse clutch with 1st, 2nd, 3rd or 4th clutch to give FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is transmitted to the output shaft.
Speed range
Clutch combination
F1
Forward, 1st
F2
Forward, 2nd
F3
Forward, 3rd
F4
Forward, 4th
R1
Reverse, 1st
R2
Reverse, 2nd
R3
Reverse, 3rd
R4
Reverse, 4th
OPERATION OF CLUTCH Engaged • The oil sent from the transmission control valve passes through the oil passage inside the transmission. When it reaches the rear of piston (2), it moves piston (2). When piston (2) moves, disc (4) and plate (5) are pressed together. Ring gear (6) is meshed with disc (4), so the rotation is stopped.
Disengaged • When the supply of oil from the transmission control valve is shut off, the pressure of the oil acting on the rear of piston (2) is reduced. The piston is then pushed back to the right by return spring (3), and disc (4) and plate (5) are separated. Ring gear (6) then rotates freely, and no motive force is transmitted.
10-18 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
FORWARD 1ST
•
In the case of FORWARD 1st, FORWARD clutch (8) and 1st clutch (21) are engaged. The power transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25).
•
FORWARD clutch (8) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (9) in position. 1st clutch (21) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (22) in position.
•
The power from the torque converter is transmitted to input shaft (1). The rotation of input shaft (1) is transmitted through sun gear (7) to planet gear (10). Ring gear (9) is held in position by FORWARD clutch (8), so the rotation of planet gear (10) rotates carrier (28) inside ring gear (9).
•
The rotation of carrier (28) is transmitted along two paths. One path goes through planet gear (11) and ring gear (14) and rotates carrier (27). The other goes through planet gear (11) and sun gear (12) and is transmitted to output shaft (25).
•
The rotation of carrier (27) is also transmitted along two paths. One path goes through planet gear (19) and ring gear (18) and is transmitted to sun gear (24). The other goes through planet gear (19) and sun gear (20) and is transmitted to output shaft (25).
•
Ring gear (22) is held in position by 1st clutch (21), so the rotation of sun gear (24) passes through planet gear (23) and is transmitted from carrier (26) to output shaft (25).
•
The rotation of output shaft (25) is output in combination with the power transmitted from sun gear (12), sun gear (20), and carrier (26).
WA700-3L
10-19 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
FORWARD 2ND
•
In the case of FORWARD 2nd, FORWARD clutch (8) and 2nd clutch (15) are engaged. The power transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25).
•
FORWARD clutch (8) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (9) in position. 2nd clutch (15) is actuated by the oil pressure applied by the clutch piston, and engages ring gear (14) and hub (16).
•
The power from the torque converter is transmitted to input shaft (1). The rotation of input shaft (1) is transmitted through sun gear (7) to planet gear (10). Ring gear (9) is held in position by FORWARD clutch (8), so the rotation of planet gear (10) rotates carrier (28) inside ring gear (9).
•
The rotation of carrier (28) is transmitted along two paths. One path goes through planet gear (11) and rotates ring gear (14). The other goes through planet gear (11) and sun gear (12) and is transmitted to output shaft (25).
•
Ring gear (14) and hub (16) are formed into one unit by 2nd clutch (15), and the rotation of hub (16) is transmitted to output shaft (25).
•
The rotation of output shaft (25) is output in combination with the power transmitted from sun gear (12) and hub (16).
10-20 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 FORWARD 3RD
•
In the case of FORWARD 3rd, FORWARD clutch (8) and 3rd clutch (17) are engaged. The power transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25).
•
FORWARD clutch (8) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (9) in position. 3rd clutch (17) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (18) in position.
•
The power from the torque converter is transmitted to input shaft (1). The rotation of input shaft (1) is transmitted through sun gear (7) to planet gear (10). Ring gear (9) is held in position by FORWARD clutch (8), so the rotation of planet gear (10) rotates carrier (28) inside ring gear (9).
•
The rotation of carrier (28) is transmitted a long two paths. One path goes through planet gear (11) and ring gear (14) and rotates carrier (27). The other goes through planet gear (11) and sun gear (12) and is transmitted to output shaft (25).
•
Ring gear (18) is held in position by 3rd clutch (17), so the rotation of carrier (27) passes through planet gear (19) and is transmitted from sun gear (20) to output shaft (25).
•
The rotation of output shaft (25) is output in combination with the power transmitted from sun gear (12) and sun gear (20).
WA700-3L
10-21 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
FORWARD 4TH
•
In the case of FORWARD 4th, FORWARD clutch (8) and 4th clutch (13) are engaged. The power transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25).
•
FORWARD clutch (8) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (9) in position. 4th clutch (13) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (14) in position.
•
The power from the torque converter is transmitted to input shaft (1). The rotation of input shaft (1) is transmitted through sun gear (7) to planet gear (10). Ring gear (9) is held in position by FORWARD clutch (8), so the rotation of planet gear (10) rotates carrier (28) inside ring gear (9).
•
Ring gear (14) is held in position by 4th clutch (13), so the rotation of carrier (28) is transmitted through planet gear (11) to sun gear (12) and rotates output shaft (25).
10-22 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 REVERSE 1ST
•
In the case of REVERSE 1st, REVERSE clutch (4) and 1st clutch (21) are engaged. The power transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25).
•
REVERSE clutch (4) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (5) in position. 1st clutch (21) is actuated by the oil pressure applied by the clutch piston, and holds ring gear (22) in position.
•
The power from the torque converter is transmitted to input shaft (1). The rotation of input shaft (1) is transmitted through sun gear (2) to planet gear (3). Ring gear (5) is held in position by REVERSE clutch (4), so carrier (29) rotates, and the rotation of planet gear (3) rotates ring gear (6). Ring gear (6) rotates in the opposite direction from input shaft (1).
•
The rotation of ring gear (6) is transmitted along two paths. One path is transmitted to carrier (28) and then goes through planet gear (11) and ring gear (14) and rotates carrier (27). The other goes through planet gear (11) and sun gear (12) and is transmitted to output shaft (25).
•
The rotation of carrier (27) is also transmitted along two paths. One path goes through planet gear (19) and ring gear (18) and is transmitted to sun gear (24). The other goes through planet gear (19) and sun gear (20) and is transmitted to output shaft (25).
•
Ring gear (22) is held in position by 1st clutch (21), so the rotation of sun gear (24) passes through planet gear (23) and is transmitted from carrier (26) to output shaft (25).
•
The rotation of output shaft (25) is output in combination with the power transmitted from sun gear (12), sun gear (20), and carrier (26).
WA700-3L
10-23 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
TRANSMISSION CONTROL VALVE
1. Lower valve
a. Pilot reducing pick-up (P5)
2. Upper valve
b. Torque converter relief pressure pick-up (P8)
3. Main relief valve
c. Transmission lubricating pressure pick-up (P9)
4. Transmission solenoid valve
d. Main relief pressure pick-up (P6)
5. Emergency manual spool
e. Priority pressure pick-up (P11)
6. Pilot oil filter
f. Reducing pressure pick-up (P3)
7. Connector
g. Modulating pressure pick-up (P1)
10-24 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 TRANSMISSION SOLENOID VALVE
1. Connector
6. FORWARD solenoid valve
2. 1st solenoid valve
7. REVERSE solenoid valve
3. 2nd solenoid valve
8. Body
4. 3rd solenoid valve
9. Emergency manual spool
5. 4th solenoid valve STRUCTURE • The transmission solenoid valve is installed to the transmission together with the transmission valve. When the directional lever or speed control lever are operated, the solenoid valve is actuated and moves the spool inside the transmission valve.
WA700-3L
10-25 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
UPPER VALVE
MAIN RELIEF VALVE
1. Reducing valve
10. 1st spool
2. Quick return valve
11. 2nd Spool
3. Modulating valve
12. 4th spool
4. Priority valve
13. FORWARD spool
5. Housing
14. Pilot filter
6. Torque converter relief valve
15. Pilot reducing valve
7. Quick fill valve
16. Lubrication valve
8. Modulating load piston
17. REVERSE spool
9. Main relief valve
18. 3rd spool
10-26 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 LOWER VALVE
OUTLINE • The oil from the torque converter charging pump enters port A of main relief valve, and passes through priority valve (4) via main relief valve (9). It is then divided into three lines; to the clutch pistons, to pilot reducing valve (4) and to main relief valve. Priority valve (4) acts to control the three lines so that pilot reducing valve (15) is the priority circuit. • The oil flowing to pilot reducing valve (15) controls the pilot pressure used to actuate the directional and speed spools. The oil regulated by pilot reducing valve (15) presses through the orifice in each spool and fills the spool. • The other oil line flows to modulating valve (3) and quick return valve (2). The action of modulating valve (3) and quick return valve (2) raises the clutch pressure smoothly. This reduces the shock when actuating the FORWARD, REVERSE and 1st, 2nd, 3rd and 4th speed clutches to change gear. • The quick fill valve controls the oil pressure when oil fills the second clutch and reduces the filling time when shifting from 1st to 2nd or from 3rd to 2nd. • Lubrication valve (16) controls the lubrication oil inside the transmission.
WA700-3L
10-27 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
MAIN RELIEF VALVE FUNCTION • The main relief valve acts to supply the necessary oil to the clutch when shifting gear. When the gears are not being shifted, it sends all of the oil directly to the torque converter.
OPERATION • The oil from the pump passes through the oil filter and enters port A of main relief valve (1). • Until the specified pressure is reached, the oil flows to the priority valve.
•
When the pressure goes above the specified level, oil passes through the orifice in relief valve (1), pushes poppet (2), and moves relief valve (1) to the left. The oil is relieved to the torque converter, so the specified pressure is maintained. ★ Specified pressure: 31.0 kgf/cm2 (440.92 lbf/in2)
10-28 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
PILOT REDUCING VALVE FUNCTION • The pilot reducing valve acts to control the pressure needed to actuate the transmission spools. OPERATION • The oil from the pump passes through the pilot filter and enters port A of pilot reducing valve (1). The oil passes through port B and enters through the orifice of transmission spool (2) to fill the inside of port C.
•
When the pressure inside port C rises, pressurized oil flows from orifice "a" of pilot reducing valve (1) and goes to port D. As a result, pilot reducing valve (1) moves to the right, and ports A and B are shut off, so the pressurized oil at port C is maintained at the same pressure.
WA700-3L
10-29 2
STRUCTURE AND FUNCTION 12 TRANSMISSION
TORQUE CONVERTER AND TRANSMISSION
SOLENOID VALVE
FUNCTION • There is one solenoid valve installed for each directional and speed spool in the transmission valve. When the directional lever and speed control levers in the operator’s compartment are operated, the solenoid valve is actuated, and oil is drained to actuate the directional and speed spools. OPERATION 1. Solenoid valve OFF The oil of spool (2) enters port A. However, valve (1) shuts off the oil, so directional and speed spool (2) does not move.
2. Solenoid valve ON When the directional and gear shift lever are operated, solenoid valve (1) is pulled up. The oil from directional and speed spool (2) enters port A and flows from port B to the drain circuit. Therefore, port A becomes the low pressure circuit, and directional and speed spool (2) is actuated.
10-30 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 PRIORITY VALVE FUNCTION • Priority valve (1) controls the minimum pressure of pilot reducing valve (2). In addition, priority valve (1) gives the oil flow to pilot reducing valve (2) priority over the other circuit. OPERATION • The oil from the pump flows to port A of priority valve (1) and port B of pilot reducing valve (2).
•
The oil entering port A flows from orifice "a" of priority valve (1) to port D. The hydraulic pressure and force of poppet spring (3) push back spring (4) and move priority valve (1) to the right. When this happens, port A and port C are connected, and the oil flows from port C to the modulating valve.
WA700-3L
10-31 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
MODULATING VALVE AND QUICK RETURN VALVE FUNCTION • The modulating valve and quick return valve act together to raise the transmission clutch pressure slowly. In this way, they reduce the shock when shifting gear, and prevent the generation of peak torque in the power train. As a result, operator fatigue is reduced, and at the same time, operator comfort and the durability of the power train is increased.
1. Immediately after shifting gear (Point A).
•
The oil sent from the pump flows from priority valve (1) through port A, passes through modulating valve (2), and enters port B of quick return valve (3). The oil passes through orifice "a" of quick return valve (3) and flows to the clutch piston, which has been actuated. However when it passes through orifice "a" it creates a difference in pressure between port B and port C. The quick return valve moves to the right and the oil flows to clutch (5). In addition, when quick return valve (3) moves to the right, drain port D is opened, and the pressurized oil at the rear of piston (4) flows to the drain circuit.
10-32 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 2. Clutch pressure rising (Point B)
•
As the pressure at the clutch piston rises, the pressure at port C also rises. Quick return valve (3) is pushed back to the left and drain port D is closed. The oil from the pump flows from port C to the clutch piston and at the same time it flows from orifice "b" through quick return valve (3) and enters port E. The oil at port E acts on the modulating piston (4). It pushes back spring (6) and moves piston (4) to the right. At the same time, pressurized oil also passes through the orifice and enters poppet (7) of modulating valve (2). It moves modulating valve (2) to the left and some of the oil at port A flows to port G.
WA700-3L
10-33 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 3. Completion of rise in clutch pressure (Point C)
•
The oil entering port E continues to push piston (4). When the piston reaches the end of its stroke, the rise in pressure stops. When this happens, the pressure reaches the set pressure of the modulating valve. In addition, port F and port G are closed by piston (4).
10-34 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
REDUCING VALVE FUNCTION • The reducing valve is in the circuit between the quick return valve and the 2nd spool. It reduces the pressure applied to the 2nd clutch. The maximum pressure in the main circuit is kept to the specified level by the main relief pressure. OPERATION • The oil from quick return valve enters port A, and then flows from port B to 2nd spool (2).
•
When the circuit to the 2nd clutch is filled with oil and the hydraulic pressure rises, the oil from port B which flows through orifice a to port C pushes poppet (3). The reaction to this compresses spring (4) and moves reducing spool (1) to the left. As a result, port A and port B are closed, and the oil stops flowing. The hydraulic pressure at this point is 23.5 kgf/cm2 (334.24 lbf/in2).
WA700-3L
10-35 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
QUICK FILL VALVE (FOR 2ND CLUTCH) •
•
The quick fill valve is used to reduce the time lag when shifting from 1st to 2nd or from 3rd to 2nd. It raises the pressure for starting modulation when engaging the 2nd clutch, and reduces the time taken for the oil to fill the clutch piston. By installing a quick fill valve, it is possible to obtain the oil pressure characteristics of the 2nd clutch shown in the graph on the right.
OPERATION • When 2nd spool (1) is switched, the oil from modulating valve (2) passes through quick return valve (3) and reducing valve (4), and enters the clutch piston. • At the same time, it enters port A of quick fill valve (5), and quick fill valve (5) is pushed to the right in the direction of the arrow. • As a result, springs (6) and (7) are compressed, the load becomes greater, and the actuation starting pressure of modulating valve (2) becomes higher than for the other clutches. • The hydraulic pressure rises suddenly to the pressure where the actuation of modulating valve (2) starts. Following this, normal modulation is carried out to raise the pressure until modulating valve (2) reaches the set pressure. • In this way, the pressure for the start of actuation of modulating valve (2) is higher than for the other clutches, and the time lag is reduced by a corresponding amount.
10-36 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
TORQUE CONVERTER RELIEF VALVE FUNCTION • This valve acts to keep the oil entering the torque converter to a constant pressure. It drains the oil if the pressure goes above the specified pressure. OPERATION • The oil from the pump passes through main relief valve (1), enters port A, and flows to the torque converter.
•
If the oil at port A goes above the set pressure, it enters port B from orifice a in torque converter relief valve (2), and moves torque converter relief valve (2) to the left. As a result, the oil at port A goes from port C, lubricates the transmission, and is drained.
WA700-3L
10-37 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
LUBRICATING RELIEF VALVE FUNCTION • The lubricating relief valve protects the transmission lubrication circuit from abnormal high pressure. OPERATION • The oil from the oil cooler and torque converter relief valve flows from port A and lubricates the transmission.
•
In this condition, if abnormal high pressure is generated by throttling of the lubrication circuit, the oil entering port A compresses spring (1), moves spool (2) to the left, opens the circuit between port A and port B, and relieves the oil in the lubricating circuit to port B. The oil pressure at this point is 3 kgf/cm2 (42.67 lbf/in2).
10-38 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 EMERGENCY MANUAL SPOOL FUNCTION • A directional spool and the speed spools are installed to make it possible to actuate the transmission valve mechanically if there should be a failure in the electrical system of the transmission controller system and the solenoid valve cannot be actuated. (This spool is used to move the machine under its own power to a place where it can be serviced.) ★ When using this spool, pay particularly careful attention to safety. OPERATION • Normal position When the solenoid valve is working normally, spool (3) is held in the position shown in the diagram. The oil from the directional spool and speed spool (1) enters port A, but it is shut off by solenoid valve (2).
•
Clutch at OFF position When emergency manual spool (3) is pushed in to the left (screwed in 10 mm), the oil at port A is shut off regardless of the operation of solenoid valve (2). It cannot flow to port B, so the clutch is not actuated.
•
Clutch at ON position When emergency manual spool (3) is pulled out to the right (loosened 10 mm), the oil at port A is drained to port B regardless of the operation of solenoid valve (2). Therefore, the clutch is actuated.
WA700-3L
10-39 2
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
LUBRICATION BYPASS VALVE FUNCTION • When traveling in 4th gear, the transmission gears are rotating at high speed. Because of this, the churning resistance of the transmission lubrication oil increases. To reduce this power loss, only enough oil to lubricate the gears at 4th speed is kept. All the rest of the oil is bypassed to the transmission case. OPERATION • 4th clutch not being operated When the 4th clutch is not being operated, there is no hydraulic pressure at port a of spool (1). As a result, spool (1) is pushed to the left by the spring. The oil from the torque converter is stopped by spool (1), so all the oil is used for lubricating the transmission.
•
4th clutch being operated When oil flows to the 4th clutch, pressure oil flows from 4th spool (2) to port a of spool (1). When pressure oil enters port a, it pushed back the spring and moves spool (1) to the right. The oil from the torque converter flows to the transmission lubrication system and drain port b.
10-40 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12
MEMORANDUM
WA700-3L
10-41 2
STRUCTURE AND FUNCTION 12 HYDRAULIC
TORQUE CONVERTER AND TRANSMISSION
CIRCUIT SCHEMATIC
FORWARD 1ST
10-42 2
WA700-3L
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION
12 OPERATION • When the directional and speed levers are operated to F1, solenoid valves (1) and (2) are actuated. •
The oil from pump (3) is divided into three lines, but during gear shifting, it flows mainly to each clutch.
•
One of the three lines passes from main relief valve (4) through torque converter (5) and enters oil cooler (6).
•
The second line goes from pilot reducing valve (7) through the orifice of each speed spool to the solenoid valve, but solenoid valves (1) and (2) of FORWARD spool (8) and 1st spool (9) are being actuated, so the oil passing through the orifice flows to the drain circuit, and a difference in pressure is created between port A and port B. This overcomes springs (10) and (11) and the port to the clutch is connected.
•
The oil flows in the third line goes from priority valve (12) into quick return valve (14), passes through orifice a, then flows to spools (8) and (9) to forward clutch (15) and 1st clutch (16). When the oil starts to flow into the clutches, it passes through orifice a, so a difference in pressure is created between port C and port D, quick return valve (14) is moved to the right, and the oil at the rear of piston (17) flows to drain circuit E. When each clutch becomes filled with oil, the difference in pressure between port C and port D disappears, so the valve is returned to the left by the difference in the cross-sectional area of the quick return valve (4), and drain circuit E is closed.
•
At this point, each clutch is filled with oil, but the set pressure is not being generated. The oil at port D passes through orifice b, goes to the rear face of piston (17), moves piston (17) to the right, and gradually raises the clutch pressure. When piston (17) reaches the end of its stroke, the set clutch pressure is reached, and the clutch is completely engaged.
WA700-3L
10-43 2
STRUCTURE AND FUNCTION
TRANSFER
12
TRANSFER
1. Transmission output shaft
OUTLINE
2. Transfer input gear (Teeth 46)
•
3. Transfer idler gear (Teeth 39)
The transfer is installed at the power output end of the transmission and is secured to the transmission case by bolts.
4. Idler gear (Teeth 40) 5. Output shaft 6. Rear coupling 7. Strainer 8. Front coupling 9. Output gear (Teeth 41)
10-44 2
WA700-3L
STRUCTURE AND FUNCTION
AXLE
12 AXLE
FRONT AXLE
1. Front axle
5. Drain plug
2. Front differential
6. Spring cylinder
3. Brake
7. Parking brake
4. Final drive
WA700-3L
10-45 2
STRUCTURE AND FUNCTION 12 REAR
AXLE
AXLE
1. Rear differential 2. Rear axle 3. Brake 4. Final drive 5. Drain plug
10-46 2
WA700-3L
STRUCTURE AND FUNCTION
DIFFERENTIAL
12 DIFFERENTIAL
FRONT DIFFERENTIAL
WA700-3L
1. Bevel gear (Teeth 43)
4. Shaft
2. Differential case
5. Bevel pinion (Teeth 9)
3. Side gear (Teeth 24)
6. Pinion gear (Teeth 17)
10-47 2
STRUCTURE AND FUNCTION 12 REAR
10-48 2
DIFFERENTIAL
DIFFERENTIAL
1. Bevel pinion (Teeth 9)
4. Side gear (Teeth 24)
2. Bevel gear (Teeth 43)
5. Shaft
3. Pinion gear (Teeth 17)
6. Differential case
WA700-3L
STRUCTURE AND FUNCTION
FINAL DRIVE
12 FINAL DRIVE
1. Axle shaft 2. Brake 3. Planetary gear (Teeth 37) 4. Ring gear (Teeth 93) 5. Planetary carrier 6. Drain plug 7. Wheel hub 8. Sun gear (Teeth 18) 9. Wheel
WA700-3L
10-49 2
STRUCTURE AND FUNCTION
FINAL DRIVE
12 OUTLINE To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and send drive force to the tires. OPERATION The motive force transmitted from the differential through axle shaft (1) to sun gear (8) is transmitted to planetary gear (3). The planetary gear rotates around the inside of fixed ring gear (4) and in this way transmits rotation at a reduced speed to planetary carrier. This motive force is then sent to wheels (9) which are installed to planetary carriers.
10-50 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 STEERING
STEERING PIPING DIAGRAM
1. Steering cylinder (R.H.)
7. Steering and switch pump
2. Steering demand valve
8. Stop valve (L.H.)
3. Steering unit (Orbit-roll valve)
9. Diverter valve (with ground driven steering)
4. Stop valve (R.H.)
10. Ground driven steering pump (with ground driven steering)
5. Hydraulic tank
11. Steering cylinder (L.H.)
6. Steering wheel
WA700-3L
10-51 2
STRUCTURE AND FUNCTION 12 STEERING
STEERING
AND SWITCH PUMP
1. Shaft (front)
5. Shoe
9. Impeller
13. End cap (rear)
2. Cradle (front)
6. Piston
10. Cradle (rear)
14. End cap (front)
3. Case (front)
7. Cylinder block
11. Shaft (Rear)
15. Servo piston
4. Swash plate
8. Valve plate
12. Case (rear)
Specification Steering and switch pump Model Rated delivery pressure Rated rpm Theoretical delivery (front) Theoretical delivery (rear) Max. Delivery
10-52 2
HPF 90 + 90 320 kgf/cm2 (4551.47 lbf/in2) 2120 rpm 97.4 cc/rev 97.4 cc/rev 206.5 + 206.5 L/min (54.55 + 54.55 gal/min)
WA700-3L
STRUCTURE AND FUNCTION
WA700-3L
STEERING
10-53 2
STRUCTURE AND FUNCTION
STEERING
12 OUTLINE (For Steering and Switch pump, previous page) • This set of pumps consists of two fixed displacement swash plate piston pumps and an impeller pump between them. For details of the operation, see MAIN PISTON PUMP. Note that the rocker cam has variable movement.
STEERING UNIT (ORBIT-ROLL VALVE)
1. Neutral position spring
6. Gear rim
a. To hydraulic tank
2. Valve body
7. Gear
b. To steering demand valve port Pb
3. Check valve
8. Cover
c.
4. Spool
9. Drive shaft
d. From PPC pump
5. Sleeve
10. Center pin
10-54 2
To steering demand valve port Pa
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 OUTLINE • The steering unit is directly connected to the shaft of the steering wheel. The oil from the PPC pump passes through the steering demand valve, and is switched to the left and right steering cylinders to determine the direction of travel of the machine. •
The steering unit can be broadly divided into the following: spool (4) and sleeve (5), which have a rotor type direction selection function, and the gear set (combination of gear (7) and gear rim (6)), which acts as a hydraulic motor when the steering is operated.
STRUCTURE • Spool (4) is interconnected with the drive shaft of the steering wheel and is connected to sleeve (5) by neutral position spring (1) and center pin (10) (when the steering wheel is at neutral, it does not contact the spool). •
The top of drive shaft (9) is meshed with center pin (10) and forms one unit with sleeve (5). The bottom is meshed with the spline of gear (7) of the gear set.
•
Valve body (2) has four ports. These are connected respectively to the pump circuit, tank circuit, and pilot circuit of the steering demand valve. In addition, the port at the pump end and the port at the tank end are connected by check valve (3) inside the housing. If there is any failure in the PPC pump, oil is sucked in directly from the tank end by the check valve.
WA700-3L
10-55 2
STRUCTURE AND FUNCTION
STEERING
12 OPERATION When turning
•
When the steering wheel is turned, spool (4) overcomes neutral position spring (1) and turns slightly in relation to sleeve (5). Because of this rotation, the ports of sleeve (5) and spool (4) overlap, so a passage is formed for the oil to flow, and the oil flows to gear (7).
•
When the steering wheel is turned, the oil inside gear (7) flows, passes inside sleeve (5) and spool (4), operates the spool of the steering demand valve, and actuates the steering cylinders.
•
When the turning of the steering wheel is stopped (the rotation of the spool is stopped), the return force of neutral position spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is shut off and the oil stops flowing.
•
When the non-reaction type steering valve is at the neutral position, the steering cylinder and spool (4) and sleeve (5) are blocked, so the reaction from the machine is not transmitted to the steering wheel.
10-56 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 STEERING DEMAND VALVE
1. Overload relief valve
A. To steering cylinder
2. Main relief valve
B. To steering cylinder
3. Steering spool
P1. From steering pump
4. Demand spool
P2. From switch pump
5. Surge cut relief valve
PB. To main control valve T. To hydraulic tank (through hydraulic oil cooler)
WA700-3L
10-57 2
STRUCTURE AND FUNCTION 12 OVERLOAD
STEERING
RELIEF VALVE 1. Poppet 2. Relief valve poppet 3. Check valve poppet 4. Pilot poppet 5. Spring
FUNCTION • The overload relief valve is installed in the cylinder circuit of the steering demand valve. When the demand valve is at neutral and any impact is applied to the steering cylinder and abnormal pressure is generated, this valve functions as a safety valve to relieve the circuit to prevent breakage of the cylinder or hydraulic piping. It also functions to prevent any vacuum if any negative pressure is generated at the cylinder end. OPERATION 1. Operation of relief valve • Port A is connected to the cylinder circuit and port B is connected to the drain circuit. The oil passes through the hole in poppet (1) and acts on the area of diameters d1 and d2. Check valve poppet (3) and relief valve poppet (2) are securely seated.
•
When the pressure at port A reaches the set pressure of the relief valve, pilot poppet (4) opens and the oil goes around pilot poppet (4) and flows to port B.
10-58 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 •
When pilot poppet (4) opens, the pressure at the rear of poppet (1) drops, poppet (1) moves to the right, and it is seated with pilot poppet (4).
•
Compared with the pressure at port A, the pressure on the inside is low, so relief valve poppet (2) opens and the oil flows from port A to port B to prevent any abnormal pressure.
2. Operation of suction valve • Negative pressure is generated at port A, the difference in the area of diameters d3 and d4 opens check valve poppet (3), and the oil flows from port B to port A to prevent a vacuum from forming in the circuit.
WA700-3L
10-59 2
STRUCTURE AND FUNCTION 12 MAIN
STEERING
RELIEF VALVE 1. Adjustment screw 2. Spring 3. Plug 4. Pilot poppet 5. Valve seat
FUNCTION The main relief valve of the steering demand valve is inside the valve and sets the maximum pressure in the steering circuit when it is operated. In other words, when the valve is being operated and the steering circuit goes above the set pressure of this valve, it relieves the oil and actuates the flow control spool of the demand valve to drain the oil to the steering circuit.
10-60 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 MAIN RELIEF VALVE
OPERATION • When the pressure in the circuit rises and reaches the pressure set by spring (2) and adjustment screw (1), pilot poppet (3) opens and drains the oil. •
When this happens, the balance of the pressure in pressure receiving chamber (1) and pressure receiving chamber (11) is lost, and demand spool (4) moves to the left.
•
When demand spool (4) moves, the oil from the steering pump is drained and the oil from the switch pump is relieved to the main control valve, so the steering circuit pressure is prevented from going above the set value.
WA700-3L
10-61 2
STRUCTURE AND FUNCTION 12 OPERATION
STEERING
OF DEMAND VALVE
When steering spool is at neutral
•
The oil from the steering pump enters port A and the oil from the switch pump enters port B.
•
When steering spool (2) is at the neutral position, pressure receiving pressure chamber (II) is connected to the drain circuit through orifice b, and notch c is closed.
•
Notch c is closed, so the pressure of the oil at port A and port B rises. This pressure passes through orifice a, goes to pressure receiving chamber (I) and moves demand spool (1) to the left.
•
When the pressure in pressure receiving chamber (I) reaches a certain value (set by spring (3)), notch f opens and the oil from the steering pump goes to the drain circuit. Notch g is closed, so the oil from the switch pump all flows to the main control valve.
10-62 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 WHEN STEERING SPOOL IS OPERATED Engine running at low speed
•
• • • •
When the steering is operated, oil flows from the Orbit-Roll to steering spool (2) and pushes steering spool (2) to the right. The circuit between pressure receiving chamber (II) and the drain circuit is shut off, and at the same time, notch c opens. As a result, the pressure in pressure receiving chamber (II) rises, and demand spool (1) moves to the right until notch b closes. The passage from port B to the main control valve is shut off, so the oil from the switch pump pushes up pump merge-divider check valve (4) and merges with the oil from the steering pump at port A. The merged oil passes through notches c and d, pushes load check valve (5), and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. When this happens, the pressure before passing through notch c is sent to pressure receiving chamber (I) and the pressure after passing through notch c is sent to pressure receiving chamber (II). Demand spool (1) is actuated so that the difference in pressure on both sides of notch c is kept constant. Therefore, an oil flow corresponding to the opening of notch c is supplied to the cylinder port. These pressure differences (control pressure) are set by spring (3).
WA700-3L
10-63 2
STRUCTURE AND FUNCTION
STEERING
12 Engine running at high speed
•
There is no need for supply of extra oil from the switch pump, so the steering pump pressure rises until notch g closes and shuts off the merge passage from port B.
•
The pressure difference on both sides of notch c is controlled only by notch f, and the excess oil from the steering pump is drained from notch f to the drain circuit. (At this point, notch g is completely closed.)
•
The oil from the steering pump passes through notches c and d, pushes load check valve (5), and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit.
•
Notch g is closed, so the oil from the switch pump all flows from port B and is sent to the main control valve.
10-64 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
OPERATION OF STEERING VALVE Neutral
•
The steering wheel is not being operated, so steering spool (2) does not move.
•
The oil from the steering pump enters port A. The oil from the switch pump enters port B.
•
When the pressure at ports A and B rises, demand spool (1) moves to the left, so the oil from the steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and all flows to the main control valve.
WA700-3L
10-65 2
STRUCTURE AND FUNCTION
STEERING
12 Turning right
•
When the steering wheel is turned to the right, the Orbit-roll valve is operated and steering spool (2) moves to the left. The oil from the steering pump enters port A, then flows to steering spool (2) through demand spool (1). The oil pushes open load check valve (6) of the spool, and flows to the bottom end of the left cylinder and the rod end of the right cylinder to turn the machine to the right. The oil from the left and right cylinders passes through load check valve (5) of the steering spool and is drained. The oil from the switch pump enters port B, goes through demand spool (1), pushes open check valve (4), and is merged with the oil from the steering pump.
10-66 2
WA700-3L
STRUCTURE AND FUNCTION
STEERING
12 Turning left
•
When the steering wheel is turned to the left, the Orbit-roll valve is operated and steering spool (2) moves to the right. The oil from the steering pump enters port A, then flows to steering spool (2) through demand spool (1). The oil pushes open load check valve (5) of the spool, and flows to the rod end of the left cylinder and the bottom end of the right cylinder to turn the machine to the left. The oil from the left and right cylinders passes through load check valve (6) of the steering spool and is drained. The oil from the switch pump enters port B, goes through demand spool (1), pushes open check valve (4), and is merged with the oil from the steering pump.
WA700-3L
10-67 2
STRUCTURE AND FUNCTION
TWO-WAY RESTRICTOR
12
TWO-WAY RESTRICTOR
1. Poppet 2. Spring 3. Body
FUNCTION • To reduce the shock caused by the inertia of the machine when the steering is operated, an orifice is installed in the oil line of the return circuit from the cylinder. This applies pressure to the returning oil, and regulates the movement of the cylinder piston.
OPERATION • When the oil is flowing to arrow (right), it pushes spring (2) and flows through the orifice, and between poppet (1) and the poppet seat.
•
When the oil is flowing to arrow (left), the oil flows only from orifice a inside poppet (1), so the flow is controlled.
10-68 2
WA700-3L
STRUCTURE AND FUNCTION
STOP VALVE
12 STOP VALVE
1. Boot
A:
From orbit-roll
2. Wiper
B:
To steering demand valve
3. Seal
DR:
To drain
4. Poppet 5. Spring 6. Spool 7. Spring
WA700-3L
10-69 2
STRUCTURE AND FUNCTION
DIVERTER VALVE
12
DIVERTER VALVE
1. Check valve
A. To ground driven steering pump
2. Check valve
B. Sensor mount port
3. Check valve
C. To hydraulic tank
4. Check valve
D. To steering valve
5. Spool
E. From hydraulic tank
6. Valve body
F.
From steering circuit
FUNCTION • The diverter valve is a selector valve which senses the pilot pressure from the steering pump and if there is no abnormality in the steering circuit, it drains the oil from the ground driven pump to the tank. If no pilot pressure from the steering pump reaches the diverter valve, the oil from the ground driven steering pump is switched to the steering circuit and flows to enable the machine to be steered.
10-70 2
WA700-3L
STRUCTURE AND FUNCTION
DIVERTER VALVE
12 OPERATION Pump and engine are working normally.
•
When the steering pump and engine are working normally, the steering pump, and switch pump are rotated by the engine. Therefore, oil is sent to the steering valve, and the machine can be steered. In addition, the ground driven steering pump is rotated by the transmission, so oil from port A of the diverter valve pushes open check valve (2) and enters port B. Pressure oil from the steering pump is flowing to port D, so it pushes spool (3) in the direction of the arrow. As a result, the oil from port B flows to port C and is drained to the hydraulic tank.
WA700-3L
10-71 2
STRUCTURE AND FUNCTION
DIVERTER VALVE
12 Failure in pump or engine when machine is traveling.
•
If there is a failure in the pump or engine when the machine is traveling, the rotation of the wheels is transmitted through the transmission to rotate the ground driven steering pump. The normal steering pump is not rotating, so no pressure oil is formed at port D. As a result, spool (3) is pushed in the direction of the arrow by spring (4). The oil from the ground driven steering pump passes from port A through port B and flows to the steering valve to make steering possible. ★ The ground driven steering pump is designed so that it can rotate in both directions.
10-72 2
WA700-3L
STRUCTURE AND FUNCTION
DIVERTER VALVE
12 GROUND DRIVEN STEERING RELIEF VALVE 1. Main valve 2. Valve seat 3. Pilot poppet 4. Spring 5. Adjustment screw
FUNCTION • Compared to the steering valve relief pressure of 320 kgf/cm2 (4551.47 lbf/in2), the rated pressure of the ground driven steering pump and diverter valve are both 210 kgf/cm2 (2986.9 lbf/in2). Therefore, to protect the ground driven steering pump and diverter valve, there is a relief valve in the piping from the diverter valve to the steering valve. When the ground driven steering is being operated, and the hydraulic pressure generated by the steering exceeds 210 kgf/cm2 (2986.9 lbf/in2), the relief valve is actuated.
OPERATION • Port A is connected to the pump circuit, and port C is connected to the drain circuit. The oil passes through the orifice in main valve (1) and fills port B. Pilot poppet (3) is in contact with valve seat (2).
•
When the pressure inside port A and B reaches the pressure set by the poppet spring (set pressure), pilot poppet (3) opens and the hydraulic pressure at port B escapes from port D to port C. This lowers the pressure at port B.
•
When the pressure at port B drops, the orifice of main valve (1) generates a difference in pressure between port A and port B. Main valve (1) is opened by the pressure at port A and the oil at port A is relieved.
WA700-3L
10-73 2
STRUCTURE AND FUNCTION
BRAKE
12
BRAKE BRAKE PIPING
1. Front brake (right)
10. Strainer
2. Brake valve (right)
11. Charge valve
3. Parking brake switch
12. Transmission cut-off valve
4. Rear brake (right)
13. Brake valve (left)
5. Slack adjuster (rear)
14. Parking brake switch
6. Torque converter charging, cooling, PPC, brake pump
15. Parking brake solenoid valve
7. Rear brake (left)
16. Front brake (left)
8. Accumulators
17. Parking brake spring cylinder
9. Brake oil tank
18. Slack adjuster (front)
10-74 2
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12 BRAKE CIRCUIT DIAGRAM
1. Brake oil tank
10. Brake valve (right)
2. Brake pump
11. Stop lamp switch
3. Strainer
12. Brake valve (left)
4. Accumulator charge valve
13. Transmission cut-off switch
4A. Safety relief valve
14. Rear slack adjuster
4B. Relief valve
15. Rear brake
4C. Relief valve
16. Front slack adjuster
4D. Relief valve
17. Front brake
5. Check valve
18. Parking brake solenoid valve
6. Emergency brake switch
19. Parking brake switch
7. Low pressure switch
20. Parking brake pilot lamp switch
8. Rear brake accumulator
21. Parking brake spring cylinder
9. Front brake accumulator
WA700-3L
10-75 2
STRUCTURE AND FUNCTION 12 BRAKE
BRAKE
VALVE
BRAKE VALVE (RIGHT)
1. Brake pedal (left, right brake)
9. Spool (left brake)
2. Rod (right brake)
10. Cylinder (left brake)
3. Pilot piston (right brake)
10-76 2
4. Spool (right brake)
A. Pilot port (right brake)
5. Upper cylinder (right brake)
B. To rear brake (right brake)
6. Spool (right brake)
C. To front brake (right brake)
7. Lower cylinder (right brake)
D. Drain (left, right brake)
8. Rod (left brake)
E. To pilot port (left brake)
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12 BRAKE VALVE (LEFT)
OUTLINE • There are two brake valves installed in parallel under the front of the operator’s cab, and these are actuated by depressing the pedal. •
When the right pedal is depressed, oil is sent to the brake cylinder to apply the brakes.
•
When the left pedal is depressed, oil is sent to the right pedal to apply the brakes in the same way as when the right pedal is depressed. In addition, the left brake pedal operates the transmission cut-off switch to actuate the transmission solenoid valve electrically and set the transmission to neutral.
WA700-3L
10-77 2
STRUCTURE AND FUNCTION
BRAKE
12 OPERATION Brake applied (right brake valve) Upper portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders. Lower portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, spool (5) is also pushed down by plunger (6). When this happens, drain port b is closed, and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders.
Brake applied (left brake pedal) • When pedal (7) is depressed, spool (10) is pushed up by rod (8) and spring (9), and drain port c is closed. The oil from the pump and the accumulator flows from port E to port F. •
Port F of the left brake valve and port Pp of the right brake valve are connected by a hose, so the oil flowing to port F flows to pilot port Pp of the right brake valve.
•
The oil entering pilot port Pp enters port G from orifice d, and pushes piston (11). The spring pushes spool (3) down, so the operation is the same as when the right brake valve is depressed.
10-78 2
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12 Applying brake when upper valve fails (right brake valve) • Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails (right brake valve) • Even if there is leakage of oil in the lower piping, the upper portion is actuated normally. When actuation is balanced Upper portion • When oil fills the rear brake cylinder and the pressure between port A and port C becomes high, the oil entering port H from orifice e of spool (3) pushes against spring (4). It pushes up spool (3) and shuts off the circuit between port A and port C. When this happens, drain port a stays closed, so the oil entering the brake cylinder is held and the brake remains applied. Lower portion • When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port B and port D rises. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port B and port D. Drain port b is closed, so the oil entering the brake cylinder is held, and the brake is applied. •
The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports B and D are fully opened, so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. Therefore, up to the point where the piston moves to the end of its stroke, the effect of the brake can be adjusted by the amount that the pedal is depressed.
WA700-3L
10-79 2
STRUCTURE AND FUNCTION
BRAKE
12 Brake released (right brake valve) Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the rear brake. Lower portion • When the pedal is released, spool (3) in the upper portion moves up. At the same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port b is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the front brake.
10-80 2
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12
MEMORANDUM
WA700-3L
10-81 2
STRUCTURE AND FUNCTION 12 CHARGE
BRAKE
VALVE
A.
To brake oil tank
FUNCTION
ACC.
To brake valve
•
PP.
To brake valve
P.
From pump
T.
To brake oil tank
10-82 2
•
The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load on the pump.
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12
WA700-3L
1. Valve body
4. PPC relief valve (R2)
2. Main relief valve (R3)
5. Relief valve (H1)
3. Relief valve (R1)
6. Filter
10-83 2
STRUCTURE AND FUNCTION
BRAKE
12 OPERATION 1. When no oil is being supplied to accumulator (cut-out condition) •
The pressure at port B is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port S. Poppet (6) is opened, so port C and port T are short circuited.
•
The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the brake oil tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14), and flows from port A to the brake oil tank. At the same time, it also passes through orifices (17), (18), and (16), and flows to the brake oil tank.
2. When oil is supplied to accumulator A. Cut-in condition • When the pressure at port B is lower than the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5). Valve seat (7) and poppet (6) are brought into tight contact, and port C and port T are shut off. •
The spring chamber at the right end of spool (15) is also shut off from port T, so the pressure rises, and the pressure at port P also rises in the same way.
•
When the pressure at port P goes above the pressure at port B (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed, and the remaining oil flows to port A.
10-84 2
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12 B. When cut-out pressure is reached • When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. •
When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is forcibly opened, and port C and port T are short circuited.
•
The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the brake oil tank pressure.
•
The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14), so the supply of oil to port B is stopped.
3. Safety relief valve (R3) • If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the brake oil tank circuit, so this sets the maximum pressure in the brake circuit and protects the circuit.
WA700-3L
10-85 2
STRUCTURE AND FUNCTION 12 ACCUMULATOR
BRAKE
(FOR BRAKE)
1. Valve
Specifications
2. Top cover
Gas used:
Nitrogen gas
3. Cylinder
Charge amount:
4000 cc
4. Piston
Charge pressure:
35 ± 1.5 kgf/cm2 at 50° C (497.81 ± 21.33 lbf/in2 at 122° F)
FUNCTION • The accumulator is installed between the charge valve and the brake valve. It is charged with nitrogen gas between cylinder (3) and free piston (4), and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop.
10-86 2
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12 SLACK ADJUSTER
1. Cylinder
Specification
2. Check valve
Check valve cracking pressure:
9.5 ± 0.5 kgf/cm2 (135.12 ± 7.11 lbf/in2)
3. Bleeder
Check valve closing pressure:
6.0 ± 0.5 kgf/cm2 (l85.34 ± 7.11 lbf/in2)
4. Piston 5. Spring A. Inlet port B. Outlet port
FUNCTION • The slack adjuster is installed in the brake oil line from the brake chamber to the brake piston. It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. In this way it acts to keep a constant time lag when the brake is operated.
WA700-3L
10-87 2
STRUCTURE AND FUNCTION
BRAKE
12 OPERATION 1. When brake pedal is depressed • Before the brake is depressed, piston (4) is returned by the distance of stroke S (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port P of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke S to the left and right.
•
When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston (7) and disc is to 0, the greater the braking force becomes.
•
If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above the set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed value.
2. When brake pedal is released • When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for stroke S, and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc.
10-88 2
WA700-3L
STRUCTURE AND FUNCTION
BRAKE
12 BRAKE
1. Guide pin 2. Return spring 3. Brake piston 4. Disc 5. Plate 6. Floating seal
WA700-3L
10-89 2
STRUCTURE AND FUNCTION
BRAKE
12 FUNCTION •
Main brakes are wet-type multiple-disc brakes and are installed to all four wheels.
OPERATION •
When the brake pedal is depressed, the pressure oil from the brake valve moves brake piston (4) to the right in the direction of the arrow. This brings disc (8) and plate (7) into contact, and friction is generated between the disc and plate. The wheel is rotating together with the disc, so the machine speed is reduced and the machine is stopped by this friction.
•
When the brake pedal is released, the pressure at the back face of brake piston (4) is released, so the piston is moved to the left in the direction of the arrow by the force of return spring (2), and the brake is released.
10-90 2
WA700-3L
STRUCTURE AND FUNCTION
PARKING BRAKE
12 PARKING BRAKE
1. Spring cylinder 2. Parking brake disc OUTLINE •
The parking brake is a disc type and is installed on the front axle.
•
The force of the spring inside spring cylinder (1) is used to apply the brake mechanically; it is released by oil pressure.
•
The parking brake caliper is fixed to the front differential case. The disc is installed to the differential yoke and rotates together with the coupling.
WA700-3L
10-91 2
STRUCTURE AND FUNCTION 12 PARKING
PARKING BRAKE
BRAKE CALIPER
1. Caliper
4. Piston shaft
2. Pad
5. Lever
3. Piston
6. Adjustment bolt
OUTLINE •
Caliper (1) is fitted with a piston guide. Piston (3) and piston shaft (4) are fitted inside, and the rotation of the piston shaft moves the piston in the axial direction to compress pad (2).
•
Lever (5) is connected by a spline to the spline side of the piston shaft. Pad (2) is fitted and held in position together with caliper (1) in the caliper mounting plate.
•
The caliper body follows the wear of pad (2) and slides in the axial direction on the plate. Adjustment bolt (6) of lever (5) is used to adjust the clearance between the pad and the disc. Hold the lever and turn the adjustment bolt to adjust the clearance as follows. To INCREASE, turn COUNTERCLOCKWISE. To DECREASE, turn CLOCKWISE.
10-92 2
WA700-3L
STRUCTURE AND FUNCTION
PARKING BRAKE
12 SPRING CYLINDER
1. Outer spring
4. Cylinder
2. Inner spring
5. Boot
3. Piston
6. Rod
OUTLINE •
The oil pressure from the parking brake solenoid valve pushes the spring and releases the parking brake. When the engine is stopped, the parking brake is applied by spring (1), so the machine is prevented from moving.
WA700-3L
10-93 2
STRUCTURE AND FUNCTION 12 PARKING
PARKING BRAKE
BRAKE SOLENOID VALVE
1. Solenoid valve assembly
B: Outlet port
2. Block
P: Inlet port T:
Drain port
FUNCTION •
The parking brake solenoid valve is installed to the inside left of the front frame. When the parking brake switch is turned ON/OFF, the solenoid valve is energized or de-energized, so the brake oil pressure is taken to the brake cylinder or removed from the brake cylinder to set the parking brake at the PARKED position or TRAVEL position.
•
Parking brake solenoid valve Energized: TRAVEL De-energized: PARKED
10-94 2
WA700-3L
STRUCTURE AND FUNCTION
PARKING BRAKE
12
MEMORANDUM
WA700-3L
10-95 2
STRUCTURE AND FUNCTION
HYDRAULIC
12
HYDRAULIC HYDRAULIC PIPING
10-96 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12
1. Bucket cylinder 2. Boom cylinder (RH) 3. PPC valve 4. Accumulator 5. Main piston pump (Work equipment) 6. Oil cooler 7. Four-tandem pump (Torque converter charging + cooling + PPC + Brake pump) 8. Piston pump (Steering + switch pump) 9. Transmission 10. Boom cylinder (LH) 11. Main control valve
WA700-3L
10-97 2
STRUCTURE AND FUNCTION 12 HYDRAULIC
10-98 2
HYDRAULIC
CIRCUIT DIAGRAM
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12
WA700-3L
10-99 2
STRUCTURE AND FUNCTION
HYDRAULIC
12
MEMORANDUM
10-100 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 MAIN PISTON PUMP
1. ES valve (Engine sensing) 2. Servo valve 3. Control pump (BAR025) 4. Rear main pump (Fixed displacement type) 5. Front main pump (Variable displacement type) 6. Relief valve
OUTLINE •
This set of pumps consists of two swash plate piston pumps, an impeller pump (built into the circuit between the front pump and rear pump), and a charging pump.
WA700-3L
10-101 2
STRUCTURE AND FUNCTION 12 PISTON
HYDRAULIC
PUMP (HPV90 + HPF90)
1. Shaft (front)
9. Impeller
2. Cradle (front)
10. Cradle (rear)
Model:
HPV 90 + HPF 90
3. Case (front)
11. Shaft (rear)
Rated delivery pressure:
320 kgf/cm2 (4551 lbf/in2)
4. Swash plate
12. Case (rear)
Rated rpm:
2124 rpm
5. Shoe
13. End cap (rear)
Theoretical delivery:
97.4 cc/rev (front & rear)
6. Piston
14. End cap (front)
7. Cylinder block
15. Servo piston
Max. delivery:
206.5 + 206.5 L/min
8. Valve plate
10-102 2
Specification
54.55 + 54.55 gal/min
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12
WA700-3L
10-103 2
STRUCTURE AND FUNCTION
HYDRAULIC
12 FUNCTION •
The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load.
•
It is possible to change the delivery amount by changing the swash plate angle.
STRUCTURE
•
Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings.
•
The tip of piston (6) is spherical, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing.
•
Rocker cam (4) has plane surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides.
•
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
•
Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).
•
Impeller (9) is connected to shaft (1) through the spline boss (10) and rotates together with the shaft. The oil sucked in through the suction port is sent to the cylinder chamber by centrifugal force to make suction easier.
10-104 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 OPERATION 1. Operation of pump • Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle α between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle α is called the swash plate angle.)
A. Center line X of rocker cam (4) maintains swash plate angle α in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volume E and F is created inside cylinder block (7). The suction and discharge is equal to this difference E - F. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. B.
If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E’ and F’ inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil.
WA700-3L
10-105 2
STRUCTURE AND FUNCTION
HYDRAULIC
2. Control of discharge amount If swash plate angle Îą becomes larger, the difference in volumes E and F becomes larger and the discharge volume increases. Swash plate angle (Îą) is changed by servo piston (15). Servo piston (15) moves in a reciprocal movement (!) in accordance with the command from the servo valve. This straight line movement is transmitted through the rod of rocker cam (4) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (10), slides in an oscillating movement in both direction along the cylindrical surface.
10-106 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 CONTROL PUMP (BAR025)
1. Collar
Specification
2. Body
Model:
BAR025
3. Housing
Theoretical delivery:
25 cc/rev
4. Drive gear
Max. delivery pressure:
30 kgf/cm2 (426.7 lbf/in2)
5. Driven gear OUTLINE • The control pump is a gear pump for the ES (engine sensing) valve
WA700-3L
10-107 2
STRUCTURE AND FUNCTION 12 CONTROL
HYDRAULIC
PUMP RELIEF VALVE 1. Adjustment screw 2. Lock nut 3. Pilot valve spring 4. Pilot valve 5. Main valve spring 6. Main valve Set pressure:
30 kgf/cm2 @ 50 L/min (426.7 lbf/in2 @ 13.2 gal/min)
FUNCTION The relief valve is built in the body of control pump. It relieves the oil delivered from the pump. Flow of the oil • Chamber A forms a pump circuit and chamber C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat.
•
If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C. In addition, the oil flows from chamber A to B through orifices.
•
If the oil flows through the orifice of valve (6), a differential pressure occurs between the chambers A and S, moving valve (6) to the left. This allows the oil in chamber A to flow into chamber C.
10-108 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 VALVE (ENGINE SENSING VALVE) ES
1. Plug
FUNCTION
2. Valve body 3. Shaft 4. Plug 5. Plug
•
This valve acts to control the delivery amount of the hydraulic pump to match the changes in the engine speed.
6. Spool 7. Spool 8. Plug
WA700-3L
10-109 2
STRUCTURE AND FUNCTION 12 SERVO
HYDRAULIC
VALVE
1. Plug 2. Arm 3. Spool 4. Body 5. Sleeve 6. Sleeve 7. Spool 8. Plug
10-110 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 PRESSURE DIFFERENTIAL VALVE
1. Valve body
FUNCTION
2. Spring 3. Shim 4. Valve
WA700-3L
•
The pressure differential valve converts the hydraulic pressure for the engine speed into a differential pressure, and controls the ES valve (engine sensing valve).
10-111 2
STRUCTURE AND FUNCTION 12 PPC
HYDRAULIC
VALVE (PROPORTIONAL PRESSURE VALVE)
10-112 2
P:
From pump
T:
To tank (drain)
P1:
To bucket cylinder (Tilt)
P2:
To boom cylinder (Raise)
P3:
To boom cylinder (Lower)
p4:
To bucket cylinder (Dump)
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12
1. Bolt
6. Center spring
2. Piston
7. Metering spring
3. Plate
8. Valve
4. Collar
9. Body
5. Retainer
WA700-3L
10-113 2
STRUCTURE AND FUNCTION
HYDRAULIC
12 OPERATION
1. Control lever at "neutral" (Fig. 1): Ports PA1, P2, PB1 and P4 are connected to drain chamber D through fine control hole (f) in spool (10).
2. Control lever operated slightly (fine control) (Fig. 2): When piston (4) starts to be pushed by plate (2), retainer (7) is pushed. Valve (10) is also pushed by spring (9) and moves down. When this happens, fine control hole (f) is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pilot pressure of the control valve is sent through fine control hole (f) to port P2 and PA. When the pressure at port P2 rises, valve (10) is pushed back. Fine control hole (f) is shut off from pump pressure chamber PP. At almost the same time it is connected to drain chamber D, so the pressure at port P2 escapes to drain chamber D. Valve (10) moves up and down until the force of spring (9) is balanced with the pressure of port P2. The position of valve (10) and body (11) (when fine control hole (f) is midway between drain chamber D and pump pressure chamber PP) does not change until the head of valve (10) contacts the bottom of piston (4). Therefore, spring (9) is compressed in proportion to the travel of the control lever, so the pressure at port P2 also rises in proportion to the travel of the control lever. The spool of the control valve moves to a position where the pressure of port PA1, (same as pressure at port P2) and the force of the return spring of the control valve are balanced.
10-114 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 3. Control lever moved back from slightly operated position to neutral (Fine control) (Fig. 3): When plate (2) starts to be pushed back, piston (4) is pushed up by a force corresponding to the force of centering spring (8) and the pressure at port P2. At the same time, fine control hole (f) of valve (10) is connected to drain chamber D, so the oil at port P2 escapes. If the pressure at port P2 drops too far, valve (10) is pushed down by spring (9). Fine control hole (f) is shut off from drain chamber D, and at almost the same time it is connected to pump pressure chamber PP. The pump pressure is supplied until the pressure at port P2 return to a pressure equivalent to the position of the lever. When the spool of the control valve returns, the oil in drain chamber D flows in from fine control hole (f’) of the valve which has not moved. The extra oil then flows through port P4 to chamber PB1.
4. Control lever operated to end of travel (Fig. 4): Plate (2) pushes piston (4) down, and piston (4) forcibly pushes in valve (10). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port P2 to chamber PA, to push the spool of the control valve. The oil returning from chamber A2 flows from port PB1, through fine control hole (f’) to drain chamber D.
WA700-3L
10-115 2
STRUCTURE AND FUNCTION 12 PPC
HYDRAULIC
RELIEF VALVE 1. Main valve 2. Valve seat 3. Pilot poppet 4. Spring 5. Adjustment screw Set pressure: 38 kgf/cm2 (540.48 lbf/in2)
FUNCTION • The PPC relief valve is between the PPC pump and the PPC valve. When the PPC valve is not being actuated, or when abnormal pressure is generated, the oil sent from the pump is relieved through this valve to protect the pump and circuit from damage. (Sets maximum pressure in the circuit).
OPERATION • Port A is connected to the pump circuit, and port C is connected to the drain circuit. The oil passes through the orifice of main valve (1) and fills port B. Pilot poppet (3) is in close contact with valve seat (2). •
If the pressure at ports A and B reach the pressure set by the poppet spring, pilot poppet (3) opens and the pressure oil at port B flows through port D to port C. As a result, the pressure at port B drops.
•
If the pressure at port B drops, a pressure difference is generated between ports A and B due to the orifice in main valve (1). Main valve (1) is pushed open by the pressure at port A, and the oil at port A is relieved.
10-116 2
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12 ACCUMULATOR (FOR PPC VALVE) 1. Valve
4. Oil port
2. Outer housing 3. Piston Specifications Type of gas: Gas amount: Max. actuation pressure: Min. actuation pressure:
Nitrogen gas 3000 cc 30 kgf/cm2 (426.7 lbf/in2) 12 kgf/cm2 (170.68 lbf/in2)
FUNCTION • The accumulator is installed between the hydraulic pump and PPC valve. The chamber above the piston is charged with nitrogen gas. Once this gas is compressed during normal operation, it can be used to lower the boom and bucket under their own weight after the engine has been shut down.
OPERATION • After the engine is shut down and the PPC valve is in a NEUTRAL position, chamber (A), which contains a specific volume of nitrogen gas above the piston is compressed by pressurized oil in chamber (B). •
When the PPC valve is operated, the pressure in chamber (B) drops below 30 kgf/cm2 (426.7 lbf/in2) and the compressed nitrogen gas in chamber (A) pushes the piston downward. The actuating pressure is 12 to 30 kgf/cm2 (171 to 427 lbf/in2).
WA700-3L
10-117 2
STRUCTURE AND FUNCTION 12 MAIN
HYDRAULIC
CONTROL VALVE
10-118 2
PA1:
From P4 of PPC valve
B1:
To bucket cylinder rod side
PA2:
From P3 of PPC valve
B2:
To boom cylinder rod side
PB1:
From P1 of PPC valve
P:
Pump port
PB2:
From P2 of PPC valve
P1:
From P3 of PPC valve
A1:
To bucket cylinder bottom side
P2:
From P2 of PPC valve
A2:
To boom cylinder bottom side
T:
To hydraulic tank
WA700-3L
STRUCTURE AND FUNCTION
HYDRAULIC
12
WA700-3L
1. Main relief valve
6. Bucket spool
2. Bucket spool return spring
7. Suction valve
3. Boom spool return spring
8. Unloader valve
4. Boom spool
9. Float selector valve
5. Body
10. Safety valve (with suction)
10-119 2
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
WORK EQUIPMENT WORK EQUIPMENT LUBRICATION
1. Bucket cylinder
6. Transmission
D. To boom pivot pin (right)
2. Front frame
7. Torque converter
✥✎ ✴❏ ▲▼❅❅❒❉■❇ ❃❙●❉■❄❅❒ ✈●❅❆▼✉
3. Steering cylinder
A. To center hinge pin (top)
F.
4. Boom cylinder
B. To bucket cylinder bottom
G. To center support
5. Bellcrank
C. To boom pivot (left)
10-120 2
To steering cylinder (right)
WA700-3L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
WA700-3L
H. To front axle support
J.
I.
K. To rear axle support cover
To torque converter trunnion
To rear axle support
10-121 2
STRUCTURE AND FUNCTION 12 WORK
WORK EQUIPMENT
EQUIPMENT LINKAGE
1. Tooth with tip
6. Bucket cylinder
2. Sweeper wing
7. Boom
3. Bucket
8. Boom cylinder
4. Bucket link
9. Cord ring
5. Bellcrank
10-122 2
WA700-3L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
WA700-3L
10-123 2
STRUCTURE AND FUNCTION 12 BUCKET
WORK EQUIPMENT
POSITIONER AND BOOM KICK-OUT
1. Proximity switch (for bucket positioner) 2. Proximity switch (for boom kick-out) 3. Bucket cylinder rod 4. Lever 5. Plate
10-124 2
WA700-3L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 BUCKET POSITIONER •
The bucket positioner is electrically actuated and is used to automatically obtain the optimum digging angle for the bucket. When the bucket is moved from the DUMP position to the TILT position, and it reaches the desired angle, the bucket lever is automatically moved from the TILT position to neutral.
•
Lever (2) is secured by bolts to bucket cylinder rod (1). A proximity switch (3) is fixed by bolts to the cylinder.
•
When the bucket is moved from the DUMP position to the TILT position, the bucket cylinder rod moves to the left. At the same time, lever (2) also moves to the left. When it reaches the desired position, lever (2) separates from proximity switch, and the bucket lever returns to neutral.
BOOM KICK-OUT •
The boom kick-out is electrically operated and acts to stop the boom. When the boom reaches the desired position before the maximum height, the boom lever is returned to neutral.
•
Plate (4) is secured to the boom. A proximity switch (5) is fixed to the frame. When the boom is moved from the LOWER position to the RAISE position, the boom rises. When it reaches the desired position, the proximity switch and plate come into contact and the boom lever is returned to neutral.
WA700-3L
10-125 2
STRUCTURE AND FUNCTION 12 PROXIMITY
WORK EQUIPMENT
SWITCH - OPERATION
BOOM RAISE •
When the boom is lower than the set position for the kickout, the detector (steel plate) is not above the detection surface of the proximity switch, so the proximity switch load circuit is shut off. The relay switch is turned OFF and the current for the solenoid is shut off.
•
When the boom lever is moved to the RAISE position, the boom spool is held at the RAISE position by the cam follower and cam on the lever, and the boom rises.
10-126 2
WA700-3L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 •
When the boom rises and reaches the set position for the kick-out, in other words, the detector (steel plate) is in position on the detection surface of the proximity switch, an electric current is sent to the solenoid by the action of the proximity switch and relay circuit. As a result, the solenoid is actuated, and the cam is pulled away from the cam detent, so the boom spool is returned to the HOLD position by the return spring.
Action of proximity switch When detector is in position at detection surface of proximity switch
When detector is separated from surface of proximity switch
Lights up
Goes out
Proximity switch load circuit (relay switch circuit)
Current flows
Current is shut off
Relay switch load circuit (solenoid circuit)
Current flows
Current is shut off
Position Proximity switch actuation display
WA700-3L
10-127 2
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
BUCKET TILT •
When the bucket is dumped beyond the set position for the auto-leveler, the sensor (steel plate) is above the detection surface of the bucket proximity switch, so electric current flows in the proximity switch load circuit. The positioner relay is turned ON and the current for the solenoid is shut off.
•
When the bucket lever is moved to the TILT position, the bucket spool is held at the TILT position by the cam follower and cam on the lever, and the bucket tilts.
10-128 2
WA700-3L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 •
When the bucket tilts and reaches the set position for the bucket leveler, in other words, the sensor (steel plate) separates from the detection surface of the proximity switch, electric current is sent to the solenoid by the action of the proximity switch and relay circuit. As a result, the solenoid is actuated, and the cam is pulled away from the cam detent, so the bucket spool is returned to the HOLD position by the return spring.
Action of proximity switch When sensor is in position at detection surface of proximity switch
When sensor is separated from detection surface of proximity switch
Proximity switch actuation display
Lights up
Goes out
Positioner relay
Current flows
Current is shut off
Current is shut off
Current flows
Position
Solenoid (for bucket)
WA700-3L
10-129 2
STRUCTURE AND FUNCTION
AIR CONDITIONER
12
AIR CONDITIONER AIR CONDITIONER PIPING
1. Vent
6. Compressor
2. Window defroster
7. Hot water inlet port
3. Vent
8. Hot water outlet port
4. Dry receiver
9. Air conditioner unit
5. Air conditioner condenser
10-130 2
WA700-3L
STRUCTURE AND FUNCTION
AIR CONDITIONER
12 AIR CONDITIONER CONDENSER
WA700-3L
1. Refrigerant gas inlet port
3. Connector
2. Fan
4. Refrigerant gas outlet port
10-131 2
STRUCTURE AND FUNCTION 12 AIR
AIR CONDITIONER
CONDITIONER COMPRESSOR 1. Refrigerant Outlet Port 2. Refrigerant Inlet Port 3. Relief valve 4. Clutch SPECIFICATIONS Type: Piston pump type Refrigerant used: R134a
10-132 2
WA700-3L
STRUCTURE AND FUNCTION
AIR CONDITIONER
12 DRY RESERVOIR
1. Cap 2. Body 3. Drier
WA700-3L
10-133 2
STRUCTURE AND FUNCTION
MAIN MONITOR SYSTEM
12
MAIN MONITOR SYSTEM
OUTLINE • The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine. •
The machine monitor system consists of the main monitor, maintenance monitor, sensors, switches, relays, alarm buzzer, and power source.
•
The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine where an alarm is given) and normal conditions which are always displayed on the instrument panel (pilot lamps and readings for the gauges, speedometer, and service meter).
•
There are also various switches built into the monitor panel which function to operate the machine.
★ The main monitor uses the network wiring to send signals to the controller, and functions to display the following information. ¿ Shift indicator: 1st - 4th, N, F, R (F, R are optional) (When auto shift, joystick steering are installed) ¡ HOLD ¬ Failure action code, failure code, time elapsed since failure (failure data display mode)
10-134 2
WA700-3L
STRUCTURE AND FUNCTION
MAIN MONITOR SYSTEM
12 MAIN MONITOR
1. Check lamp
4D. Speedometer
5B. Engine low idling switch
2. Caution lamp
4E. Shift hold
5C. Working lamp (front sw)
3. Cautions items
4F. Parking brake
5D. Working lamp (rear sw)
4G. Ground steering normal
5E. Transmission cut-off sw
4H. Monitor pilot lamp (preheating, afterheating)
5F. Auto shift, manual selector sw
3A. Ground steering actuated 4. Pilot items 4A Turn signal (left) 4BTurn signal (right) 4C. Shift indicator
4I. Failure action code 5. Switches 5A. Auto grease switch
OUTLINE • The main motor has display function for the speedometer and other gauges and a switching function to control the electric components and controllers. • There is one CPU (Central Processing Unit) installed internally, and this processes the signals from the sensors and outputs the display. • A liquid crystal display and LEDs are used for the display. The switches are embossed sheet switches.
WA700-3L
10-135 2
STRUCTURE AND FUNCTION 12 MAIN
MAIN MONITOR SYSTEM
MONITOR DISPLAY FUNCTION TABLE
Display category
Display range
Display method
Check
When there is abnormality display on maintenance monitor
Display flashes (for details, see MAINTENANCE MONITOR DISPLAY FUNCTION)
Ground driven steering actuated (when equipped with ground driven steering)
When actuated
Displays flashes
Parking brake actuated, transmission not at neutral
Display flashes and buzzer sounds
When there is abnormality display on maintenance monitor
Display flashes (buzzer may also sound) (for details, see MAINTENANCE MONITOR DISPLAY FUNCTION)
Turn signal (left, right)
When operated
Display lights up
Parking brake
When operated
Display lights up, buzzer sounds when parking brake is applied and shift lever is not at N
Ground driven steering actuated (when equipped with ground driven steering)
When normal (oil is flowing in hydraulic circuit)
Display lights up
Preheating
When preheating
Lights up, lighting up time changes according to engine water temperature when starting switch is turned on (for details, see PREHEATING CIRCUIT)
Shift hold (machine equipped with auto shift)
When shift is held
Displays lights up
Speedometer
Travel speed
0 - 99 km/h or 0 - 61.5 mi/h which ever is set in the speedometer (to change speed read out, see section twenty of the shop manual)
Digital display (display switches between tachometer and speedometer)
Shift indicator
Shift indicator
1 - 4, N
Digital display
Check
Symbol
Display item
Caution Caution
Pilot
10-136 2
WA700-3L
STRUCTURE AND FUNCTION Display category
Symbol
MAIN MONITOR SYSTEM
Display item
Display range
Display method Digital display Buzzer sounds (for details of travel data display mode, see TROUBLE DATA DISPLAY MODE)
Digital display
Failure action code
Failure action code
When controller detects failure and action by operator is needed, CALL is displayed, or CALL and E _ _ (action code) are displayed in turn
Shift indicator
F, R, display (when equipped with joystick steering)
F, R
WA700-3L
10-137 2
STRUCTURE AND FUNCTION 12 MAIN
MAIN MONITOR SYSTEM
MONITOR SWITCH FUNCTION Item
Auto-greasing
Engine low idling
Working lamp (front)
Working lamp (rear)
Transmission cut-off
Manual
10-138 2
Function
Display
Actuation
Lights up (goes out momentarily when switch is turned ON)
Auto-greasing control actuated (automatic greasing carried out at fixed internal)
Flashes (slowly)
Grease empty
Flashes (rapidly)
Abnormality in auto-greasing
Goes out
Auto-greasing no installed
Engine low idling speed is changed between two stages each time switch is pressed
Lights up
Low idling speed set to approx. 850 rpm
Goes out
Low idling speed set to approx. 650 rpm
Front working lamp lights up or goes out each time switch is pressed when side lamps are lighted up
Lights up
Front working lamp lights up
Goes out
Front working lamp goes out
Rear working lamp lights up or goes out each time switch is pressed when side lamps are lighted up
Lights up
Rear working lamp lights up
Goes out
Rear working lamp goes out
Transmission cut-off function is actuated or stopped each time switch is pressed
Lights up
Cut-off function actuated
Goes out
Cut-off function stopped
Auto shift mode switches to manual mode when switch is pressed (when equipped with auto shift)
Lights up
Manual mode
Goes out
Auto shift mode
Forced greasing is carried out while switch is being pressed when display is lighted up (when equipped)
controller
WA700-3L
STRUCTURE AND FUNCTION
MAIN MONITOR SYSTEM
12 TROUBLE DATA DISPLAY MODE Item
Switch operation
Actuation
Method of switching to trouble data display mode
With engine stopped and starting switch turned ON, press 2nd switch from top on left side of main monitor (switch below ground steering display) and working lamp (front) switch simultaneously for at least 5 seconds.
All switch displays (LEDs) go out and failure code is displayed on speedometer display and time elapsed since failure is displayed on failure action code display. • Failure code is a two-digit display given in numbers or letters. The display for the failure now occurring flashes and the display for past failures lights up If there is no failure, CC is displayed (000 is displayed for time elapsed since failure. • The time elapsed since failure is displayed as a three-digit number to show how long ago the failure occurred. (the oldest failure time is displayed. Any time greater than 999H is displayed as 999H). • A maximum of 9 items are stored in memory for the failure code.
Method of sending failure code
Press working lamp (front) switch
Failure code and time elapsed since failure change to next item
Clearing failure code
Press working lamp (rear) switch for at least 2 seconds
Failure code and time elapsed since failure being displayed are cleared. Failure code for problem now occurring (flashing display) cannot be cleared.
Resetting to travel data display mode
Press 2nd switch from top on left side of main monitor (switch below ground driven steering display) and working lamp (front) switch simultaneously for at least 5 seconds or start the engine.
Changes to normal display
WA700-3L
10-139 2
STRUCTURE AND FUNCTION
MAINTENANCE MONITOR
12
MAINTENANCE MONITOR
1.
2.
Check Items (Checks Before Starting)
2D. Air cleaner (LH)
1A. Engine water level
2E. Air cleaner (RH)
4A. Service meter numeric display
1B. Engine oil level
2F. Transmission oil filter
4B. Service meter RUN pilot lamp
Caution items (warning items)
3.
4.
Service meter
Gauges items
5.
Monitor module
2A. Engine oil pressure
3A. Fuel level
6.
Switch module
2B. Brake oil pressure
3B. Engine water temperature
2C. Battery charge
3C. Torque converter oil temperature
OUTLINE • The maintenance monitor has a display function for the caution items and gauges. • The maintenance monitor consists of the monitor module, switch module, service meter, case, and other mechanisms. • The monitor module has a built-in CPU (Central Processing Unit). It processes the signal from the sensors, and carries out the display and output. • A liquid crystal display and LEDs are used for the display portions. The switches are embossed sheet switches.
10-140 2
WA700-3L
STRUCTURE AND FUNCTION
MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION TABLE Display Category
Symbol
Display item Engine water level
Display range Below low level
Display method Displays when engine is stopped and starting switch is ON.
Display when normal: OFF Display when abnormal: Flashes CHECK lamp flashes
Engine oil level
Below level
Transmission oil filter
Above specified differential pressure
Displays when engine is running
Below level
Displays when engine is running
Check
Engine water level
Caution
Display when normal: OFF Display when abnormal: Flashes
Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Buzzer sounds
Engine oil pressure
Below specified pressure
Brake oil pressure
Below specified pressure
Engine water temperature
Above 102°C / 215.6°F
Buzzer sounds if above 105°C / 221°F
Torque converter oil temperature
Above 120°C / 248°F
Buzzer sounds if above 130°C / 266°F
Fuel level
Below low level
Displays when engine is running
Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Battery charge
Air cleaner
WA700-3L
When charge defective
is
Displays when engine is running
Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes
Above specified negative pressure
10-141 2
STRUCTURE AND FUNCTION Display Category
Symbol
Display item Service meter
Service meter
MAINTENANCE MONITOR Display range 0 - 9999.9h
Service meter indicator
Display method Actuated when charge is normal Advances 1 for every hour
Lights up when service meter is running ---
Fuel level
All lamps light up below applicable level
Flashes when level is 1
Engine water temperature
One place lights up to show applicable level
Flashes when level is 6 or 7
Gauges
Torque converter oil temperature
10-142 2
WA700-3L
STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 AUTOMATIC TRANSMISSION SYSTEM (ATM)
OUTLINE OF SYSTEM • Automatic transmission system consists of the transmission controller, directional and speed levers, engine speed sensor, speed sensor and all-speed-range solenoid. •
The transmission controller controls the shifting to the appropriate speed range according to the lever position and travel speed signal.
•
A travel damper function and joystick steering control function are available as options, and these controls are possible if the function is installed to the machine.
•
To improve durability, there is a safety function which prevents the machine from moving suddenly when the engine is started, and a transmission protection function which protects the clutch when the direction of travel is changed.
•
The self-diagnostic function always observes the input and output condition, and displays the output condition on the two 7-segment LED displays on the transmission controller. There is also a failure detection function, and if any abnormality occurs, it displays a failure code. Depending on the condition, it also displays a failure action code on the main monitor and flashes the caution lamp to improve safety.
•
The transmission controller has a communications function, and it sends the speed range (N, 1st - 4th) data to the main monitor, which displays the speed range. (If the joystick mode is used, it also displays F and R.)
WA700-3L
10-143 2
STRUCTURE AND FUNCTION 12 SYSTEM
10-144 2
AUTOMATIC TRANSMISSION SYSTEM (ATM)
STRUCTURE DIAGRAM
WA700-3L
STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 OUTLINE 1. Auto-shift function Shifting the transmission up or down is carried out when the engine speed is above 1450 rpm. Shifting is decided by signals from the directional lever, speed lever, and travel speed sensor according to [Table 1 Automatic gear shift change point table] recorded in the memory of the transmission controller. A. Speed lever (1st - 4th) This controls the maximum speed range (available speed range) for automatic gear shifting. Example: Speed lever at 4: 2nd - 4th Speed lever at 2: 2nd only Speed lever at 1: 1st only B. Directional lever N position At the neutral position, only the speed range clutch is engaged in the transmission. C. Directional lever F position When the directional lever is operated from N to F, the transmission turns ON (F2) the F and 2nd SOLs solenoids). (Automatic start in 2nd) i.
Shift up (when speed lever is at 4) When the accelerator pedal is depressed to increase the engine speed and the travel speed rises, SOL 3rd is turned ON when the travel speed reaches approx. 9.3 km/h (5.7 mi/h), and at the same time, 2nd is turned OFF. (Shifts to F3) When the travel speed rises further to approx. 17.6 km/h (10.9 mi/h), SOL 4th is turned ON and at the same time, 3rd is turned OFF. (Shifts to F4)
ii.
Shift down (speed lever at 4) When traveling in 4th, if the accelerator pedal is let back, and the travel speed comes down to approx. 15.6 km/h (9.6 mi/h), SOL 3rd is turned ON and 4th is turned OFF. (Shifts to F3) When the travel speed goes down further to approx. 9.8 km/h (6.0 mi/h), SOL 2nd is turned ON and 3rd is turned OFF. (Shifts to F2)
D. Directional lever R position Automatic gear shifting is carried out between 2nd and 4th speeds according to the travel speed (when the speed lever is at 4) in the same way as when the directional lever is at the F position. E. Skip shift When coasting (in engine speed OFF mode) in 3rd or 4th speed with the accelerator pedal depressed, if the travel speed is less than 8 km/h (4.9 mi/h), the gear shifts down to 2nd to make it easier to accelerate. If the travel speed is more than 8 km/h (4.9 mi/h), the speed range is maintained, and when the engine speed goes above 1450 rpm, the gear is shifted to a range that matches the travel speed. F.
Gear shift prevention interval To prevent shift hunting after shifting gear, a time interval is set to maintain the speed range. The gear shift prevention interval differs according to the shift pattern. For details, see [Table 1 Automatic gear shift change point table].
2. HOLD function When the HOLD switch is pressed, the speed range is held at the optimum speed range, and even if the travel speed goes down, the transmission does not shift down. However, when switching between forward and reverse, the transmission normally shifts down to 2nd according to the travel speed, and then shifts up to the HOLD shift range according to the travel speed and gear shifting conditions. (This prevents any unnecessary shift down when leveling or when traveling downhill.) 3. Kick-down function When the operator turns the kick-down switch ON, it overrides the auto-shift and switches down forcibly to 1st
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AUTOMATIC TRANSMISSION SYSTEM (ATM)
if the conditions (speed range, travel speed) in [Table 1 Automatic gear shift change point table, Item 5 Kickdown] are fulfilled. The conditions for canceling this are if the travel speed rises or if the direction is shifted between forward and reverse. In these conditions, the gear is shifted to 2nd. This function is also active when holding the speed range (hold, engine speed OFF mode). 4. Travel mode A.
Manual mode (option) It is possible to switch between auto and manual shift. When using the manual mode, if the speed lever is operated, the gear is shifted immediately according to the operation of the speed lever. When traveling in F2, it is also possible to use the kick down function.
B. Joystick steering control function (option) i.
If the machine is equipped with the joystick steering function, the operator can switch between steering wheel and joystick steering mode as desired.
ii.
When switching the steering between steering wheel and joystick steering, always stop the machine first, return the speed lever to the N position, then switch the steering. When this is done, the transmission controller is set to the neutral safety condition to prevent the machine from suddenly moving. For details, see [Transmission controller travel mode and function table].
5. Safety functions A. Neutral safety When the engine is started, if the directional lever is at any position other than N, the transmission controller keeps the transmission in neutral and prevents the machine from moving. If the N signal is input after the engine is started, the neutral safety is canceled. B. Neutral interlock • When switching from steering wheel to joystick steering, the transmission is always set to neutral. • When switching from joystick steering to steering wheel, it is impossible to start the machine until the N signal is input. C. Speed lever priority It is possible to shift down immediately by operating the speed lever, so the engine can be used as a brake when traveling downhill. D. Transmission protection When traveling in 3rd or 4th speed, the travel speed range is controlled and a warning buzzer sounds to protect the transmission if the operator tries to shift between forward and reverse. i.
Speed range control When the speed range and travel speed fulfill the conditions for Range I, the transmission shifts down to 2nd. When the speed range and travel speed fulfill the conditions for Range II, the speed range is maintained and the transmission shifts down to 2nd according to the deceleration. (For details, see Fig. 1 F - R selector shift pattern, [Table 1 Automatic gear shift change point table, Item 7 F - R selection].)
ii.
Alarm buzzer When the speed range and travel speed are in Range III, the alarm buzzer sounds to warn the operator. (If the engine speed is above 1700 rpm and the travel speed is above 13 km/h [8.0 mi/h], or the travel speed is above 14 km/h. [8.6 mi/h]) (See Fig. 2 F - R selection alarm buzzer range.)
E. Transmission protection in joystick manual mode Together with the easier shift down and shifting between F and R, in the joystick manual mode, for 1st and
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
2nd also, there is a function to protect the transmission by shifting up to 3rd or 4th according to the travel speed and engine speed. The alarm buzzer also sounds in this case. F.
Table 1
Manual shift If the travel speed sensor is abnormal and it is impossible to detect the travel speed data, the transmission is set to manual (shift) mode. Automatic gear shift change point table
Item
1.
2.
3.
4.
5.
6.
7.
8.
Speed range
Travel speed
Gear shift prevention interval (sec.)
1?2
5.3 (5.5) km/h 3.2 (3.4) mi/h or above
2
2?3
8.9 (9.4) km/h 5.5 (5.8) mi/h or above
2
3?4
16.6 km/h 10.3 mi/h or above
1
4?3
Less than 14.6 km/h 9.0 mi/h
1
3?2
Less than 9.4 (8.9) km/h 5.8 (5.5) mi/h
2
Engine speed (less than 1450 rpm)
4?2
Less than 1.0 km/h 0.6 mi/h
0
3?2
Less than 1.0 km/h 0.6 mi/h
0
Engine speed (less than 1450 rpm ? more than 1450 rpm
4?2
Less than 8.0 km/h 4.9 mi/h
2
3?2
Less than 8.0 km/h 4.9 mi/h
2
1?2
5.3 km/h 3.2 mi/h
0
2?3
8.9 km/h 5.5 mi/h
0
3?4
16.6 km/h 10.3 mi/h
0
2?1
Whole range
5
3?1
Less than 11.1 km/h 6.8 mi/h
5
4?1
Less than 11.1 km/h 6.8 mi/h
5
FR selection (Fig. 1, Range I) (F ?) N ? R (R ?) N ? F
4?2 3?2 1?2
Note 1
FR selection (Fig. 1, Range II) (F ?) N ? R (R ?) N ? F
?4 ?3
Note 2 16.6 km/h 10.3 mi/h or above 1.9 - 16.5 km/h 1.1 - 10.2 mi/h
2
FR selection F?N?F R?N?R
?4 ?3 ?2
16.6 km/h 10.3 mi/h or above 8.9 - 16.5 km/h 5.5 - 10.2 mi/h Less than 8.9 km/h 5.5 mi/h
0
Basic shift change
Shift up when HOLD is ON
Shift down when kick down is ON
2
NOTE 1: When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h (9.9 mi/h), or when the travel speed is less than 13 km/h (8.0 mi/h). NOTE 2: When the engine speed is 1900 rpm or above and the travel speed is 13 km/h (8.0 mi/h) or above, or when the travel speed is 16 km/h (9.9 mi/h) or above, the speed range is maintained and the transmission shifts down to 2nd according to the deceleration.
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 6. Transmission controller travel mode and function table Steering wheel
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12ing Joystick steering
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
7. Switching transmission controller travel mode Specification when shifting modes [steering wheel ÷ joystick] and [auto ÷ manual] A. Neutral interlock function When shifting the mode, the neutral condition is maintained until the N signal is correctly received. B. Speed range The output for the speed range changes according to the mode selected. Table 2
Output speed range when mode is switched Condition after switching mode
Condition before switching mode
Steering wheel
Joystick
Auto
Manual
Auto
Manual
Auto
---
Position of speed lever (*2¿)
2nd (*1) (Switches at N)
---
Manual
2nd (*2¬)
---
---
Maintains speed range (switches at N)
Auto
2nd (*1) (Switches at N)
---
---
Holds previous position (*2¡)
Manual
---
Position of speed lever (switches at N)
2nd (*2¬)
---
Steering wheel
Joystick
(*1):
Normally, when switching the mode [steering wheel ÷ joystick], the switching is carried out with them machine stopped and in neutral, so the speed range becomes 2nd. If the machine is moving, the auto-shift [restart data] is used, and the transmission is set to a speed range that matches the travel speed. However, if the shift lever position is 1, the speed range becomes 1st.
(*2):
It is possible to switch between auto and manual when traveling if the same mode is retained. ¿ Steering wheel mode: For auto ? manual, the speed range is the position of the shift lever. ¡ Joystick mode: For auto ? manual, the speed range before shifting the mode is maintained (the speed range does not change). ¬ For manual ? auto, the auto-shift data [Table 1 Automatic shift change point table, Item 8 Switching between F and R] is used, and the transmission is set to a speed range that matches the travel speed. However, if the shift lever position is 1, the speed range becomes 1 st.
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 8. Self-diagnostic function The transmission controller always observes the input and output signals of the automatic gearshifting system. It carries out self-diagnosis and displays the results on the LEDs of the transmission controller. In addition, it sends the following data to the main monitor. A. Normal display:Transmission controller LEDs display output speed range. B. Failure code display: If an abnormality is detected, the nature of the failure is displayed as a code. For details of the failure codes, see [Table 3 Failure code table]. Table 3 Failure code table • Transmission controller (O = system monitored; X = system not monitored; --- = not applicable) Auto/manual transmission control system System Code
Main monitor
Item Short circuit
Disconnection
Action code
10
Backup lamp relay
O
O
None
11
None
---
---
---
12
F solenoid
O
O
CALL
13
R solenoid
O
O
CALL
14
1st solenoid
O
O
CALL
15
2nd solenoid
O
O
CALL
16
3rd solenoid
O
O
CALL
17
4th solenoid
O
O
CALL
18
None
---
---
---
19
Joystick direction switch
O
O
E00
20
Direction switch signal
O
O
CALL
21
Speed switch signal
O
O
None
22
Travel speed sensor
X
O
E00
23
Engine speed sensor
X
O
E00
Joystick control system System Code
Main monitor
Item Short circuit
Disconnection
Action code
56
Joystick caution relay output
O
X
None
57
Steering right solenoid (detected when output)
O
O
E00
58
Steering left solenoid (detected when output)
O
O
E00
59
Steering right solenoid Short circuit at HOT end
O
X
E00
60
Steering left solenoid Short circuit at HOT end
O
X
E00
61
Steering solenoid cut relay output
O
O
E00
62
Abnormality in joystick neutral switch (see separate page for range of detection)
O
O
E00
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WA700-3L
STRUCTURE AND FUNCTION Abnormality in joystick potentiometer (outside 0.5 - 4.5V)
63
AUTOMATIC TRANSMISSION SYSTEM (ATM) O
O
E00
★ E59 and E60 cannot be distinguished and are output at the same time. ★ E56 always outputs ON, so it is impossible to judge if there is a disconnection.
9. Communications function The transmission controller is equipped with a communications function using S-NET, and it always maintains communications with the main monitor. When any abnormality occurs, it displays an action code on the main monitor according to the condition of the problem to warn the operator in order to increase safety. The failure code can recognize the codes recorded in the main monitor memory using the main monitor trouble data mode. For details of operating the main monitor, see the section on the main monitor. 10. Transmission controller power source When the starting switch is turned ON and the supply voltage is more than 20V, and +20V or more is supplied to the transmission controller solenoid power source input, it is possible to control the drive of each solenoid valve. If the supply voltage is less than 19V, all outputs are turned OFF and the solenoids cannot carry out control (travel is impossible). 11. Input signals A. Directional lever signal (F, N, R) This signal is a +24V/OPEN digital signal, and when it is normal, one of F, N, or R signals (+24V) is input. B. Speed lever signal (1st - 4th) This signal is a +24V/OPEN digital signal and +24V is input for the signal for the lever position. C. Kick down switch/shift-down switch This signal is a +24V/OPEN digital signal. When the kicking switch installed to the work equipment control lever is pressed, +24V is input. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. In the joystick manual mode it is used as the shift-down switch. D. Hold switch/shift-up switch This signal is a +24 V/OPEN digital signal. When the HOLD switch installed to the work equipment control lever is pressed, +24V is input. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. In the joystick manual mode it is used as the shift-up switch. E. Neutralizer relay signal This signal is a +24V/OPEN digital signal. When the parking brake switch is released, +24V is input and travel becomes possible. When signal is OPEN, the transmission controller maintains the neutral condition. 24V: Parking brake released OPEN: Parking brake applied F.
Transmission cut-off signal This signal is a GND/OPEN digital signal, and when the transmission cut-off switch is operated (using the left brake), it changes to OPEN. When it is actuated, the transmission controller changes to the neutral output condition, and when it is canceled, it sets to a suitable speed range for the travel speed at that point.
G. Manual mode signal This signal is a GND/OPEN digital signal. When the manual mode switch is ON, GND is input.
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 12. Function selection signal This signal is a GND/OPEN digital signal. When the engine is started, the function is judged from this signal. A. Mode Table 4
Machine selection signal table
CN3-22
CN3-30
CN3-23
GND
OPEN
OPEN
B. Engine Table 5 Engine selection table Signal and data
Komatsu engine
Engine selection (CN3-10)
OPEN
C. Option function selection Table 6 Option (function) selection table Input signal
Signal condition
Auto-shift transmission (opt) (CN3-20)
OPEN
GND
OPEN
GND
Joystick steering (opt) (CN3-21)
OPEN
OPEN
GND
GND
--WA700-3L
Function Not set (*1)
Transmission auto/manual (opt)
Not set (*1)
Transmission auto/manual (opt) & joystick auto/ manual (opt)
*1: When NOT set condition is detected, all controller outputs are turned OFF and it is impossible to travel.
13. Engine speed sensor signal This signal is a pulse signal. It converts the pulses from the electromagnetic pickup sensor to rotation speed for control. When the engine speed is 1450 rpm or above, it is called the engine speed ON mode, and when the speed is less than 1450 rpm, it is called the engine speed OFF mode. 14. Travel speed sensor signal This signal is a pulse signal. It converts the pulses from the electromagnetic pickup sensor to rotation speed for control. 15. Communications signal (S-NET) This transmits the troubleshooting code to the main monitor.
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 16. Output signal A. Transmission signal ab
Table 7
Combination of speed ranges and solenoid O: ON
Speed range
SOL
---
F
F1
O
F2
O
F3
O
F4
O
R
1st
2nd
3rd
4th
O O O O
N R1
O
R2
O
R3
O
R4
O
O O O O
B. Backup lamp relay signal This signal is a +24V digital (ON/OFF) output. It is actuated when the directional lever is placed at R and lights up the backup lamp and caution lamp. C. Engine speed signal This outputs a signal at the same cycle as the engine speed sensor signal input to the transmission controller. D. Communications signal (main monitor display data) For details of the display position and operation of the main monitor, see the section on the main monitor.
i.
ii.
Speed range display 1st speed range output 2nd speed range output: 3rd speed range output: 4th speed range output: Neutral:
[1] [2] [3] [4] [N]
F, R display F, R are displayed in the joystick steering mode (option).
iii. HOLD display The pilot display is given on the main monitor when the HOLD function is ON.
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM (ATM)
12 17. LED display • When the engine is started, the display goes first to 1. "Program quality display mode" and next to 2. "Output speed range display mode". However, if any abnormality is detected, it goes immediately to the troubleshooting mode A. Program quality display mode When the power source is on, it switches once every second.
B. Output speed range display mode LED display X.Y.. (Both dots are out) X: Direction SOL drive condition FORWARD [F]: F, REVERSE [R]: A, Neutral: 0 T: Speed range SOL drive condition 1 - 4 Example
Display
Content
’0.2.’ ’F.1.’ ’A.2.’ ’F.F.’
Neutral, 2nd FORWARD, 1st REVERSE, 2nd Neutral safety condition
C. Troubleshooting display mode (currently existing failure) A cycle of [E-(2 sec)], [Code (2 sec)] is repeated. i.
When there is one abnormal item
ii.
When there is two abnormal items
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STRUCTURE AND FUNCTION
JOYSTICK
12 JOYSTICK
JOYSTICK TRANSMISSION SYSTEM 1. Combination of joystick steering, transmission control functions. O: Function is employed Steering wheel
Joystick
Boom lever switch Automatic
Manual
Automatic
Manual
Kick down function
O
O
O
---
Hold function
O
---
O
---
Up/down function
---
---
---
O
CN C5-5 input signal
Kick down
Kick down
Kick down
Shift down
CN C5-13 input signal
Hold
---
Hold
Shift up
2. Controller input signals • Common signal input for kick-down/shift down switch (CN C5-5 terminal). • Common signal input for hold/shift up switch (CN C5-13 terminal) Whether the joystick or the steering wheel is in use is indicated by the above signals. 3. • • •
•
Up/down shift switch function Shift up switch: Normal shift up is output by signal input. Shift down switch: Normal shift down is output by signal input. Judgement of the input of the switch uses the change in the ON/OFF condition of the signal. (When the switch is pushed, it becomes 0N (GND). In addition, it always uses the latest signal to judge shift up or down. The maximum speed range is set by the transmission lever. Range lever position
Speed range used
4 3 2 1
4-1 3-1 2, 1 1
4. Main monitor display
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STRUCTURE AND FUNCTION 12 TRANSMISSION
JOYSTICK
AND JOYSTICK CONTROLLER
Connector signal CN1 Pin No
Name of signal
Input/output
1
S/T SOL cut relay
Output
2
T/M F SOL
Output
3
T/M 1 SOL
Output
4
Engine revolution output
Output
5
T/M 3 SOL
Output
6
GND
Input
7
Power supply (+24V)
Input
8
Back lamp relay
Output
9
T/M R SOL
Output
10
T/M 2 SOL
Output
11
T/M 4 SOL
Output
12
GND
Input
13
Power supply (+24V)
Input
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STRUCTURE AND FUNCTION
JOYSTICK
Connector signal CN2 Pin No
CN3A Name of signal
Input/ output
Pin No
1
SOL power supply (+24V)
Input
1
NC
---
2
S/T RH SOL (+)
Output
2
NC
---
3
S/T LH SOL (+)
Output
3
S/T lever potentio meter
4
F LED (S/T)
Output
4
NC
---
5
R LED (S/T)
Output
5
NC
---
6
NC
---
6
Pressure sensor power supply
Output
7
N LED (S/T)
Output
7
Potentio power supply
Output
8
Neutral safety output (+)
Output
8
NC
---
9
Caution relay (S/T) (+)
Output
9
NC
---
10
Caution (monitor) (+)
Output
10
Engine select
11
PGND
Input
11
NC
---
12
SOL power supply (+24V)
Input
12
NC
---
13
S/T RH SOL (-)
Output
13
NC
---
14
S/T LH SOL (-)
Output
14
NC
---
15
NC
---
15
NC
---
16
NC
---
16
GND (for pressor sensor)
Output
17
NC
---
17
GND (for potentio)
Output
18
NC
---
18
NC
19
Caution relay (S/T) (-)
Output
19
Neutralizer relay
Input
20
NC
---
20
Auto shift T/M option
Input
21
PGND
WA700-3L
Name of signal
Input/ output
Input
Input
---
Input
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STRUCTURE AND FUNCTION
JOYSTICK
12 Connector signal CN3B Pin No
CN4 Name of signal
Input/ output
Pin No
Name of signal
Input/ output
1
Joystick S/T option
Input
1
NC
2
Machine select 1
Input
2
Engine revolution sensor (+)
Input
3
Machine select (EVEN parity)
Input
3
RS232C TXD
Input
4
S-NET +
Input
4
RS232C RXD
Input
5
Direction F
Input
5
NC
---
6
Directional R
Input
6
NC
---
7
Range SW1
Input
7
NC
---
8
Range SW3
Input
8
Flash write sig
9
NC
---
9
Engine rev/speed sensor (-)
10
Machine select 2
Input
10
RS232C GND
11
NC
---
11
NC
---
12
S-NET +
Input
12
NC
---
13
Direction N
Input
CN5
14
Joystick ON/OFF switch
Input
1
GND (for Plus)
15
Range SW2
Input
2
Speed sensor (+)
16
Range SW4
Input
3
GND
Output
4
GND
Output
5
Kick down SW/Shift down SW
Input
Machine Select Table Pin
---
Input Output Input
Output Input
CN3-22
GND
6
T/M cut off switch
Input
CN3-30
OPEN
7
Joystick N (NC)
Input
CN3-23
OPEN
8
Joystick F (NC)
Input
NOTE:
GND: connect CN2-9
9
Joystick R (NC)
Input
10
GND (for Plus)
Output
ON
11
S/T lever neutral switch
GND CN2-9
12
NC
13
Hold SW/ Shift up SW
Input
ON
14
Manual SW
Input
GND CN2-9
15
Joystick N (NO)
Input
16
Joystick F (NO)
Input
17
Joystick R (NO)
Input
Automatic T/M Functional Table Pin
OFF
CN3-20
OPEN
Joystick System Functional Table Pin
OFF
CN3-21
OPEN
Engine (Komatsu) Table Pin CN3-10
10-160 2
OPEN
Input ---
GND CN2-9
WA700-3L
STRUCTURE AND FUNCTION
ELECTRICAL
ELECTRICAL ENGINE STARTING CIRCUIT
Function • It is possible to start or stop the engine by turning the starting switch ON or OFF. An electrical device is used which controls the fuel injection amount and improves the ease of operation. Operation • When the directional lever is placed at the N position, the neutral contacts of the directional lever switch are closed. In this condition, if the starting switch is turned to the ON position, electric current flows from the starting switch terminal BR ? battery relay coil ? ground, and the switch of the battery relay coil is closed. The power supply from the battery passes through the directional lever switch, the neutral relay is actuated, and terminals 3 - 5 close. • When the starting switch is turned to START, electric current flows from starting switch terminal C ? neutral relay terminals 3 - 5 ? starting motor terminal C ? starting motor terminal E ? ground. • At the same time, the electric current from starting switch terminal ACC flows to the engine throttle controller as the governor cut relay and starting motor signal. Here, various signals, such as the water temperature, are calculated, and a signal is sent to the fuel injection pump to set the fuel injection amount to the optimum value. • A circuit is formed from the battery ? battery relay ? starting motor terminal B, so the engine starts. • If the directional lever is not at the N position, the neutral relay is not actuated, so the circuit is not formed and the engine does not start.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
STARTING WITH APS (actuated when engine water temperature is below 20°C[68°F]) 1. Open the APS fuel valve in the center of the left side of the engine. Leave the fuel valve open during the cold season when the temperature goes down and the APS is used. 2. Turn the starting switch ON. 3. Turn the fuel cut-off switch OFF, then turn the starting switch to the START position and crank the starting motor for approx. 10 seconds. ★ Do this to lubricate the whole engine with oil. ★ When the fuel cut-off switch is turned OFF, the fuel cut solenoid is turned OFF and the fuel injection pump is set to the NO INJECTION position. 4. Turn the fuel cut-off switch ON. ★ Release the switch and it will automatically return to the ON position. 5.
If the heater switch is set to the ON position, the monitor pilot lamp will light up and the glow lamp will preheat. ★ When the monitor pilot lamp lights up, set the heater switch to AUTO.
6. Depress the accelerator pedal half way. 7. The preheating stops after approx. 12 seconds and the monitor pilot lamp goes out. Turn the starting switch key to the START position to start the engine. ★ If the starting switch is turned to the START position while the monitor pilot lamp is still lighted up, the glow plug will become wet and it will be impossible to carry out ignition. 8. When the engine starts, return the starting switch to the ON position. 9. After the engine starts, when the engine rotation becomes smooth and the exhaust gas color becomes normal, turn the heater switch OFF.
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STRUCTURE AND FUNCTION
ELECTRICAL
★ After the engine is started and the engine water temperature reaches approx. 20°C (68°F), the monitor pilot lamp flashes to inform the operator that the afterheating has been completed. At the same time, the afterheating is automatically canceled.
ENGINE STOP CIRCUIT
Function • An electrical device is used which controls the fuel injection amount and improves the ease of operation by making it possible to start or stop the engine by turning the starting switch ON or OFF. Operation • When the starting switch is turned OFF, starting switch terminal B and terminals BR and C are opened. • The current to the engine throttle controller is also shut off, so there is no injection from the injection pump, and the engine stops.
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STRUCTURE AND FUNCTION 12 AUTO
ELECTRICAL
PRIMING SYSTEM (APS) 1. Main monitor 2. Monitor pilot lamp (preheating, afterheating) 3. Heater switch 4. Starting switch 5. Fuel cut-off switch 6. APS controller 7. APS water temperature 8. Battery 9. Fuel tank 10. Fuel injection pump 11. Engine cut-off valve 12. Fuel filter 13. Fuel valve 14. APS fuel injection nozzle 15. Glow plug 16. APS assister
FUNCTION • The APS system is used in cold areas to make it easier to start the engine. It works by burning fuel inside the intake manifold to heat the intake air. • The APS assister turns OFF the spray signal to the APS controller when starting in low temperatures, when the engine speed pickup is slow, or when the starting switch is released before the engine speed picks up (when the engine speed has not reached the speed required for the alternator to start generating). Therefore, it acts to hold the starting switch signal and maintain a continuous spray by the APS.
OUTLINE • The fuel flows from the tank through the feed pump of fuel injection pump (10) and is sent to fuel filter (12). At the outlet port of the fuel filter, it is connected to the APS fuel circuit. • The APS fuel circuit consists of fuel valve (13), bracket which divides the fuel, and APS fuel injection nozzle (14) which uses APS controller (6) to automatically adjust the amount of the fuel spray.
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STRUCTURE AND FUNCTION
ELECTRICAL
12 APS CONTROLLER
APS ASSISTER
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STRUCTURE AND FUNCTION
ELECTRICAL
12 OPERATION OF APS 1. OPERATION OF PREHEATING
• •
• •
When the starting switch is ON and the preheating switch is turned ON, electricity flows to the APS controller and APS assister power source circuit and makes it possible for it to be actuated. When this happens, if the engine cooling water temperature is below 13°C (55°F), the APS water temperature sensor is closed (ON). For this reason, even if the preheating switch is returned from ON ? AUTO, electric power is flowing to the APS controller, so the circuit is connected inside the controller. When the water temperature is below 20°C (68°F), the APS water temperature sensor closes (is turned ON). When the APS water temperature sensor is turned ON, the output signal is sent to glow 1 and glow 2 circuits inside the APS controller. Electric current flows in a circuit from glow plugs 1, 2 ? ground, and the glow plugs become red hot. While glow plugs 1 and 2 are being heated, the output signal is also sent to the preheating lamp circuit inside the APS controller, so the preheating/afterheating pilot lamp lights up. After the preheating pilot lamp lights up for the set time (approx. 12 sec), it goes out. This shows that glow plugs 1 and 2 have been heated enough by the action of the APS. The APS assister acts to hold the starting switch signal and maintain a continuous spray by the APS when starting in low temperatures, when the engine speed pick-up is slow, or when the starting switch is released before the engine speed picks up.
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12 2. OPERATION OF AFTER HEATING
•
•
After the preheating pilot lamp goes out, if the starting switch is turned to the START position, electric current flows to neutral relay terminals 3 - 5 and the starting motor starts to turn. At the same time, electric current flows from APS assister terminal S through terminal C to the circuit of starting switch terminal C of the APS controller and actuates the controller. The APS fuel injection nozzle inside the intake manifold is switched ON/OFF to inject fuel intermittently (10 times/sec) to glow plugs 1 and 2. (When electric power is applied, the APS controller sends the start signal, or when the stop signal is input because the starting safety relay is actuated, the intermittent injection signal is output to the APS fuel injection nozzle.) The fuel injection to glow plugs 1 and 2 is burned inside the intake manifold and heats the intake air. After the engine starts, the signal from the preheating switch - APS water temperature sensor actuates the fuel injection nozzle and carries out afterheating. After the engine starts and the warming-up operation raises the engine cooling water temperature to 20°C (68°F) or above, the APS water temperature sensor opens (OFF). As a result, the water temperature sensor signal to the APS controller is turned OFF. The output signal to glow plugs 1 and 2 is cut off, and at the same time the afterheating pilot lamp flashes. When starting work when the engine is running with the APS actuated and the engine water temperature above 20°’C (68°F), if the preheating switch is turned OFF, the APS controller power circuit is cut off, and the operation of the APS is stopped. At the same time, the afterheating pilot lamp display goes out.
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STRUCTURE AND FUNCTION 12 ELECTRICAL
ELECTRICAL
TRANSMISSION CONTROL
1. Transmission cut-off selector switch
6. Maintenance monitor
11. Speed sensor
2. Parking brake switch
7. Relays
12. Transmission cut-off switch
3. Directional lever
8. Fuse boxes
13. Brake valve (left)
4. Speed lever
9. Transmission controller
14. Brake valve (right)
5. Kick-down switch
10. Transmission control valve
FUNCTION 1
Selection of F, R and N positions
Using directional lever
2
Selection of speed range
Using speed lever
3
Kick-down switch
When traveling in F2, it is possible to shift down to 1st using this switch without using the speed lever. If directional lever is operated to R or N, speed range automatically returned to 2nd.
4
Transmission cut-off function
Transmission is shifted to neutral when left brake is operated.
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5
Transmission cut-off selector function
It is possible to select whether to actuate or not actuate the transmission cut-off function. In this way, it is possible to obtain the same or greater ease of operation as on conventional loaders with the left brake when carrying out scooping work or when loading or unloading the machine from a trailer
6
Neutralizer
To prevent seizure of the parking brake when traveling with the parking brake applied, the transmission is shifted to neutral when the parking brake is applied.
7
Neutral safety function
If the directional lever is not at the N position, the engine will not start when the starting switch is turned. This prevents the machine from starting suddenly. (For details see STARTING CIRCUIT.)
8
Warning function
When traveling in reverse, the backup lamp lights up and the backup horn sounds to warn people in the area.
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STRUCTURE AND FUNCTION 12 COMBINATION
ELECTRICAL
SWITCH
OUTLINE • The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is secured to the body by three screws. When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric current to flow to that circuit only. GENERAL LOCATIONS, FUNCTION 1
Directional lever switch
Switches between F, R and N
2
Speed lever switch
Selects speed range
3
Speed lever stopper
Stopper used to prevent speed lever from entering 3rd or 4th during operations
4
Turn signal indicators
Direction indicator lamps used when turning left or right
5
Self cancel
Turn signal lever automatically returns to central position after machines turns left or right
6
Lamp switch
Switches on clearance lamp, head lamp, parking lamp, etc.
7
Dimmer switch
Selects high beam for travel and low beam for passing
8
Hazard switch
Makes both left and right turn signal indicator lamps flash at the same time.
9
Emergency flashing pilot lamp
Flashes at the same time as the emergency flashing lamp flashes
10
Parking brake switch
Applies or releases parking brake
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12 OPERATION • Directional lever (1) and shaft (2) of the speed lever of the combination switch form one unit with magnet (3), and magnet (3) also moves together with lever (1). • Control switch (5) with built-in hole IC (4) is installed at the bottom of magnet (3), and hole IC (4) is positioned on the board to match each position. • When directional lever (1) is operated to the F position, magnet (3) is immediately above hole IC (4) for the F position of the control switch. The magnetism from magnet (3) passes through the gap and case (6), and magnetism is applied to hole IC (4). • When this happens, hole IC (4) is inside a magnetism detection circuit, so it detects the magnetism of magnet (3) and sends the F position signal to the electric current amplification circuit. In the electric current amplification circuit, a signal is output to actuate the transmission.
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STRUCTURE AND FUNCTION 12 KICK-DOWN,
ELECTRICAL
HOLD SWITCH
1. 2. 3. 4. 5.
Kick-down switch Spring Spring Hold switch Wiring harness
KICK-DOWN SWITCH OPERATION • The kick-down (shifting down from 2nd to 1st) is actuated only when traveling in F2. • When traveling in F2, if it is desired to shift down to 1st without operating the speed lever, operate the kickdown switch on the boom lever to ON to shift down to F1. • After this, even if the kick-down switch is pressed, the transmission is kept at F1. CANCELLATION (or not actuated) • When directional lever is at N • When directional lever is at R • When speed lever is not at 2nd • When starting switch is OFF HOLD SWITCH • The hold switch is installed to the boom lever, and when the hold switch is pressed, the speed range displayed on the main monitor transmission indicator is held. • Press the hold switch again to cancel.
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12 KICK-DOWN ELECTRICAL CIRCUIT NORMAL OPERATION
When directional lever is operated to F • When the directional lever is operated to F, electric current flows in the following circuit. Battery ? directional lever switch terminal F ? FORWARD solenoid relay terminal 6 - 5 ? ground. Because of this, the FORWARD solenoid relay is actuated, and the circuits between terminals 1 and 2, and between terminal 3 and 4 are closed. • In addition, electric current flows in the following circuit. Battery ? parking brake safety relay terminals 3 - 5 ? parking brake switch terminals 3 - 2 ? neutralizer relay terminals 2 - 1 ? ground, and neutralizer relay terminals 3 - 5 are connected. • Next, electric current flows from battery ? neutralizer relay terminals 3 - 5 ? transmission cut-off switch ? FORWARD solenoid relay terminals I - 2 ? FORWARD solenoid ? ground, so the FORWARD solenoid is actuated and the FORWARD clutch is engaged. When speed lever is set to 2nd • When the speed lever is set to 2nd, electric current flows from battery ? transmission lever power source? speed lever switch 2nd terminal ? 2nd-1st selector relay terminals 3 - 6 ? 2nd solenoid ? ground, and the 2nd solenoid is actuated. • When the kick-down switch is operated, the kick-down relay is actuated, so the circuit between 2nd-1st selector relay terminals 3 - 6 opens, and the contacts of terminals 3 - 6 close. As a result, electricity flows to the 1st solenoid and the transmission is shifted to 1st.
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STRUCTURE AND FUNCTION
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12 WHEN KICK-DOWN SWITCH IS OPERATED When operating or traveling with transmission lever at F2 position
WHEN KICK-DOWN SWITCH IS PUSHED ON • When the directional lever is operated to F, electric current flows in the circuit from battery ? directional lever switch terminal F FORWARD solenoid relay terminals 6 - 5 ? ground. Because of this, the FORWARD solenoid relay is actuated, and the circuits between terminals 1 and 2, and between terminal 3 and 4 are closed. In addition, if the speed lever is at 2nd, electric current flows from the battery ? speed lever 2nd switch ? FORWARD solenoid relay terminals 3 - 4 ? kick-down switch and kick-down relay terminal 1. • In this condition, if the kick-down switch is pushed, electric current flows from FORWARD solenoid relay terminals 3 - 5 ? kick-down switch ? kick-down relay 6 - 5 ? ground. Because of this, the kick-down relay is actuated, and the circuits between terminals 1 and 2, and between terminals 3 and 4 are closed. • When this happens, a circuit is formed from FORWARD solenoid relay terminal 4 ? kick-down relay terminals 1 - 2 ? kick-down relay terminals 6 - 5 ? ground. As a result, even if the kick-down switch is returned, the kickdown relay continues to be actuated. (Self-hold circuit of kick-down relay) • When the kick-down relay is actuated, electric current flows from battery ? kick-down relay terminals 3 - 4 ? 2nd-1st selector relay terminals 2 - 1 ? ground in the 2nd-1st selector relay coil, the relay coil is actuated, the circuit between terminals 3 - 6 is opened, and the circuit between terminals 3 - 5 is closed. • When 2nd-1st selector relay terminals 3 - 5 are connected, electric current flows from battery ? 2nd-1st selector relay terminals 3 - 5 ? 1st solenoid ? ground, and the transmission is shifted down from 2nd to 1st. After the kick-down is operated, even if the kick-down switch is pressed many times, it is connected in parallel and the circuit between kick-down terminals 1 - 2 is closed, so it has no effect on the actuation of the kickdown.
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OPERATION FOR CANCELING KICK-DOWN I When directional lever is placed at N or R
•
• •
• •
•
When the directional lever switch is at a position other than F, the F terminal contact is OFF, so the electric current from the battery is cut off. No electric current flows to FORWARD solenoid relay terminals 6 - 5 and the FORWARD solenoid is reset. When this happens, FORWARD solenoid relay terminals 3 - 4 are opened, so the electric current stops flowing to kick-down relay coil terminals 6 - 5, the kick-down relay is reset, and the self-hold circuit is canceled. When the kick-down relay is reset, kick-down relay terminals 3 - 4 are opened, so the electric current from the battery is cut off and stops flowing. The 2nd-1st selector relay is reset, the circuit between relay terminals 3 - 5 is opened, and the circuit between terminals 3 - 6 is closed. The electric current flowing to the 1st solenoid is cut off and the kick-down setting to 1st is canceled. In addition, the circuit between 2nd-1st selector relay terminals 3 - 6 is closed, so the electric current from the battery flows to the 2nd solenoid, and the transmission speed range is set to 2nd, the same as the position of the speed lever. In this way, the actuation of the kick-down switch is canceled and travel operations are carried out according to the normal lever commands. If the directional lever is set to R, the machine will travel in R2.
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STRUCTURE AND FUNCTION
ELECTRICAL
12 OPERATION FOR CANCELING KICK-DOWN II When speed lever is at a position other than 2nd
•
• •
• •
When the speed lever is operated to a position other than 2nd, speed lever switch 2nd terminal is cut off. The electric current stops flowing from battery ? FORWARD solenoid relay terminals 3 - 4 ? kick-down relay terminals 1 - 2, 6 - 5 ? ground, and the kick-down relay is reset. When this happens, the circuit between kick-down relay terminals 1 - 2 is opened and the self-hold is canceled, so even if the speed lever is again set to 2nd, the kick-down switch is not actuated. At the same time, kick-down relay terminals 3 - 4 are also opened, so electric current from the battery stops flowing. To 2nd-1st selector relay terminals 2 - 1, and 2nd-1st selector relay is reset. When the relay is reset, relay terminals 3 - 5 are opened, and electric current stops flowing to the 1st solenoid, so the kick-down setting to 1st canceled and the transmission returns to the speed range set by the position of the speed lever. The speed lever switch 2nd terminal is opened, so even if 2nd-1st selector relay terminals 3 - 6 are closed, electric current does not flow to the 2nd solenoid and it is not actuated. In this way, the actuation of the kick-down switch is canceled and travel operations are carried out according to the normal lever commands.
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12 OPERATION FOR CANCELING KICK-DOWN III When parking brake is applied
•
•
•
•
When the parking brake switch is turned ON (applied), electric current stops flowing to the parking brake valve and the parking brake is actuated. At the same time, the neutralizer relay is also reset, so neutralizer relay terminals 3 - 5 are opened. The electric current from the battery is cut off and does not flow to the FORWARD solenoid, so the transmission is set to neutral. At the same time, in directional lever switch terminal F, electric current flows from the battery ? FORWARD solenoid relay terminals 6 - 5 ? ground, so the circuits between terminals 1 - 2 and between terminals 3 - 4 are closed. The speed lever switch is at 2nd, so electric current flows from FORWARD solenoid relay terminals 3 - 4 ? kickdown switch ? kick-down relay terminals 6 - 5 ? ground, the relay is actuated, and the circuit between terminals 1 - 2 and between terminals 3 - 4 are closed. As a result, electricity flows from the battery ? kick-down relay terminals 3 - 4 ? 2nd-1st selector relay terminals 2 - 1. The relay is actuated, so electric current flows from terminals 3 - 5 ? 1st solenoid ? ground, and the 1st clutch is actuated. In this way, when the parking brake is applied, the actuation of the kick-down switch is not canceled, but the directional lever switch is set to neutral and the speed range to 1st, and the machine is stopped from moving.
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STRUCTURE AND FUNCTION
ELECTRICAL
12 OPERATION FOR CANCELING KICK-DOWN IV When starting switch is turned OFF
• •
When the starting switch is turned OFF, the battery relay is opened, so electric current stops flowing to the transmission directional circuit and speed circuit, and the kick-down switch operation is canceled. If the starting switch is at OFF, even if the kick-down switch is turned ON (actuated), the kick-down switch will not work.
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STRUCTURE AND FUNCTION
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12 ELECTRIC PARKING BRAKE CONTROL
1. Parking brake switch
4. Parking brake display switch
7. Neutralizer relay
2. Accumulator
5. Parking brake valve
8. Parking safety relay
3. Emergency brake switch
6. Spring cylinder
OUTLINE • When electric current flows to the parking brake valve (solenoid valve), the hydraulic pressure from the accumulator is applied to the spring cylinder to release the parking brake. On the other hand, if the electric current is turned off, the oil pressure from the accumulator is cut off, so the oil pressure inside the spring cylinder passes through the parking brake valve and is drained, the parking brake is actuated by the force of the spring. FUNCTION 1. Applying and releasing brake • The parking brake is applied or released by using the parking brake switch (combination switch).
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STRUCTURE AND FUNCTION
ELECTRICAL
2. Emergency brake • If there is damage to the hydraulic circuit, and the pressure inside the accumulator drops and it is impossible to guarantee the braking force of the brake, the parking brake is automatically applied to act as an emergency brake. 3. Parking brake safety • It is dangerous if the parking brake can be released simply by turning the starting switch ON after the automatic parking brake has been applied. Therefore, to ensure safety, the system is designed so the brake cannot be released unless the starting switch is turned ON and then the parking brake switch is also turned ON. 4. Neutralizer • The parking brake may seize if the machine is driven with the parking brake still applied. To prevent this problem, the caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken operation. In addition to this, when the parking brake is applied, the transmission is forcibly shifted to neutral to make it impossible to drive the machine. However, the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is applied. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on railway crossings). To overcome this, the circuit is designed so that the transmission is not shifted to neutral when the emergency brake is applied.
PARKING BRAKE SWITCH
10-180 2
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STRUCTURE AND FUNCTION
ELECTRICAL
12 PARKING BRAKE VALVE
PARKING SAFETY RELAY NEUTRALIZER RELAY
EMERGENCY BRAKE SWITCH
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STRUCTURE AND FUNCTION
ELECTRICAL
12 OPERATION 1. STARTING SWITCH OFF
•
When the starting switch is turned OFF, the battery relay is opened, so electricity does not flow to the parking brake circuit. For this reason, if the starting switch is at the OFF position, no electric current flows to the parking brake solenoid valve, regardless of whether the parking brake switch is ON (applied) or OFF (released), so the parking brake is actuated.
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12 2. STARTING SWITCH ON A. When parking brake switch is ON (actuated) before starting switch is turned ON
•
•
• •
The electric current flows in circuit ¿ from the battery ? starting switch ? battery relay coil ? ground, so the battery relay is closed. When this happens, electric current flows in circuit ¡ from the battery ? battery relay ? parking brake switch terminal 1 - 3 ? parking brake safety relay terminal 1 - 2 ? ground. In this way, the parking safety relay is actuated and safety relay terminals 3 - 5 are closed. When this happens, circuit ¬ is formed from the battery ? battery relay ? parking safety relay terminal 5 - 3 ? parking safety relay terminal 1 - 2 ? ground. From this point, the parking safety relay is in the condition of circuit ¬ until the starting switch is turned OFF. In this condition, electric current does not flow to the parking brake solenoid valve, so the parking brake is actuated. In addition, in this condition, neutralizer relay terminals 3 and 5 are open, so electric current does not flows to the transmission directional circuit, and the transmission is shifted to neutral.
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STRUCTURE AND FUNCTION
ELECTRICAL
12 B. When parking brake switch is OFF (actuated) before starting switch is turned ON
•
•
Electric current flows in circuit ¿ from the battery ? starting switch ? battery relay coil ? ground, so the battery relay is closed. However, in this case, the parking brake switch is OFF (released), so the parking safety relay is not actuated. For this reason, the electric current does not flow to the parking brake solenoid valve, so after the automatic parking brake is applied, the parking brake is not released automatically even when the starting switch is turned ON. In addition, the electric current does not flow to the transmission directional circuit, so the machine does not move.
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12 3. PARKING BRAKE SWITCH OFF (RELEASED) When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
•
If the parking brake switch is turned from ON (actuated) to OFF (released), the circuit for terminals 2 and 3 of the parking brake switch is connected, and the parking brake safety relay is also actuated. For this reason, electric current flows in circuit ¿ from the battery (+) ? battery relay ? parking brake safety relay ? parking brake switch, and then flows to circuit ¡ and ¬ given below. ¡ This circuit is formed from the emergency brake switch ? parking brake solenoid valve ? ground, and the parking brake is released. ¬ This circuit is formed from the battery (+) ? battery relay ? neutralizer relay terminal 3 - 5 ? transmission directional circuit, so when the directional lever is operated, the machine will move.
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STRUCTURE AND FUNCTION
ELECTRICAL
12 4. PARKING BRAKE SWITCH ON (ACTUATED)
• •
•
If the parking brake switch is turned ON (applied) after carrying out operations with the parking brake switch OFF (released), the circuit in the diagram above is formed. Electric current does not flow to the parking brake solenoid valve, so the oil pressure from the accumulator to the spring cylinder is shut off. At the same time, the oil pressure inside the spring cylinder passes through the parking brake valve and is drained, so the parking brake is applied by the force of the spring. In addition, at the same time, the neutralizer relay is reset, so the circuit between terminals 3 and 5 is opened, and no electricity flows to the transmission directional circuit, so the transmission is shifted to neutral. This kind of neutralizer relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts the transmission to neutral to prevent seizure of the parking brake if the operator should drive the machine with the parking brake still applied.
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12 5. WHEN MAIN BRAKE OIL PRESSURE DROPS (EMERGENCY BRAKE ACTUATED)
OPERATION • If the accumulator pressure drops, the emergency brake switch installed to the accumulator is opened. For this reason, the electric current stops flowing to the parking brake solenoid valve, so the oil pressure inside the spring cylinder is drained and the parking brake is applied. However, in this case, the condition is different from the case where the parking brake switch is ON (applied), because there is electric current flowing to the neutralizer relay coil. • For this reason, electric current flows to the transmission directional circuit, and it is possible to engage the transmission clutch. In this way, it is possible to use the engine brake when the emergency brake is applied, so the braking distance becomes shorter. At the same time, if the emergency brake has been applied and it is necessary to move the machine (for example, if the emergency brake is applied when the machine is on a railway crossing), it is possible to move the machine by operating the transmission lever.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-188 2
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STRUCTURE AND FUNCTION
ELECTRICAL
12 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (1 0F 6)
Refer to Foldout No. 10-189 at the end of manual. If desired, replace this page with Foldout.
WA700-3L
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STRUCTURE AND FUNCTION
ELECTRICAL
MEMORANDUM
10-190 2
WA700-3L
STRUCTURE AND FUNCTION
ELECTRICAL
12 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (2 0F 6)
Refer to Foldout No. 10-191 at the end of manual. If desired, replace this page with Foldout.
WA700-3L
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-192 2
WA700-3L
STRUCTURE AND FUNCTION
ELECTRICAL
12 ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (3 OF 6)
Refer to Foldout No. 10-193 at the end of manual. If desired, replace this page with Foldout.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-194 2
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ELECTRICAL
12
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (4 OF 6)
Refer to Foldout No. 10-195 at the end of manual. If desired, replace this page with Foldout.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-196 2
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12
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (5 OF 6)
Refer to Foldout No. 10-197 at the end of manual. If desired, replace this page with Foldout.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-198 2
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STRUCTURE AND FUNCTION
ELECTRICAL
12
ELECTRICAL CIRCUIT DIAGRAM FOLDOUT (6 OF 6)
Refer to Foldout No. 10-199 at the end of manual. If desired, replace this page with Foldout.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
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ELECTRICAL
12
ELECTRICAL CIRCUIT DIAGRAM (2) (1 OF 4)
Refer to Foldout No. 10-201 at the end of manual. If desired, replace this page with Foldout.
WA700-3L
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-202 2
WA700-3L
STRUCTURE AND FUNCTION
ELECTRICAL
12 ELECTRICAL CIRCUIT DIAGRAM (2) (2 OF 4)
Refer to Foldout No. 10-203 at the end of manual. If desired, replace this page with Foldout.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-204 2
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STRUCTURE AND FUNCTION
ELECTRICAL
12 ELECTRICAL CIRCUIT DIAGRAM (2) (3 OF 4)
Refer to Foldout No. 10-205 at the end of manual. If desired, replace this page with Foldout.
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STRUCTURE AND FUNCTION
ELECTRICAL
12
MEMORANDUM
10-206 2
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STRUCTURE AND FUNCTION
ELECTRICAL
12 ELECTRICAL CIRCUIT DIAGRAM (2) (4 OF 4)
Refer to Foldout No. 10-207 at the end of manual. If desired, replace this page with Foldout.
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12
MEMORANDUM
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20
TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 ENGINE TABLE - IN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 CHASSIS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5 STANDARD VALUE TABLE FOR ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10 SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-18 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 ADJUSTING ENGINE STOP MOTOR CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20 ADJUSTING ENGINE STOP SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING AND ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20 MEASURING COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING ENGINE LUBRICATING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING ENGINE SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING EXHAUST COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING EXHAUST GAS TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 MEASURING FUEL FILTER INLET RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 TEST AND ADJUSTING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 TEST AND ADJUSTING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 ADJUSTING PEDAL TRAVEL, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22 ADJUSTING PEDAL MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24 TORQUE CONVERTER & TRANSMISSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-28 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-28 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 STEERING STOPPER BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31 JOYSTICK STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32 JOYSTICK LEVER NEUTRAL DETECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-35 MEASURING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35 BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-36 MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 20-37 MEASURING PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 MEASURING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
WA700-3L
20-1 2
TESTING AND ADJUSTING
TABLE OF CONTENTS
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-38 ACCUMULATOR CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 20-39 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-39 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 MEASURING HYDRUALIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 ADJUSTING HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41 HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43 PISTON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47 BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48 PROXIMITY SWITCH ACTUATION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49 LAMP (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49 MAIN MONITOR (SPEEDOMETER MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50 ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50 BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51 BLEEDING AIR FROM BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51 BLEEDING AIR FROM HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52 BLEEDING AIR FROM THE HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-52 BLEEDING AIR FROM THE PISTON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53 BLEEDING AIR FROM THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54 TROUBLESHOOTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101 ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201 TROUBLESHOOTING SYSTEMS OF: E MODE - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301 G MODE - ENGINE (ELECTRONIC GOVERNOR) CONTROLLER AND APS CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401 H MODE - HYDRAULIC AND MECHANICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501 J MODE - JOYSTICK STEERING CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-601 K MODE - MAINTENANCE MONITOR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701 M MODE - MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801 S MODE - ENGINE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901 T MODE - TRANSMISSION CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1001 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1101
20-2 2
WA700-3L
TESTING AND ADJUSTING ★
See ENGINE SHOP MANUAL.
★ When using the standard value tables to make judgement for testing, adjusting, and troubleshooting, the following precautions are necessary: 1.
The standard values in the tables are the values for a new machine and are given as reference values for the time when the machine is shipped from the factory. These values should be used as a guide when estimating wear after the machine is operated, and when carrying out repairs.
2.
The permissible values given in the tables are values estimated based on the results of various tests carried out on the machines shipped from the factory, so they should be used together with the information on the repair condition and other information such as the operating history of the machine when judging the condition of the machine.
3.
These standard values do not form a basis for judging claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and blocks to prevent the machine from moving
WARNING! When carrying out work together with co- workers, always use signals and do not let unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed when the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WA700-3L
20-3 2
TESTING AND ADJUSTING
STANDARD VALUE TABLE
STANDARD VALUE TABLE ENGINE TABLE - IN CHASSIS
Item
Machine model
WA700-3L
Engine model
Komatsu SAA6D170E
Measurement condition
Unit
High idle Engine speeds
Low idle
rpm
Rated Speed Sudden acceleration Exhaust gas color At high idling
Bosch index
Intake valve Valve clearance (normal temperature)
mm in Exhaust valve
Standard value for new machine
Service limit value
2270 ± 30
2270 ± 30
650 +50 0
650 +50 0
2000
---
Max. 4.5
6.0
Max. 1.5
2.5
0.4 (0.015)
-----
1.0 (0.039)
-----
Compression pressure (SAE30 oil)
Oil temperature: 40 - 60° Engine speed: 210-250 rpm
kg/cm2 (lbf/in2)
Min. 30 (427)
21 (298)
Blow-by pressure (SAE30 oil)
Water temperature: Operating range At high idling
kPa (inH2O)
Max. 3.92 (Max. 15.73)
7.85 (31.51)
---
---
4.0 - 5.5 (56.8 - 78.2)
2.1 29.8
3.5 - 5.0 (49.7 - 71.1)
1.8 25.6
At low idling (SAE30)
Min. 1.2 (Min. 17.0)
0.7 (9.9)
At low idling (SAE10W)
Min. 1.0 (Min. 14.2)
0.7 (9.9)
Water temperature: Operating range At high idling (SAE30) Oil pressure
At high idling (SAE10W)
kgf/cm2 (lbf/in2)
Oil temperature
Whole speed range (oil pan)
°C (°F)
80 - 110 (176 - 230)
120 (248)
Fuel injection timing
Compression B.T.D.C.
deg.
22 ± 0.5
22 ± 0.5
Fan belt tension (Alternator)
Deflection when pressed with finger force of approximate 59 N (approximate 6 kg)
mm in
10 - 15 (0.39 - 0.59)
10 - 15 (0.39 - 0.59)
★ For further detailed information, refer to Engine Shop Manual.
20-4 2
WA700-3L
TESTING AND ADJUSTING
STANDARD VALUE TABLE
CHASSIS TABLE Machine model
Directional lever
Cate gory
Item
WA700-3L
Measurement conditions
Operating effort
N-FORWARD, REVERSE
Travel
N-FORWARD, REVERSE
Engine stopped Measure at center of lever knob
Unit kgf (lbf) mm
Speed control lever
1st - 2nd 2nd - 3rd 3rd - 4th
Operating effort Play
Operating effort Steering wheel
kgf (lbf)
Turns Low idling Operating time
WA700-3L
High idling
(1.3 +1.1 -0.6 )
Service limit value Max. 1.7 (3.7) 35 ± 10 Max. 1.7 (3.7)
Max. 1.7 (3.7)
Max. 1.7 (3.7)
(1.3 +1.1 -0.6 ) 35 ± 10 35 ± 10 35 ± 10 Max. 2.4 (5.2) Max. 1.6 (3.5) Max. 2.5 (5.5) --Max. 3.5 (7.7) Max. 1.5 (3.3) Max. 2.4 (5.2) Max. 2.4 (5.2) Max. 1.5 (3.3) 67 ± 15 53 ± 15 67 ± 15 60 ± 15 60 ± 15
35 ± 10 35 ± 10 35 ± 10 Max. 3.6 (7.9) Max. 2.4 (5.2) Max. 3.8 (8.3) --Max. 5.3 (11.6) Max. 2.3 (5.0) Max. 3.6 (7.9) Max. 3.6 (7.9) Max. 2.3 (5.0) 67 ± 30 53 ± 30 67 ± 30 60 ± 30 60 ± 30
mm
Max. 20
Max. 20
kgf (lbf)
1.0 ± 0.3 (2.2 ± 0.6)
Max. 2.0 (4.4)
Turns
4.0 ± 0.7
Max. 4.5
Max. 5.5
Max 6.5
Max. 4.7
Max. 5.0
mm
Engine speed: Low idling Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
kgf (lbf)
Engine speed: Low idling Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
mm
Engine stopped Machine facing straight to front Flat, horizontal, straight, dry paved road surface Engine speed: High idling Lift lock - right lock Engine running Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
0.6 +0.5 -0.3 0.6 +0.5 -0.3
3rd - 4th
Travel
Work equipment control lever
2nd - 3rd
HOLD⇒RAISE RAISE⇒HOLD HOLD⇒LOWER Boom LOWER⇒HOLD LOWER⇒FLOAT FLOAT⇒HOLD HOLD⇒DUMP Bucket HOLD⇒TILT TILT⇒HOLD HOLD⇒RAISE Boom HOLD⇒LOWER HOLD⇒FLOAT HOLD⇒DUMP Bucket HOLD⇒TILT
35 ± 10
(1.3 +1.1 -0.6 )
Engine stopped Measure at center of lever knob
Travel
(1.3 +1.1 -0.6 )
0.6 +0.5 -0.3
1st - 2nd
Operating effort
Standard value for new machine 0.6 +0.5 -0.3
sec.
20-5 2
TESTING AND ADJUSTING Cate gory
Item
STANDARD VALUE TABLE Measurement conditions
Accelerator pedal
Operating angle
Operating effort (Measure at 150 mm Engine speed: Low idling point from pedal fulcrum) Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Neutral (∠ 1) Max. (∠ 2)
45
---
30
---
51
---
Operating effort (Measure at 150 mm Engine speed: Low idling point from pedal fulcrum) Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Neutral (∠ 1)
kgf (lbf)
30 ± 3 (66.1 ± 6.6)
43.0 94.7
45
---
15 +10
---
5 ± 0.5
---
Max. 2.5
---
Max. 4.0
---
20 - 35
---
2175 ± 50
2175 ± 200
2150 ± 50
2150 ± 200
1620 ± 100
1620 ± 300
10.8 ± 1.0 (153.6 ± 14.2) 31.5 ± 1.5 (448.0 ± 21.3) 2±1 (28.4 ± 14.2) 23.5 ± 1 (334.2 ± 14.2) 6.0 ± 0.5 (85.3 ± 7.1) 7.6 ± 1 (108.0 ± 14.2) 28.5 ± 1.5 (405.3 ± 21.3) 31.5 ± 1.5 (448.0 ± 21.3)
10.8 ± 1.0 (153.6 ± 14.2) 31.5 ± 1.5 (448.0 ± 21.3) 2±1 (28.4 ± 14.2) 23.5 ± 1 (334.2 ± 14.2) 6.0 ± 0.5 (85.3 ± 7.1) 7.6 ± 1 (108.0 ± 14.2) 28.5 ± 1.5 (405.3 ± 21.3) 31.5 ± 1.5 (448.0 ± 21.3)
Brake pedal
Operating angle
mm
deg. Max. (∠ 2)
mm
Fitting of wheel lock
Tire inflation pressure: Specified value mm
B
Clearance of wheel lock ring
C
Torque converter stall Hydraulic stall Torque converter stall + hydraulic stall
Engine water temperature: Green range Torque converter oil temperature: 60 - 80° C (140 - 176° F) Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Gearshift lever: F4 or R4
rpm
Pilot reducing pressure Transmission torque converter
Service limit value Max. 9.0 Max. (19.8)
Stopper height (L)
A Tire
kgf (lbf)
Standard value for new machine 6.0 (13.2)
deg.
Play
Engine speed
Unit
Modulate pressure Lubricating valve pressure (except F4, R4)
Torque converter oil temperature: 60 - 80° C (140 - 176° F) Reducing valve pressure (for F1, F2) Engine speed: High idling Measure torque converter inlet port Torque converter outlet port pressure pressure with the transmission speed set to Neutral. Torque converter inlet port pressure Main relief pressure
20-6 2
Low idling High idling
kgf/cm2 (lbf/in2)
WA700-3L
TESTING AND ADJUSTING
Steering
Cate gory
Item Steering relief pressure
Orbit-roll output pressure
Accumulator
Charge cut-in pressure
Charge cut-out pressure
STANDARD VALUE TABLE Measurement conditions
Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Engine speed: High idling
Standard value for new machine 320 +20
Unit
kgf/cm2 (lbf/in2)
Engine speed: Low idling Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Point when brake oil pressure warning lamp goes out Engine speed: Low idling Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Point when oil pressure is going up, then starts to go down
60 +50 (853.4
100 +10 0
Power train
1st
6.4 ± 0.5 (3.9 ± 0.31) 11.1 ± 0.5 (6.8 ± 0.31) 18.7 ± 0.5 (11.6 ± 0.31) 30.0 ± 0.5 (18.6 ± 0.31) 7.1 ± 0.5 (4.4 ± 0.31) 12.3 ± 0.5 (7.6 ± 0.31) 20.5 ± 0.5 (12.7 ± 0.31) 32.3 ± 0.5 (20.0 ± 0.31) 50 ± 7 (711.1 ± 99.5)
Max. 5 (Max. 71.1)
Max. 5 (Max. 71.1)
m
Max. 6
6
mm
3.6 ± 1.9
Max. 9.7
km/h (mi/h)
3rd 4th
Wheel brake Disc wear
WA700-3L
100+15 -5
6.4 ± 0.5 (3.9 ± 0.31) 11.1 ± 0.5 (6.8 ± 0.31) 18.7 ± 0.5 (11.6 ± 0.31) 30.0 ± 0.5 (18.6 ± 0.31) 7.1 ± 0.5 (4.4 ± 0.31) 12.3 ± 0.5 (7.6 ± 0.31) 20.5 ± 0.5 (12.7 ± 0.31) 32.3 ± 0.5 (20.0 ± 0.31) 50 ± 5 (711.1 ± 71.1)
2nd
Performance
60+10-5 ) (853+142.2 -71.1
(1422+213 ) -71
REVERSE
Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Engine: Stopped Keep brake pedal depressed at 50 kgf/ cm2 (711.1 lbf/in2) and measure drop in oil pressure after 5 min. Tire inflation pressure: Specified pressure Flat, horizontal, straight, dry paved road surface Speed when applying brake: 20 km/h (12.4 mi/h), Braking delay: 0.1 second Measure piston stroke
(540 +56.8 ) -28.4
(1422.3 +142.2 ) 0
3rd 4th
38+4 -2
kgf/cm (lbf/in2)
2nd
Travel speed
+71.1 0 )
(4551+142 -42 )
2
FORWARD
Drop in brake pressure
38 +20 (540.4 +28.4 ) 0
1st
Brake oil pressure
(4551.4 +71.1 0 )
Service limit value 320+10 -3
kgf/cm2 (lbf/in2)
20-7 2
TESTING AND ADJUSTING Cate gory
Item
Parking brake
Parking brake inlet port pressure
Brake released Brake operated
STANDARD VALUE TABLE Measurement conditions Torque converter oil temperature: 60 - 80° C (140 - 176° F) Engine at high idling
Standard value for new machine 60 - 100 (853.4 - 1422.3) Max. 1.4 (Max. 19.9)
Service limit value 60 - 100 (853.4 - 1422.3) 1.4 (19.9)
---
Stopped
Stopped
mm
31.7 ± 3.0 1.06 ± 0.18
12.7 Max. 2.1 38 +2 -2
Unit kgf/cm2 (lbf/in2)
Tire inflation pressure: Specified pressure Flat dry paved road with 1/5 (11°20’) grade Machine at operating condition
Performance
Pad thickness Clearance
Including back metal Total of each end
38 +20
PPC
PPC valve source pressure (Orbit-roll Hydraulic oil temperature: source pressure) 45 - 55° C (113 - 131° F)
(540 +28 0 ) 2
Boom RAISE, FLOAT; bucket PPC valve output DUMP, TILT pressure Boom LOWER
20-8 2
Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Engine speed: High idling Work equipment control lever: Operated fully
kgf/cm (lbf/in2)
(540 +28 -28 )
38 +20
38 +2 -2
(540 +28 0 )
(540 +28 -28 ) 26 ± 0.5 (369 ± 7.1)
26 ± 0.5 (369 ± 7.1)
WA700-3L
TESTING AND ADJUSTING Cate gory
Item
Work equipment relief pressure
Measurement conditions Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Engine speed: High idling
Unit kgf/cm2 (lbf/in2)
Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Engine speed: High idling No load
Boom LOWER
Bucket tilt back
Work equipment
Work equipment speed
Boom RAISE
STANDARD VALUE TABLE
When fully operated
Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Engine speed: High idling No load
Hydraulic drift
Hydraulic oil temperature: 45 - 55° C (113 - 131° F) Leave for 5 minutes after stopping engine, then measure for next 15 minutes Bucket empty, boom, bucket horizontal
Proximity switch
(4551.4 +71.1 ) 0
(4551.4 +142 -42 )
9.1 ± 0.5
Min. 11.6
3.6 ± 0.5
Min. 6.1
3.7 ± 0.3
Min. 4.8
1.9 ± 0.3
Min. 2.7
Max. 40
Max. 40
Max. 20
Max. 20
3-5
---
3-5
---
mm
Retraction of bucket cylinder rod
Clearance of bucket positioner proximity switch Clearance of boom kick-out proximity switch
WA700-3L
320 +5 0
Service limit value 320 +10 -3
sec.
Bucket horizontal (above ground)
Retraction of boom cylinder rod
Standard value for new machine
--mm ---
20-9 2
TESTING AND ADJUSTING
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ELECTRICAL PARTS System
Name of component
Connector No.
Inspection method
Measurement conditions
Judgement table
Solenoid (1st)
T01 (male)
Measure resistance
If the condition is as shown below, it is normal. Between (B) - (H)
50 - 70Ω
Between (B), (H) - chassis
Max. 1 MΩ
Solenoid (2nd)
T01 (male)
Measure resistance
If the condition is as shown below, it is normal. Between (B) - (G)
50 - 70Ω
Between (B), (G) - chassis
Max. 1 MΩ
Solenoid (3rd)
T01 (male)
Measure resistance
If the condition is as shown below, it is normal. Between (B) - (F)
50 - 70Ω
Between (B), (F) - chassis
Max. 1 MΩ
T01 (male)
Between (B) - (E)
50 - 70Ω
Between (B), (E) - chassis
Max. 1 MΩ
Solenoid (F)
T01 (male)
Measure resistance
If the condition is as shown below, it is normal. Between (A) - (D)
50 - 70Ω
Between (A), (D) - chassis
Max. 1 MΩ
If the condition is as shown below, it is normal. Solenoid (R)
T01 (male)
Measure resistance
Transmission control
Solenoid (4th)
Measure resistance
If the condition is as shown below, it is normal.
Between (A) - (C)
50 - 70Ω
Between (A), (C) - chassis
Max. 1 MΩ
Speed sensor
T05 (male)
---
Adjust
Speed sensor
Measure resistance
If the condition is as shown below, it is normal. 500 - 1000 Ω
Between (1) - (2) Between (1), (2) - chassis
Max. 1 MΩ
1. Screw in until speed sensor contacts ring gear, then back 3/4 - 1 turn. 2. Sensor should work normally after adjusted as above.
Kick switch
down
L15 (male)
Measure resistance
If the condition is as shown below, it is normal. Max. 1 Ω
Kick down switch ON Between (1) - (2)
Kick down switch OFF
Min. 1 MΩ
Transmission cut off switch
20-10 2
L12 (male)
Measure resistance
If the condition is as shown below, it is normal. Max. 1 Ω
Normal condition Left brake depressed
pedal
is
Between (1) - (2)
Min. 1 MΩ
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter --1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter
WA700-3L
TESTING AND ADJUSTING Name of component
System
Connector No.
STANDARD VALUE TABLE Inspection method
Measurement conditions
Judgement table
Power supply
L05
Measure voltage
If the condition is as shown below, it is normal. Between (1), (2) - chassis 20 - 30 V
Between (1), (2) - (3)
1. Turn starting switch OFF. 2. Insert T-adapter 3. Turn starting switch ON.
Battery charge (alternator)
L05
Measure voltage
If the condition is as shown below, it is normal. Engine running (at above 1/2 throttle) Starting switch ON
Between (5) - (3)
28 ± 2 V Max. 1 V
★ If the battery is old or after starting in cold areas, the voltage may not rise for some time.
L05
Measure voltage
If the condition is as shown below, it is normal. Directional switch (N)
1. Turn starting switch OFF. 2. Insert T-adapter.
Directional lever at N Directional lever not at N
20 - 30 V Between (8) - (3)
Max. 1 V
1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON.
L09 (male)
Measure voltage
If the condition is as shown below, it is normal. Starting switch terminal C
Starting switch at Start
20 - 30 V
Starting switch at OFF or (3) - chassis ON
Max. 1 V
1. Turn starting switch OFF. 2. Insert T-adapter.
Measure voltage
If the condition is as shown below, it is normal. Starting switch terminal C
20 - 30 V Max. 1 V
Measure voltage
Between (19) - (3)
Starting switch terminal BR
L09 (male)
L07
Measure voltage
If the condition is as shown below, it is normal. Starting switch terminal BR
Starting switch ON
If the condition is as shown below, it is normal.
Starting switch OFF
Starting switch ON Starting switch OFF
20 - 30 V (2) - chassis
Between (10) - (12)
Max. 1 V
20 - 30 V Max. 1 V
F-12 (male)
Measure resistance
If the condition is as shown below, it is normal. Parking brake indicator switch
Parking brake ON parking brake OFF
Max. 1Ω Between (1) - (2)
Min. 1 MΩ
If the condition is as shown below, it is normal.
L08 Directional switch (R)
Measure voltage
Directional lever F
Directional switch (F)
Directional lever not at F
20 - 30 V Between (7) - chassis
Max. 1 V
If the condition is as shown below, it is normal. Directional lever R Directional lever not at R
WA700-3L
1. Turn starting switch OFF. 2. Insert T-adapter.
★20 - 30→ 1 V 1. Turn starting switch OFF. Starting switch at OFF Max. 1 V 2. Insert T-adapter. ★ During preheating, lamp lights up; when preheating is completed, lamp goes out. Starting switch at Start
Measure voltage
Main monitor
Starting switch at OFF or ON
Between (4) - (3)
If the condition is as shown below, it is normal.
L05 Preheating ON
Starting switch at Start
20 - 30 V Between (8) - chassis
Max. 1 V
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Insert T-adapter. 1. Turn starting switch OFF. 2. Insert T-adapter. 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON
20-11 2
TESTING AND ADJUSTING System
Name of component
Connector No.
STANDARD VALUE TABLE Inspection method
Measurement conditions
Judgement table
Power supply
L18
Measure resistance
If the condition is as shown below, it is normal. Between (1), (2) - chassis 20 - 30 V
Between (1), (2) - (3)
1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON
Engine water temperature sensor
E09 (male)
Measure resistance
If the condition is as shown below, it is normal. Normal temperature 25°C (77° F) 130° C (266° F)
Between (1) - (2)
1. Turn starting switch Approximately OFF. 40 kΩ 2. Disconnect Approximately connectors. 3. Connect T-adapter. 1.7 kΩ
T06 (male)
Measure resistance
If the condition is as shown below, it is normal. Torque converter oil temperature sensor
Normal temperature 25°C (77° F) 130° C (266° F)
Between (1) - (2)
1. Turn starting switch Approximately OFF. 40 kΩ 2. Disconnect Approximately connectors. 3. Connect T-adapter. 1.7 kΩ
If the condition is as shown below, it is normal.
Measure resistance
R05 (male)
If the condition is as shown below, it is normal. Radiator water level sensor
G03 (male)
Measure resistance
Maintenance monitor
Fuel level sensor
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Drain fuel 4. Remove fuel level sensor. 5 Connect T-adapter
Water level normal Water level low
Max. 1Ω Between (1) - (2)
Min. 1 MΩ
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter.
Engine oil pressure sensor
ER1
Measure resistance
If the condition is as shown below, it is normal. Engine oil pressure: Min. 0.7 kgf/cm2 (9.95 lbf/in2) Engine running Engine oil pressure: Min. 0.3 kgf/cm2 (4.26 lbf/in2) Engine stopped
Max. 1 MΩ Between (2) - (7) Min. 1 Ω
1. Turn starting switch OFF. 2. Disconnect terminal. 3. Engine running
Brake accumulator low pressure switch
C03 C04
Measure resistance
If the condition is as shown below, it is normal. Accumulator pressure: Min. 55 ± 5 kgf/cm2 (782.2 ± 71.1 lbf/in2) Depress brake and lower accumulator pressure to below 45 ± 5 kgf/cm2 (640.0 ± 71.1 lbf/in2)
Max. 1Ω Between (1) - (2)
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter.
Min. 1 MΩ
Charge Alternator
20-12 2
L18
Measure voltage
If the condition is as shown below, it is normal. Engine running (above half throttle) Starting switch ON
Between (12) - (3)
28 ± 2 V Max. 1 V
★ If the battery is old or after starting in cold areas, the
1. Turn starting switch OFF. 2. Insert T-adapter. 3. Start engine.
voltage may not rise for some time.
WA700-3L
TESTING AND ADJUSTING Connector No.
Engine oil level sensor
ER1 (male)
Inspection method
Measure resistance
Name of component
System
STANDARD VALUE TABLE Measurement conditions
Judgement table
If the condition is as shown below, it is normal. Engine oil level normal
Between Engine oil level abnormal (3) - chassis
Max. 1â„Ś Min. 1 Mâ„Ś
1. Turn starting switch OFF. 2. Disconnect terminal
Dust indicator (L.H.)
BR1
Measure continuity
If the condition is as shown below, it is normal. Air cleaner normal Air cleaner clogged
1. Turn starting switch OFF. 2. Disconnect Between connector BR1 (6) - (9) No Continuity 3. Start engine. 4. Measure continuity. Continuity
Maintenance monitor
Dust indicator (R.H.)
BR1
Measure continuity
If the condition is as shown below, it is normal. Air cleaner normal Air cleaner clogged
1. Turn starting switch OFF. Continuity 2. Disconnect Between connector BR1 (7) - (9) No Continuity 3. Start engine. 4. Measure continuity.
If the condition is as shown below, it is normal.
Check items Caution items
WA700-3L
1. Insert T-adapter
20-13 2
TESTING AND ADJUSTING
Maintenance monitor
System
Name of component
Connector No.
STANDARD VALUE TABLE Inspection method
Measurement conditions
Judgement table
1. Turn starting switch OFF, then insert dummy resistance or measure resistance of sensor. 2. Turn starting switch ON and check display.
Gauge
C07, C08 (male)
Others
Emergency brake switch
Measure resistance
If the condition is as shown below, it is normal.
Depress brake and lower accumulator pressure to below 37 ± 5 kgf/cm2 (526 ± 71.1 lbf/in2)
Max. 1Ω Between C07, C08 (1) - (2)
Min. 1 MΩ
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter
BC01
Measure voltage
If the condition is as shown below, it is normal.
Emergency brake switch
20-14 2
Accumulator pressure: Min. 40 ± 5 kgf/cm2 (568 ± 71.1 lbf/in2)
Accumulator pressure: Min. 40 ± 5 kgf/cm2 (568 ± 71.1 lbf/in2) Depress brake and lower accumulator pressure to below 37 ± 5 kgf/cm2 (526 ± 71.1 lbf/in2)
20 - 30 V Between (4) - (5) Max. 1 V
1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON.
WA700-3L
TESTING AND ADJUSTING Name of component
System
Connector No.
STANDARD VALUE TABLE Inspection method
Measurement conditions
Judgement table
Bucket positioner proximity switch
F05
Measure voltage
If the condition is as shown below, it is normal. When screwdriver is brought close
---
Between (1) - (2)
20 - 30 V
Between (1) - (3)
20 - 30 V
Between (2) - (3)
Max. 3 V
When screwdriver is 1. Turn starting switch not brought OFF. 2. Insert T-adapter. close 3. Turn starting switch Max. 3 V ON. 20 - 30 V 20 - 30 V
Boom kick-out proximity switch
F06
Measure voltage
Others
If the condition is as shown below, it is normal. When screwdriver is brought close
---
Between (1) - (2)
20 - 30 V
Between (1) - (3)
20 - 30 V
Between (2) - (3)
Max. 3 V
When screwdriver is 1. Turn starting switch not brought OFF. 2. Insert T-adapter. close 3. Turn starting switch Max. 3 V ON. 20 - 30 V 20 - 30 V
Boom kick-out solenoid
L16
Measure resistance
If the condition is as shown below, it is normal. 19 - 23 Ω
Between (1) - (2) Between (1) - (2) - chassis
Min. 1 MΩ
Measure voltage
C1 C2
19 - 23 Ω
Between (1) - (2) Between (1) - (2) - chassis
Min. 1 MΩ
If the condition is as shown below, it is normal. Between C1(7), (13) - chassis Between C2(1), (12) - chassis Between C1(7), (13) - (6), (12)
20 - 30 V
Between C2(1), (12) - (11), (21)
Power supply (for signal)
C3A
Measure voltage
If the condition is as shown below, it is normal. Between (6) - (17) 20 - 30 V
Between (6) - chassis
If the condition is as shown below, it is normal. Parking brake switch
L01
Measure voltage
Transmission & Joystick steering controller
Power supply
L17
Measure resistance
If the condition is as shown below, it is normal. Bucket positioner solenoid
Turn parking switch ON
brake
Turn parking switch OFF
brake
Between (1) - (3)
20 - 30 V Max. 1 V
Speed control lever (1st)
WA700-3L
C3B (female)
Measure voltage
If the condition is as shown below, it is normal. Speed control lever at 1st
20 - 30 V
Between Speed control lever not at (7) - chassis 1st
Max. 1 V
1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 4. Turn parking brake switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON.
20-15 2
TESTING AND ADJUSTING System
Name of component
Connector No.
STANDARD VALUE TABLE Inspection method
Measurement conditions
Judgement table
Measure voltage
If the condition is as shown below, it is normal. Speed control lever (2nd)
Speed control lever at 2nd
Between (15) - chassis Speed control lever not at 2nd
20 - 30 V Max. 1 V
Measure voltage
If the condition is as shown below, it is normal. Speed control lever (3rd)
Speed control lever at 3rd
20 - 30 V
Between Speed control lever not at (8) - chassis 3rd
Max. 1 V
Speed control lever (3rd)
Measure voltage
Directional lever (F)
Speed control lever at 4th
20 - 30 V
Between Speed control lever not at (16) - chassis 4th
Max. 1 V
If the condition is as shown below, it is normal. Speed control lever at F
20 - 30 V
Between Speed control lever not at (5) - chassis F
Max. 1 V
Measure voltage
If the condition is as shown below, it is normal. Directional lever (R)
Speed control lever at R
20 - 30 V
Between Speed control lever not at (6) - chassis R
Max. 1 V
Measure voltage
If the condition is as shown below, it is normal. Directional lever (N)
Speed control lever at N
20 - 30 V
Between Speed control lever not at (13) - chassis N
Max. 1 V
Speed
Speed
T05 (male)
---
Measure resistance
If the condition is as shown below, it is normal.
Adjust
Transmission & Joystick steering controller
C3B (female)
Measure voltage
If the condition is as shown below, it is normal.
Between (1) - (2) Between (1), (2) - chassis
500 - 1000 Ω Max. 1 MΩ
1. Screw in until the tip of sensor contact gear, then turn back 3/4 - 1 turn. 2. Sensor should work normally when adjusted as above.
Controller C4 engine speed
Engine speed
20-16 2
---
Measure voltage
E10 (male) E13 (male)
Adjust
Engine speed sensor
Measure resistance
If the condition is as shown below, it is normal. Between (1) - (2) Between (1), (2) - chassis
500 - 1000 Ω Max. 1 MΩ
Measure in AC range Between (2) - (9)
Min. 0.5 V
1. Screw in until the tip of sensor contact gear, then turn back 3/4 - 1 turn. 2. Sensor should work normally when adjusted as above.
1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter --1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Start engine. ---
WA700-3L
TESTING AND ADJUSTING Name of component
System
Connector No.
STANDARD VALUE TABLE Inspection method
S-NET (between transmission controller and main monitor)
If the condition is as shown below, it is normal.
C3B
Measure voltage
Controller
Measurement conditions
Judgement table
Between (4), (12) - chassis
4-8V
Measure resistance
If the condition is as shown below, it is normal. Kick-down switch (Shift down switch) L15 (male)
Between (1) - (2)
Kick-down switch OFF
Min. 1 MΩ
If the condition is as shown below, it is normal. Measure resistance
Hold switch (Shift up switch)
Max. 1 Ω
Kick-down switch ON
Max. 1 Ω
Kick-down switch ON Between (3) - (4)
Kick-down switch OFF
Min. 1 MΩ
L12 (male)
Measure resistance
Transmission cut-off switch
Max. 1 Ω
Normal condition L.H. brake depressed
pedal
is
Between (1) - (2)
Min. 1 MΩ
C5 Manual switch
Measure voltage
If the condition is as shown below, it is normal. Controller
Manual switch is at ON Manual switch is at OFF
Max. 1 V Between (14) - chassis
20 - 30 V
Joystick R (right) solenoid
L84 (male)
Measure resistance
If the condition is as shown below, it is normal. Between (1) - (2) Between (1) - chassis
10 - 20 Ω Min. 1 MΩ
Joystick L (left) solenoid
Joystick neutral switch
L83 (male)
JL1
Measure resistance
If the condition is as shown below, it is normal.
Measure resistance
Transmission & Joystick steering controller
If the condition is as shown below, it is normal.
Between (1) - (2) Between (1) - chassis
10 - 20 Ω Min. 1 MΩ
If the condition is as shown below, it is normal. Joystick neutral switch between (6) - (7) Not at N At N
Max. 1 Ω Min. 1 MΩ
Joystick potentiometer
WA700-3L
JL1 (male)
C3A
Measure voltage
Joystick potentiometer
Measure resistance
If the condition is as shown below, it is normal. Between (3) - (4)
0 − 5 kΩ
Between (4) - (5)
4 − 5 kΩ
Between (3) - (5)
0 − 5 kΩ
If the condition is as shown below, it is normal. Between (3) - (17) When actuated
0.5 - 4.5 V
1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON. 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Disconnect connectors. 3. Connect T-adapter 1. Turn starting switch OFF. 2. Insert T-adapter. 3. Turn starting switch ON.
20-17 2
TESTING AND ADJUSTING
SERVICE TOOLS
SERVICE TOOLS Check or measurement item
Symbol
Part Number
Part Name
Remarks
Engine speed
A
799-203-8001
Multi-tachometer
Digital display: L: 60 - 2000 rpm H: 60 - 19999 rpm Kit part number: 799-203-9000
Water, oil, exhaust temperatures
B
799-101-1502
Digital temperature gauge
-99.9 to +1299° C -212 to +2370° F
799-101-5002
Analog hydraulic tester
Pressure gauge: 25, 60, 400, 600 kgf/cm2 355, 853, 5689, 8534 lbf/in2
790-261-1203
Digital hydraulic tester
Pressure gauge: 700 kgf/cm2 9956 lbf/in2
799-401-2320
Hydraulic gauge
10 kgf/cm2 142 lbf/in2
1
Oil Pressure
C
2
790-261-1311 3
Adapter 790-261-1321
Compression pressure
D
Blow-by pressure
E
Valve clearance
Exhaust color
1
795-502-1590
Compression gauge
2
795-502-1350
Adapter
1
799-201-1504
Blow-by checker
2
799-201-1590
Gauge
Commercially available
Feeler gauge
1
799-201-9000
Smoke checker
2
Commercially available
Smoke meter
799-201-2202
Pressure gauge
793-520-1805
Brake tester kit
2
793-520-1851
Nipple
3
790-301-1230
Elbow
1
79A-264-0020
2
79A-264-0090
F
G
Air supply pressure (boost pressure)
H 1
Brake oil pressure
Operating effort
I
J
Push-pull scale
Both male and female 14 x 1.5 (female PT 1/8) Both male and female 18 x 1.5 (female PT 1/8) 0 - 70 kgf/cm 2 0 - 995 lbf/in2 Kit part number: 795-502-1205 --0 - 1000 mmH2O 0 - 39.3 inH2O --Discoloration 0 - 70% (with standard color) (Discoloration x 1/10 ref. Bosch index) -760 - 1500 mmHg -3.988 - 59.0549 inHg ----Kit part number: 799-101-5002 0 - 294.2 N, 0 - 66.138 lbf 0 - 490.3 N, 0 - 110.224 lbf
Stroke, hydraulic drift
K
Commercially available
Scale
---
Work equipment speed
L
Commercially available
Stop watch
---
Measuring brake disc wear
M
Commercially available
Caliper gauge
---
Moving voltage, resistance value
N
79A-264-0211
Tester
---
Adjusting fuel injection timing
P
795-471-1200
Gauge assembly
---
20-18 2
WA700-3L
TESTING AND ADJUSTING Check or measurement item
Troubleshooting of wiring harness, sensors
WA700-3L
SERVICE TOOLS
Symbol
Part Number
Part Name
1
799-601-7400
T-adapter assembly
2
799-601-3460
3
799-601-7360
4
799-601-7370
Q
Remarks --MS 10P
Adapter
Relay 5P Relay 6P
20-19 2
TESTING AND ADJUSTING
ENGINE
ENGINE Remark To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and proper procedure.
ADJUSTING ENGINE STOP MOTOR CABLE ADJUSTING ENGINE STOP SOLENOID MEASURING AND ADJUSTING VALVE CLEARANCE MEASURING BLOW-BY PRESSURE MEASURING COMPRESSION PRESSURE MEASURING COOLANT TEMPERATURE MEASURING ENGINE LUBRICATING OIL PRESSURE MEASURING ENGINE SPEEDS MEASURING EXHAUST COLOR MEASURING EXHAUST GAS TEMPERATURE MEASURING FUEL FILTER INLET RESTRICTION TEST AND ADJUSTING FAN BELT TENSION TEST AND ADJUSTING FUEL INJECTION TIMING
20-20 2
WA700-3L
TESTING AND ADJUSTING
ACCELERATOR PEDAL
ACCELERATOR PEDAL ★ Measurement conditions • Engine water temperature: Within green range on engine water temperature gauge
OPERATING FORCE MEASURING 1.
Set push-pull scale J at a position 150 mm from pedal fulcrum a. ★ Put the center of push-pull scale J in contact with a point 150 mm from the pedal fulcrum.
2.
Start the engine, then measure the maximum value when the pedal is moved from the pushed position (low idling) to the end of its travel (high idling).
WA700-3L
20-21 2
TESTING AND ADJUSTING
ACCELERATOR PEDAL
ADJUSTING PEDAL TRAVEL, POTENTIOMETER MEASURING 1.
Stop the engine.
2.
Put angle gauge ➀ in contact with the accelerator pedal, and measure operating angle α (α = α1 − α2) when the pedal is operated from low idling position α1 to high idling position α2.
3.
Output voltage of accelerator pedal potentiometer Measure the output voltage of the potentiometer when the engine is running at low idling and high idling. ★ Connect a T-adapter to CNL13 and measure the voltage between (1) and the ground.
20-22 2
WA700-3L
TESTING AND ADJUSTING
ACCELERATOR PEDAL
ADJUSTING 1.
Adjusting output voltage of potentiometer A. Check that punch mark (2) made on intermediate connector (1) between the case and potentiometer is on the side where it can be seen. Insert the protruding part of the potentiometer into the groove in the intermediate connector, then temporarily tighten the mount screw. Potentiometer mount surface: Cemedyne POS seal
Potentiometer mount screw: LT-2
B. Set the pedal to the low idling position, impress a voltage of DC5V on the potentiometer, and turn the potentiometer to the left and right to set it within the range for the low idling output voltage. Output voltage at low idling: . . . . . . . . . . . . . . . . . . . 4.1+0.2 V -0.1 Operate the pedal 2 or 3 times and check that the voltage is within the specified output voltage range at the low idling position. If the voltage is not within the specified range, carry out the adjustment again. ★ When adjusting the low idling output voltage, first operate the pedal 2 or 3 times at the lowest output voltage position, then turn the potentiometer to increase the voltage until it is within the specified voltage range. This will keep the play on one side and make it easier to adjust. C. Next, operate the pedal to the high idling position and check that the voltage is within the high idling output voltage range. Output voltage at high idling: . . . . . . . . . . . . . . . . . . . 0.7 ± 0.2 V If the voltage is not within the specified range, adjust the low idling voltage again within the specified range and adjust so that both the low idling and high idling voltages are the specified voltage. D. If the high idling voltage does not enter the voltage range with the procedure up to Step C, remove the pin from the bottom of stopper bolt (3), loosen the stopper bolt, and move it up or down to adjust so that the high idling voltage is within the voltage range. ★ Adjust the position of the hole so that the pin can enter the hole at the bottom of the bolt. ★ The stopper bolt is already properly adjusted, so do not adjust it unless there is some special reason. E. Tighten the potentiometer mount screw.
WA700-3L
20-23 2
TESTING AND ADJUSTING
ACCELERATOR PEDAL
ADJUSTING PEDAL MICRO SWITCH 1.
Remove the accelerator pedal assembly.
2.
Remove case (1).
3.
Set so that rod (2) pushes against body (3) and guide (4) pushes against the step portion of the rod. Then insert a clearance gauge between the guide and bracket, and tighten screw (6) so that the clearance between spring guide (4) and bracket (5) is 0.1 - 0.2 mm.
4.
Installation of case A. Install case (1) to body (3). Mount surface of case: Cemedyne POS seal
B. Install rod guide (7). Rod guide mount surface: Cemedyne POS seal
5.
Install the accelerator pedal assembly to the machine.
20-24 2
WA700-3L
TESTING AND ADJUSTING
TORQUE CONVERTER & TRANSMISSION PRESSURE
TORQUE CONVERTER & TRANSMISSION PRESSURE ★ Measurement conditions • Engine water temperature: Within operating range • Torque converter oil temperature: 60 - 80° C (140 - 176° F) • Engine speed: High idling WARNING! Put blocks under the wheels. METHOD OF MEASURING ★ The following work is necessary before measuring the hydraulic pressure. • Open inspection cover (1) at the rear of the cab. • Turn transmission cut-off switch (2) OFF and use the left brake. (Check that the pilot lamp goes out.) • Install the hydraulic test kit to the measurement port, extend the gauge to the operator’s compartment, then start the engine and measure the pressure. ★ Check that there is no oil leaking from any joint. 1.
Torque converter inlet port pressure A. Measurement port P10 or P8 [not called out]. B. Start the engine and measure the pressure at high idling. C. Measure with the speed range at Neutral.
2.
Torque converter outlet port pressure A. Measurement port P11. B. Start the engine and measure the pressure at high idling.
WA700-3L
20-25 2
TESTING AND ADJUSTING 3.
TORQUE CONVERTER & TRANSMISSION PRESSURE
Main relief pressure A. Measurement port P6. B. Start the engine and measure the pressure at low idling and high idling.
4.
Pilot reducing pressure A. Measurement port P5. B. Place the directional lever at neutral, operate the speed lever and measure the pressure.
5.
Modulating pressure A. Measurement port P1. B. Place the directional lever at neutral, operate the speed lever and measure the pressure. ★ Do not measure at F3 or R3.
6.
Lubricating valve pressure A. Measurement port P9. B. Start the engine and measure the pressure at high idling.
7.
Reducing valve pressure A. Measurement port P3. B. Start the engine and measure the pressure at high idling and low idling.
20-26 2
WA700-3L
TESTING AND ADJUSTING
TORQUE CONVERTER & TRANSMISSION PRESSURE
MEMORANDUM
WA700-3L
20-27 2
TESTING AND ADJUSTING
EMERGENCY MANUAL SPOOL
EMERGENCY MANUAL SPOOL OUTLINE •
The transmission valve is controlled electrically. Therefore, the emergency manual spool is installed to enable the machine to be moved if there is any failure in the electrical system or in the solenoid valve and spool. WARNING! The emergency manual spool is for use when failure in the transmission control prevents the machine from being moved. It allows the machine to be moved from a dangerous place to a place where repairs can be carried out safety. The emergency manual spool must never be used except when the transmission control has broken down. WARNING! When operating the emergency manual spool, follow the correct order of operation exactly, and pay full attention to safety when moving the machine. WARNING! To prevent the machine from moving, lower the bucket to the ground, apply the parking brake, and put blocks under the tires. Check that the brake accumulator pressure is the specified pressure.
OPERATION 1.
Open cover (1) on rear side of cab. WARNING! Always stop the engine before operating the spool.
2.
Remove lock plate (3) of the emergency manual spool (2) of the transmission valve. ★ Simply loosen the mount bolts to remove the lock plate (3).
3.
Decide the direction to move the machine (forward or in reverse), then move the emergency manual spool to the operating position. FORWARD: Rotate FORWARD clutch spool and 1st spool counterclockwise, and pull out approximately 10 mm to the operating position. REVERSE:
20-28 2
Rotate REVERSE clutch spool and 1st spool counterclockwise, and pull out approximately 10 mm to the operating operation.
WA700-3L
TESTING AND ADJUSTING
EMERGENCY MANUAL SPOOL
4.
Check that the area around the machine is safe, remove the blocks from under the wheels.
5.
Sit in the operator’s seat, and depress the left brake pedal fully.
6.
Start the engine, release the parking brake, then release the brake pedal gradually to start the machine. WARNING! When the engine is started, the transmission is engaged and the machine will start. Therefore, before starting the engine, always check that the direction of travel is safe, and always keep the brake pedal depressed. If the machine does not start with the above operation, return the 1st spool to the neutral position, then turn the 2nd spool, 3rd spool, or 4th spool clockwise (screw in approximately 10 mm), to set to the STOP (OFF) position.
WARNING! If two or more spools for the speed ranges are screwed in at the same time, the transmission is locked, and the machine does not move. 7.
After moving the machine, stop the engine, apply the parking brake, and block the wheels.
8.
Return the emergency manual spool to the neutral position, and install the lock plate.
WA700-3L
20-29 2
TESTING AND ADJUSTING
STEERING
STEERING STEERING OIL PRESSURE ★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
MEASURING 1.
Measuring steering relief pressure WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping.
WARNING! Install the safety bar to the frame.
A. Remove oil pressure measurement plug (PT1/8) (1) from the elbow at the right steering cylinder head end, then install oil pressure gauge C1 400 kgf/cm2 (5689 lbf/in2). B. Start the engine, run the engine at high idling, then turn the steering wheel to the right and measure the pressure when the relief valve is actuated. ★ When removing the oil pressure measurement plug on the left steering cylinder, turn the steering wheel to the left.
ADJUSTING WARNING! Always stop the engine before adjusting the pressure. 1.
Adjusting steering relief valve Loosen locknut (2) of steering relief valve (1), then turn adjustment nut (3) to adjust. ★ Turn the adjustment screw to adjust the set pressure as follows. To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTER-CLOCKWISE ★ Pressure adjustment for one turn of adjustment screw: Approximately 145 kgf/cm2 (2062 lbf/in2) Lock nut: 29.4 ± 2.0 Nm (21.6 ± 1.4 lbf ft)
20-30 2
WA700-3L
TESTING AND ADJUSTING
STEERING
STEERING STOPPER BOLT PREPARATORY WORK Operate the steering before adjusting the stopper bolt and check that there is contact of the frame stopper at the steering end. ★ If there is no contact because of chipping of the frame stopper, carry out repairs so that there is contact on both the left and right sides.
ADJUSTING 1.
Set the stopper bolt to the minimum length.
2.
Run the engine at low idling and operate the steering slowly to contact the frame end. In this condition, loosen the bolt to pull it out until the head of the stopper bolt contacts the tip of the stop valve spool. ★ Be careful not to loosen the bolt too far and push the spool.
3.
From this condition, turn the chassis back to make a clearance of approximately 20 mm between the tip of the stop valve and the head of the stopper bolt, then stop the engine.
4.
From the condition in Step 3, loosen the bolt 8.5 - 9 turns (14.9 - 15.8 mm), and secure it in position with the lock nut.
5.
Carry out Steps 1 to 4 on the opposite side.
WA700-3L
20-31 2
TESTING AND ADJUSTING
STEERING
JOYSTICK STEERING PREPARATORY WORK Loosen the potentiometer mount screw and connect a T-adapter (X type, 3 pin) between the potentiometer connect and connector JS2. ★ Turn the starting switch OFF before doing this.
ADJUSTING 1.
Adjusting neutral position A. Set the joystick selector switch to the OFF position (wheel mark side) and set the joystick lever to the N position. B. Turn the starting switch ON. ★ Turn only to the ON position, do not start the engine.
C. Check the voltage between pins ② and ③ of the T-adapter. Voltage between pins: . . . . . . . . . . . . . . . . . . . . . . DC 5 ± 0.05 V Adjust the voltage by turning the potentiometer slowly so that the voltage between pins ① and ③ of the T-adapter become the standard value. Voltage between pins: . . . . . . . . . . . . . DC 2.5 ± 0.l V (set value)
20-32 2
WA700-3L
TESTING AND ADJUSTING
STEERING
After adjusting the voltage, tighten the potentiometer mount screws.
2.
Adjusting left and right turning position A. Operate the potentiometer to adjust the voltage at the left and right turn positions.
Lever position
Voltage between pins (1) and (3)
Left turn
DC 0.83 ± 0.l V
Right turn
DC 4.17 ± 0.1 V
B. After adjusting the voltage, lock the stopper bolt in position.
JOYSTICK LEVER NEUTRAL DETECTION SWITCH PREPARATORY WORK After adjusting the neutral position with the potentiometer, set the lever to the neutral position and loosen the nut of the cam plate.
ADJUSTING 1.
Set so that the tip of the roller of the neutral detection switch contacts the concave portion of the cam plate, then tighten the switch mount bolts. ★ Never make the roller of the neutral detection switch push into the concave portion of the cam plate.
2.
Tighten the nut so that the cam plate is not at an angle.
WA700-3L
20-33 2
TESTING AND ADJUSTING
BRAKE
BRAKE BRAKE OIL PRESSURE TESTING 1.
Inspecting brake oil pressure A. Remove bleeder-screw (1), then install oil pressure gauge tool I 200 kgf/cm2 (2844 lbf/in2), the elbow, joint, bleeder screw, and nipple, B. Connect hose (2) to the bleeder screw and bleed the air from the brake circuit. For details, see BLEEDING AIR. C. Depress the left brake and measure the brake oil pressure.
2.
Measuring drop in brake piston pressure A. Remove bleeder screw (1), then install oil pressure gauge tool I 200 kgf/cm2 (2844 lbf/in2), the elbow, joint, bleeder screw, and nipple. B. Connect hose (2) to the bleeder screw and bleed the air from the brake circuit. For details, see BLEEDING AIR.
C. Stop the engine, depress the left brake pedal, leave for 5 minutes with the oil pressure at 50 kgf/cm2 (711 lbf/in2), and measure the drop in pressure. ★ Be careful not to move the brake pedal for 5 minutes. ★ After completing the operation, bleed the air from the brake circuit again.
20-34 2
WA700-3L
TESTING AND ADJUSTING
BRAKE
BRAKE DISC Brake oil pressure: . . . . . . . . . . . 50 ± 5 kgf/cm2 (711 ± 71 lbf/in2) WARNING! Park the machine on horizontal ground and put blocks securely under the tires.
MEASURING WEAR 1.
Remove plug (1).
2.
Depress the brake pedal fully.
3.
Use calliper gauge M to measure depth a from the end face of the housing to the spring guide. ★ When measuring, keep the brake pedal depressed.
4.
Install a vinyl hose (3) to bleeder (2), then loosen the bleeder and drain the brake oil. ★ After draining the brake oil, check that the brake piston has returned to the end of its stroke.
5.
Measure depth b from the end face of the housing to the spring guide.
Calculating piston stroke S=a-b S: Max. 9.7 mm
WA700-3L
20-35 2
TESTING AND ADJUSTING
BRAKE
BRAKE PERFORMANCE ★ Measurement conditions Road surface: Flat, horizontal, dry paved surface. Travel speed: 20 km/h (12.42 mi/h) when brakes are applied Delay in applying brakes: 0.1 sec. Tire inflation pressure: Specified pressure
MEASURING 1.
Start the engine and move the machine.
2.
Set the speed lever to the highest speed position and drive the machine.
3.
When the travel speed reaches 20 km/h (12.42 mi/h) , depress the left brake pedal with the specified operating force. ★ Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the brakes when the machine reaches that point. ★ Switch the transmission cut-off switch ON when carrying out this operation.
4.
Measure the distance from the point where the brakes were applied to the point where the machine stopped. ★ Repeat this measurement three times and take the average.
20-36 2
WA700-3L
TESTING AND ADJUSTING
PARKING BRAKE
PARKING BRAKE WARNING! Put blocks securely under the tires.
TESTING MEASURING PAD 1.
Turn the starting switch ON, then turn the parking brake switch OFF to release the brake.
2.
Remove pad (1) from clipper (2) and measure the thickness of the pad. WARNING! If the starting switch is turned OFF, the parking brake is actuated, so be extremely careful not to turn the starting switch OFF. For details of removing and replacing the pad, see DISASSEMBLY AND ASSEMBLY. Measure the two pads. ★ If the measurement is not within the standard value, replace the two pads as one set.
MEASURING CLEARANCE 1.
Turn the parking brake switch OFF to release the brake.
2.
Insert feeler gauge F between pad (1) and disc (3), and measure the clearance. • The clearance is the total value (a + b) of the measurements at both sides.
WA700-3L
20-37 2
TESTING AND ADJUSTING
PARKING BRAKE
ADJUSTING If the measurement is not within the standard value, adjust as follows. 1.
Turn the starting switch ON, then turn the parking brake switch OFF to release the brake. WARNING! If the starting switch is turned OFF, the parking brake is actuated, so be extremely careful not to turn the starting switch OFF.
2.
Turn adjustment bolt (4) at the caliper lever counterclockwise until pad (1) and disc (3) are brought into tight contact and resistance is felt when turning the bolt.
3.
From the above position, turn adjustment bolt (4) 180° ± 30° (3 notches) back in the clockwise direction. This adjusts the total clearance on the left a and right b between pad (1) and disc (3) to the standard value of 1.06 ± 0.18 mm.
After completing the above adjustment, measure the performance of the parking brake to check that it is the standard value.
20-38 2
WA700-3L
TESTING AND ADJUSTING
ACCUMULATOR CHARGE PRESSURE
ACCUMULATOR CHARGE PRESSURE TESTING Hydraulic oil temperature: . . . . . . . . . . . 45 - 55° C (113 - 131° F) WARNING! Put blocks securely under the tires.
WARNING! Depress the brake pedal at least 100 times with the engine stopped to release the pressure inside the accumulator circuit. 1.
Disconnect hose (port PP) (2) from accumulator (1).
2.
Install the adapter C3 to elbow (3) at the charge valve end, then assemble hose (2) again.
3.
Install oil pressure gauge C1 400 kgf/cm2 (5689 lbf/in2) to adapter C3.
4.
Measure the accumulator charge cut-in pressure. Start the engine, run the engine at low idling, and measure the oil pressure when the accumulator pressure warning pilot lamp on the maintenance meter goes out.
5.
Measure the accumulator charge cut-out pressure. After the accumulator charge cut-in is actuated, measure the oil pressure when the indicator of the oil pressure gauge has risen and suddenly starts to drop.
ADJUSTING Remark When-the accumulator charge cut-out pressure is adjusted, the cut-in pressure also changes in proportion to the ratio of the valve area. For this reason, there is no adjustment nut for the cut-in pressure. 1.
Loosen locknut (5) of accumulator charge cutout valve (4), then turn adjustment screw (6) to adjust. ★ Turn the adjustment screw to adjust the pressure as follows. To RAISE pressure, turn CLOCKWISE To LOWER pressure, turn COUNTER-CLOCKWISE ★ Pressure adjustment for 1 turn of adjustment screw: 57 kgf/cm2 (810 lbf/in2) Lock nut: 9.8 ± 1.8 Nm (7.22 ± 1.32 lbf ft)
Remark After completion of adjustment, repeat the measurement procedure given above to check the accumulator cut-in pressure and cut-out pressure again.
WA700-3L
20-39 2
TESTING AND ADJUSTING
WORK EQUIPMENT
WORK EQUIPMENT PPC RELIEF VALVE MEASURING HYDRUALIC PRESSURE Hydraulic oil temperature: . . . . . . . . . . . 45 - 55° C (113 - 131° F) WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
WARNING! Operate the control levers several times to release the pressure in the PPC accumulator circuit. •
Raise the lift arm, set a support in position under the lift arm, then remove front frame inspection cover (1).
1.
Measuring PPC relief valve pressure A. Remove plug (2) for measuring the hydraulic pressure in the dump cylinder circuit of the main control valve. B. Install the hydraulic tester kit to the measurement port. ★ Check that there is no oil leaking from any joint. ★ Use a hose which is long enough to reach the operator’s compartment. C. Start the engine, raise the lift arm approximately 400 mm from the ground, then operate the control lever to tilt back the bucket and measure the pressure when the relief valve is actuated. WARNING! When removing the oil pressure gauge, release the pressure inside the circuit in the same way as when installing the gauge.
20-40 2
WA700-3L
TESTING AND ADJUSTING
WORK EQUIPMENT
ADJUSTING HYDRAULIC PRESSURE 1.
Adjusting PPC relief valve WARNING! Always stop the engine before adjusting the oil pressure. WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. WARNING! Operate the control levers several times to release the pressure in the PPC accumulator circuit. A. Remove cap nut (3) of PPC relief valve (1). ★ Loosen locknut (4), then turn adjustment screw (5) to adjust. Turn the adjustment screw to adjust the pressure as follows. To RAISE pressure, turn CLOCKWISE To LOWER pressure, turn COUNTER-CLOCKWISE ★ Pressure adjustment for one turn of adjustment screw: Approximately 19.8 kgf/cm2 (281.6 lbf/in2)
WA700-3L
20-41 2
TESTING AND ADJUSTING
WORK EQUIPMENT
HYDRAULIC PRESSURE TESTING Hydraulic oil temperature: 45 - 55° C (113 - 131° F) WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1.
Measuring work equipment relief pressure A. Set the bucket so that portion a is raised 30 - 50 mm, then lower portion b to the ground. B. Stop the engine, then operate the work equipment control lever, and check that both bottom surfaces of the bucket (portions a and b) are in contact with the ground surface. WARNING! After lowering the bucket to the ground, operate the control levers several times to release the remaining pressure in the hydraulic piping. C. Remove oil pressure measurement plug (1) from the dump cylinder circuit and install the hydraulic tester kit. D. Start the engine, raise the lift arm approximately 400 mm, then operate the control lever to tilt back the bucket, and measure the pressure when the relief valve is actuated. WARNING! When removing the oil pressure gauge, release the pressure inside the circuit in the same way as when installing the gauge.
20-42 2
WA700-3L
TESTING AND ADJUSTING
WORK EQUIPMENT
ADJUSTING
WARNING! Airways stop the engine before adjusting the oil pressure. 1.
Raise the lift arm, set a support in position under the lift arm, then remove front frame inspection cover (1).
2.
Remove locknut (3) of relief valve (2). ★ Turn adjustment screw (4) to adjust. Turn the adjustment screw to adjust the pressure as follows. To RAISE pressure, turn CLOCKWISE To LOWER pressure, turn COUNTER-CLOCKWISE ★ Pressure adjustment for one turn of adjustment screw: Approximately 128 kgf/cm2 (1820.5 lbf/in2)
WARNING! Do not carry out any adjustment if the relief pressure cannot be measured accurately.
WA700-3L
20-43 2
TESTING AND ADJUSTING
WORK EQUIPMENT
PISTON PUMP BLEEDING AIR Remark If the oil in the hydraulic tank has been changed, or the piston pump has been removed, or the piston pump piping has been removed, bleed the air as follows to prevent seizure of the pump. 1. Check that the oil in the hydraulic tank is at the upper level. Remark The cap of the hydraulic tank some times will move (shake), until the air bleeding off the piston pump is depleted. 2.
Loosen plugs (1) and (2) of the tube at the suction side of the piston pump.
3.
Let oil flow out in turn from plugs (1) and (2), and when the air is completely bled from the piston pump, tighten the plugs. After that, in order to fill the inside of the pump with the hydraulic oil, leave it for 10 minutes. Remark The oil level in the hydraulic tank is higher than the positions of parts (1) and (2), so it is possible to bleed the air easily. 4.
Loosen the mouthpiece of the case drain hose (3), start the engine at the condition of low idling. Tighten the mouthpiece, confirming that hydraulic oil flows from the mouthpiece.
20-44 2
WA700-3L
TESTING AND ADJUSTING
WORK EQUIPMENT
LEVER LINKAGE ADJUSTING If the operating effort or travel of the work equipment control lever is not within the standard value, or the work equipment control lever, PPC valve, or bucket solenoid have been removed, adjust as follows. ★ Carry out the adjustment with the engine stopped. ★ Check if the operating effort of the work equipment lever is within the standard value. ★ Remove the side cover at the bottom of the work equipment lever 1.
PPC valve linkage A. Adjust dimension a from the center of trunnion (1) of the PPC valve linkage to the top surface of the floor.
Dimension a (target value): . . . . . . . . . . . . . . . . . . . . . . . . 54 mm B. Loosen nuts (2) and (3), and adjust the installation height of trunnion (1) so that there is no play at lever (4). C. After adjusting, tighten nuts (2) and (3). 2.
Work equipment linkage A. Operate boom lever (5) and adjust rod (8) so that boom lever cam follower (6) enters the detent at both ends of cam (7) uniformly and clearance b is 0 - 1 mm.
Installed dimension d of rod (8): . . . . . 337 mm (reference value) B. Operate bucket lever (9) and adjust rod (12) so that bucket lever cam follower (10) enters the detent at both ends of cam (11) without any play and clearance c is 0 - 1 mm. Installed dimension d of rod (12): . . . . 337 mm (reference value)
WA700-3L
20-45 2
TESTING AND ADJUSTING
3.
WORK EQUIPMENT
Installation of solenoid Do as follows to set boom kick out solenoid (13) and bucket positioner solenoid (14) at the pulled (electricity flowing) condition. A. Disconnect wiring connectors F05 (15) and F06 (16). ★ F05 (15): Proximity switch for bucket positioner ★ F06 (16): Proximity switch for boom kick out B. Connect a T-adapter and short circuit the terminals between connectors (1) and (2). ★ Check that the solenoid is pulled back 12 mm to release the cam. C. Set with boom kick out solenoid (13, see previous page) pulled, then move the solenoid so that clearance e between boom lever cam (7) and cam follower (6) is 0 - 0.5 mm. ★ Adjust with the boom lever at HOLD. D. Set with bucket positioner solenoid (14, see previous page) pulled, then move the solenoid so that clearance f between bucket lever cam (11) and cam follower (10) is 0 - 0.5 mm. ★ Adjust with the bucket lever at HOLD. E. If the operating effort for releasing the boom lever and bucket lever is not within 23.5 N (5.28 lbf), change the position of the mount holes (4 places) of spring (17) to adjust the release effort.
Remark When the machine is shipped from the factory, the spring is hooked to the 2nd mount hole from the top. F.
After adjusting, operate the boom lever and bucket lever and check that the work equipment moves normally.
20-46 2
WA700-3L
TESTING AND ADJUSTING
WORK EQUIPMENT
BUCKET POSITIONER ★ Engine water temperature: Within green range on engine water temperature gauge ★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
TESTING 1.
With the engine stopped, check that clearance a between proximity switch (1) and detector bar (2) is the standard value. • Clearance a: 3 - 5 mm
2. Start the engine, run at high idling and check the actuating position. Remark Check three times and take the average.
ADJUSTING 1.
Lower the bucket to the ground, set the bucket to the desired digging angle, return the lever to the HOLD position, and stop the engine.
2.
Adjust nut (4) of the switch so that clearance b between the tip of switch protector (3) and the sensing surface and the switch is the standard value, then secure in position. • Standard clearance b: 0.5 - 1.0 mm Proximity switch mount nut: 14.7 Nm (10.8 lbf ft)
3.
Secure detector bar (2) in position so that clearance a between the sensing surface of proximity switch (1) and detector bar (2) is the standard value. • Clearance a: 3 - 5 mm Adjust so that the clearance a is within the standard value for the whole stroke of detector bar (2).
4.
Secure switch protector (3) to the bucket cylinder so that tip c of detector bar (2) matches the center of proximity switch (1). ★ After adjusting, operate the bucket lever and check that the bucket positioner is actuated at the desired position.
WA700-3L
20-47 2
TESTING AND ADJUSTING
WORK EQUIPMENT
BOOM KICK-OUT ★ Engine water temperature: Within green range on engine water temperature gauge ★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
TESTING 1.
With the engine stopped, check that clearance a between proximity switch (1) and sensor plate (2) is the standard value. ★ Clearance a: 3 - 5 mm
2. Start the engine, run at high idling and check the actuating position. Remark Check three times and take the average.
ADJUSTING 1.
Raise the boom to the desired height, then mark the boom to show the position where the center of proximity switch (1) is at the top of sensor plate (2). WARNING! Always be sure to apply the safety lock to the work equipment control lever.
2.
Lower the boom and stop the engine.
3.
Align the marks and adjust the position of sensor plate (2) so that the center of proximity switch (1) is at the top of sensor plate (2), then secure in position.
4.
Adjust proximity switch (1) so that clearance a between the sensing surface of proximity switch (1) and sensor plate (2) is the standard value, then secure in position. ★ Standard clearance a: 3 -5 mm Proximity switch mount nut: 14.7 Nm (10.8 lbf ft) ★ After adjusting, operate the boom lever and check that the boom kick-out is actuated at the desired position.
20-48 2
WA700-3L
TESTING AND ADJUSTING
WORK EQUIPMENT
PROXIMITY SWITCH ACTUATION PILOT LAMP LAMP (RED) The proximity switch is equipped with a pilot lamp which shows when it is being actuated, so use this when adjusting.
Proximity switch actuation pilot lamp Detector position
Lights up When detector is positioned at detection surface of proximity switch
Goes out When detector has moved away from detection surface of proximity switch
Bucket positioner
Boom kick-out
WA700-3L
20-49 2
TESTING AND ADJUSTING
MAIN MONITOR (SPEEDOMETER MODULE)
MAIN MONITOR (SPEEDOMETER MODULE) The speedometer on the main monitor is a common part for all machines, and the input signal for the travel speed differs according to the machine, so it is necessary to adjust the monitor for use with the particular model. In addition, the tire diameter also differs according to the type of tire fitted, so it is necessary to adjust to give the correct travel speed. It is also necessary to change the switches if the optional E.C.S.S. (Electronically Controlled Suspension System) is installed.
ADJUSTMENT PROCEDURE WARNING! Turn off the power, then remove the machine monitor and adjust the switches at the back of the speedometer. 1.
Setting machine model A. Remove the rubber caps from dipswitchs (1), (2) and (3) at the back of the speedometer. B. When the rubber cap is removed, a rotary switch can be seen inside. Using a flathead screwdriver, turn this switch to adjust it to the settings in the table below.
Tire size
DIP SW 1 (model selection)
DIP SW 2 (speedometer correction)
DIP SW 3 (tachometer input selection)
46/65-39-36PR
7
7
0
C. When the cap is removed from dipswitch (4) at the back of the speedometer, an ON/OFF switch can be seen. Adjust the setting if the transmission and joystick steering controller is installed. D. After completing the adjustment, fit the rubber caps securely and install the main monitor. Reference - Amount of correction for switch (2) Switch position
0
1
2
3
4
5
6
7
Amount of correction (%)
+14
+12
+10
+8
+6
+4
+2
0
Switch position
8
9
A
B
C
D
E
F
Amount of correction (%)
0
-2
-4
-6
-8
-10
-12
-14
20-50 2
WA700-3L
TESTING AND ADJUSTING
BLEEDING AIR
BLEEDING AIR BLEEDING AIR FROM BRAKE SYSTEM WARNING! Put blocks securely under the tires.
A. After charging the accumulator, stop the engine, insert vinyl hose (2) into bleeder screw (1), and put the other end in a container. B. Depress the brake pedal, then loosen bleeder screw (1) and bleed the air. Tighten bleeder screw (1), then slowly release the brake pedal. ★ When depressing the brake pedal, use the left pedal. C. Repeat the above operation, and when no more bubbles come out with the fluid from vinyl hose (2), depress the pedal fully and tighten bleeder screw (1) while the oil is still flowing. D. Repeat the procedure to bleed the air from each brake cylinder. ★ To bleed the air completely, start with the brake cylinder that is farthest from the brake pedal. ★ If the accumulator pressure goes down, start the engine and charge the accumulator again. ★ Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check the level in the oil tank and add more oil if necessary.
BLEEDING AIR FROM HYDRAULIC CYLINDERS A. Start the engine and run at idling for approximately 5 minutes. B. Run the engine at low idling, then raise and lower the boom 4 - 5 times in succession. ★ Operate the piston rod to a point approximately 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. C. Run the engine at full throttle and repeat Step B. After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. D. Repeat Step B and C to bleed the air from the bucket and steering cylinder. ★ When the cylinder has been replaced, bleed the air before connecting the piston rod.
WA700-3L
20-51 2
TESTING AND ADJUSTING
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 1.
Releasing remaining pressure between each hydraulic cylinder and control valve ★ If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. A. Stop the engine. B. Loosen the oil filler cap slowly to release the pressure inside the tank. C. Operate the control levers. ★ When the levers are operated 2 - 3 times, the pressure stored in the PPC accumulator is removed. Start the engine, run at low idling for approximately 5 minutes, then stop the engine and operate the control levers. ★ Repeat the above operation 2 - 3 times to release all the remaining pressure.
2.
Releasing remaining pressure in brake accumulator circuit ★ If the piping between the brake accumulator and parking brake solenoid valve, between the accumulator and accumulator check valve, or between the accumulator and brake valve was disconnected, release the remaining pressure from the circuit as follows. A. Stop the engine. B. Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit.
3.
Releasing remaining pressure in PPC circuit ★ If the piping between the PPC relief valve and PPC valve is to be disconnected, release the remaining pressure from the circuit as follows. • Operate the control levers 2 - 3 times to release the remaining pressure in the circuit.
BLEEDING AIR FROM THE HYDRAULIC TANK •
Bleed the air from the circuit after replacing the oil and filter elements or cleaning the strainer.
•
After changing the oil in the hydraulic tank, replacing the hydraulic tank element, or removing the hydraulic cylinder or work equipment piping has been removed, bleed the air as follows after reassembly.
•
Bleed air from hydraulic circuit after bleeding air from piston pump.
20-52 2
WA700-3L
TESTING AND ADJUSTING
BLEEDING AIR
BLEEDING AIR FROM THE PISTON PUMP Remark The piston pump may be damaged if air is not bled completely, so always perform the air bleeding operation correctly. Remark Check that the hydraulic oil level is up to the top of the sight gauge before bleeding the air from the piston pump. Add oil if the level is low. 1.
Loosen oil filler cap (1).
2.
Loosen plug (2) on top of the tubes at suction side of the piston pump. There is one plug for each pump, loosen all plugs (2 places). Allow oil to flow out of each plug until no air is evident. After the air is completely, tighten plugs (2 places).
3.
Check oil level and add oil if necessary. Tighten the oil filler cap (1) securely.
4.
Loosen connector (4) at the block side of case drain hose (3) of the piston pump. There is no need to loosen the connectors at the other two case drain hoses.
5.
Run the engine at low idle and let oil and air flow from around connector of hose (3) until no air is evident. This process may require 10 minutes.
6.
Tighten connector, and check the oil level and add oil if necessary. •
For details, contact your Komatsu distributor.
WA700-3L
20-53 2
TESTING AND ADJUSTING
BLEEDING AIR
BLEEDING AIR FROM THE HYDRAULIC CIRCUIT 1.
Check that the oil in the hydraulic tank is at the specified level.
2.
Run the engine at low idle and operate each hydraulic cylinder (steering, bucket and lift arm) 4 to 5 times, stopping 100 mm (3.94 in.) from stroke end.
3.
Next, operate each cylinder 3 to 4 times to the end of its stroke, stop the engine and loosen air bleed plug (1) of the hydraulic tank to bleed the air. After bleeding the air, tighten the plug.
4.
Check the hydraulic oil level and add more if necessary.
5.
Start the engine, increase the engine speed and repeat step 3 to bleed the air until no more bubbles come out from plug (1).
Remark If the engine is run at high speed at first or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage the piston packing, etc. 6.
After bleeding the air, tighten the air bleeding plug (1). Air bleed plug tightening torque: 11.3 ± 1.5 N•m (8 ± 1 lbf ft)
7.
Check the oil level in the hydraulic tank and add more if necessary. After adding oil, tighten the oil filler cap securely.
20-54 2
WA700-3L
TROUBLESHOOTING GENERAL POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103 SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107 HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-113 CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115 JUDGEMENT OF POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116 PRECAUTIONS WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117 PREVENTING RECURRENCE OF TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118 HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118 OIL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118 CLEANING FRAGMENTS OF DAMAGED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118 METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119 CATEGORY OF TROUBLESHOOTING CODE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE. . 20-119 METHOD OF USING MATRIX TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121 METHOD OF USING ENGINE RELATED CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
WA700-3L
20-101 1
TROUBLESHOOTING 12
MEMORANDUM
20-102 1
WA700-3L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
12 POINTS TO REMEMBER WHEN TROUBLESHOOTING WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts. WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the battery first. WARNING! When removing the plug or cap from a location which is under pressure from oil, water or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after a failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2.
Points to ask the user or operator. A. Have any other problems occurred apart from the problem that has been reported? B. Was there anything strange about the machine before the failure occurred? C. Did the failure occur suddenly, or were there problems with the machine condition before this? D. Under what conditions did the failure occur? E. Had any repairs been carried out before the failure? When were these repairs carried out? F.
Has the same kind of failure occurred before?
WA700-3L
20-103 1
TROUBLESHOOTING 3.
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Check before troubleshooting. A. Check the oil level. B. Check for any external leakage of oil from the piping or hydraulic equipment. C. Check the travel of the control levers. D. Check the stroke of the control valve spool. E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4.
Confirming the failure. A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. i.
Reenact the failure and check the condition of the machine (particular conditions at the time of failure).
ii.
Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or by feeling.
iii. Compare extent of failure with standard values. iv. Check safety before carrying out any check. ★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. B. Try to locate the possible causes for the failure. The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical control. In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as follows; • Transmission itself, or transmission control valve. • Transmission electric control. • To decide which of the two is the location of the failure, refer to “JUDGMENT ON POWER TRAIN”.
5.
Troubleshooting A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the troubleshooting flowchart to locate the position of the failure exactly. B. Carry out troubleshooting using the troubleshooting charts. There are the following two types of troubleshooting charts.
i.
20-104 1
TROUBLESHOOTING TABLE POWER TRAIN STEERING SYSTEM BRAKE AND AIR SYSTEM WORK EQUIPMENT SYSTEM
WA700-3L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
12 ii.
TROUBLESHOOTING FLOW CHART ELECTRICAL SYSTEM
The troubleshooting charts consist of: i.
Items which can be checked easily.
ii.
Items which are likely to be the cause of such failures.
Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points. • Check related items. • Check that there are no other failures or breakdowns. A. The basic procedure for troubleshooting is as follows. i.
Start from the simple points.
ii.
Start from the most likely points.
iii. Investigate other related parts or information. 6.
Measures to remove root cause of failure. A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
WA700-3L
20-105 1
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-106 1
WA700-3L
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 1.
Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protector or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness A. Faulty contact of connectors (faulty contact between male and female). Problems with faulty contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidation of the contact surfaces. B. Defective compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion, but there is excessive force on the wiring, and the plating peels to cause improper connection or breakage.
WA700-3L
20-107 1
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 C. Disconnections in wiring If the wiring is held and tugged and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping compression of the connectors to the wire may be loosened, or the soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. The connector is designed to prevent water from entering, but if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
E. Oil, grease or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, and this will cause a defective contact. If there is oil or grease or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with a contact restorer. ★ When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. ★ If there is water or oil present, it will increase the contamination of the points, so clean with air until all water and oil has been removed.
20-108 1
WA700-3L
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 3. Removing, installing, and drying connectors and wiring harnesses. A. Disconnecting connectors i.
Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart.
ii.
When removing the connectors from the clips, pull the connector in a parallel direction to the clip. ★ If the connector is twisted to the left and right or up and down, the housing may break.
iii. When disconnecting male and female connectors, release the lock and pull in parallel with both hands. ★ Never try to pull apart with one hand.
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20-109 1
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 iv. Action to take after removing connectors. After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion.
B. Connecting connectors i.
Check the connector visually. • Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). • Check that there is no deformation, faulty contact, corrosion, or damage to the connector pins. • Check that there is no damage or breakage to the outside of the connector. ★ If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has gotten inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ★ If there is any damage or breakage, replace the connector.
ii.
Assemble the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with a lock stopper: Push in the connector until the stopper clicks into position.
iii. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. ★ When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with properly filtered air.
20-110 1
WA700-3L
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 iv. When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that there is no looseness of the clamp.
C. Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows: i.
Disconnect the connector and wipe off the water with a dry cloth. ★ If the connector is blown dry with air, there is the risk that oil in the air may cause a faulty contact, so avoid blowing with air.
ii.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. ★ Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
iii. Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water.
★ After completely drying the connector, spray it with contact restorer and reassemble.
WA700-3L
20-111 1
TROUBLESHOOTING 12 HANDLING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CONTROL BOX
1.
The control box contains a microcomputer and electronic control circuits. This controls all of the electronic circuits on the machine, so be extremely careful when handling the control box.
2.
Do not open the cover of the control box unless necessary.
3.
Do not place objects on top of the control box.
4.
Cover the control connectors with tape or a vinyl bag.
5.
Do not leave the control box in a place where it is exposed to rain.
6.
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand)
7.
Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
20-112 1
WA700-3L
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust proof workshop, and the performance should be confirmed with special test equipment.
3.
Seal or cover all openings of disconnected piping After any piping or equipment is removed, the openings should be sealed with caps, tape, or vinyl bags to prevent any dirt or dust from entering. Never leave any openings opened or blocked with a rag, this could cause particles or dirt to get into the system. Drain all oil into a container and not unto the ground and be sure to follow the proper environmental regulation for any disposal of oil.
4.
Do not let any dirt, or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
WA700-3L
20-113 1
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12 5. Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3Âľ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
20-114 1
WA700-3L
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
12 CHECKS BEFORE TROUBLESHOOTING
Hydraulic, mechanical equipment
Electrical equipment
Lubricating oil, cooling water
Item
Remedy
1. Check fuel level, type of fuel
-
Add fuel
2. Check for impurities in fuel
-
Clean, drain
3. Check hydraulic oil level
-
Add oil
4. Check hydraulic filter (Torque converter, transmission oil)
-
Clean, drain, replace element
5. Check brake oil level
-
Add oil
6. Check engine oil level
-
Add oil
7. Check coolant level
-
Add coolant
8. Check dust indicator for clogging
-
Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring
-
Tighten or replace
10. Check for looseness, corrosion of alternator terminal, wiring
-
Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring
-
Repair or replace
12. Check operation of instruments
-
Repair or replace
13. Check for abnormal noise, smell
-
Repair
14. Check for oil leakage
-
Repair
15. Carry out air bleeding
-
Bleed air
16. Check effect of parking brake, wheel brake
-
Adjust, repair or replace
24 - 26 V
Repair or replace
17. Check battery voltage (engine stopped)
Electrical equipment
Judgement standard
18. Check battery electrolyte level
-
Add or replace
19. Check for discolored, burnt, exposed wiring
-
Repair or replace
20. Check for missing wiring clamps, hanging wire
-
Repair
21. Check for water leaking on wiring (pay particular attention to water leaking on connectors or terminals)
-
Disconnect connector and dry
-
Replace
22. Check for blown, corroded fuses 23. Check alternator voltage (engine running at 1/2 throttle or above) (If the battery charge is low, the voltage may be approximately. 25V immediately after charging 24. Sound of actuation of battery relay (when starting switch is turned ON, OFF
WA700-3L
28.5 - 29.5 V -
Check, repair or replace Replace
20-115 1
TROUBLESHOOTING
JUDGEMENT OF POWER TRAIN
12
JUDGEMENT OF POWER TRAIN To judge if any abnormality in the power train is in the electrical system of the transmission or in the transmission itself, use the following judgement flow chart. If the abnormality is in the electrical system, carry out troubleshooting for E-5, and if the abnormality is in the transmission system, go to troubleshooting T-1 - T-4.
Testing transmission solenoid WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1.
Install a T-adapter checker to connector CNFT1, and check the voltage between the connector pins and the chassis ground.
2.
Turn the start switch ON. ★ Do not start the engine under any circumstances.
3.
Turn the parking brake switch ON âžž OFF (release).
4.
When using the foot brake, press the right brake so that the transmission cut-off is not turned off.
20-116 1
WA700-3L
TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING
12 PRECAUTIONS WHEN TROUBLESHOOTING
SAFETY WARNING! Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied, and that the tires are blocked. WARNING! When working in groups, use agreed upon signals and do not allow unauthorized persons near machine. WARNING! Be careful not to get burned by hot parts or get caught in rotating parts. WARNING! Always disconnect the cable from the negative (-) terminals of the battery before disconnecting any wiring. WARNING! Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure, and connect all measuring tools correctly.
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting". When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and bottom. Check the match marks, or make match marks to prevent mistakes when installing. If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the part to see if there is any problem with it and remove the problem before trying to disassemble the part. When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before coating with gasket sealant.
WA700-3L
20-117 1
TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
12
PREVENTING RECURRENCE OF TROUBLE • • • •
The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment. However, it is not able to establish the root cause of the damage or failure. Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention what action should be taken to prevent a recurrence of the root cause. In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to the following items. Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the Shop Manual.
HYDRAULIC EQUIPMENT OIL CHECKS The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and then take appropriate action.
1.
Oil checks • Check for water contamination. Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate. • Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a contamination checker. • Viscosity check Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory.
2.
Check of contamination point If, as a result of the above checks, it is discovered that the oil is contaminated by water or other foreign matter, it is necessary to find out where the contamination is occurring and also to take steps to prevent it. Water: Oil storage tank, breather, etc. Sand: Oil replenishing or replacing method, etc. Rubber: Cylinder packing, etc. Metal: Wear or damage to hydraulic equipment such as pump and motor, as well as transmission and torque converter, etc.
3.
Oil cleaning and replacement If a large amount of metal particles or other foreign matter is discovered in the oil, either wash the oil using an oil refresher or replace it. ★ If the oil is contaminated by water, it is not possible to remove the water by means of an oil refresher. ★ When washing the oil, also wash or replace the strainer and replace the filter.
CLEANING FRAGMENTS OF DAMAGED PARTS If a part becomes damaged, fragments may pass into the oil line. It is thus necessary to wash the oil. In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the engine or hydraulic equipment.
20-118 1
WA700-3L
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
12 METHOD OF USING TROUBLESHOOTING CHARTS
CATEGORY OF TROUBLESHOOTING CODE NUMBER Troubleshooting code No.
Component
E - 00
Troubleshooting of Electrical System
G - 00
Troubleshooting of Engine (Electronic Governor) Controller and APS Controller System
H - 00
Troubleshooting of Hydraulic & Mechanical Systems
J - 00
Troubleshooting of Joystick Steering Controller System
K - 00
Troubleshooting of Maintenance Monitor System
M - 00
Troubleshooting of Main Monitor System
S - 00
Troubleshooting of Engine System
T - 00
Troubleshooting of Transmission Control System
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE. 1.
Troubleshooting code number and problem. The title of the troubleshooting chart gives the troubleshooting code, service code and failure mode (problem with the machine). (See Example (1)).
2.
Distinguishing conditions. Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, (a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start the troubleshooting from the first check item in the failure mode. (See Example (2)).
3.
Method of following troubleshooting chart. •
• •
•
Check or measure the item inside , and according to the answer, follow either the YES line or the NO line to go to the next condition box. (Note: The number at the top right corner of the condition box is an index number; it does not indicate the order to follow.) Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. (See Example (3)) Below the condition box, there are the methods for inspection or measurement, and the judgement values. If the judgement values below the condition box are correct or the answer to the question inside the condition box is YES, follow the YES line. If the judgement value is not correct, or the answer to the question in NO, then follow the NO line. Below the condition box is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is the danger that it may cause mistaken judgement or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from the first item 1.
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20-119 1
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
4.
General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items are given at the top of the page and marked with a !.(See Example (4)). The precautions marked ! are not given in the condition box, but must always be followed when carrying out the check inside the condition box.
5.
Troubleshooting tools When carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.
6.
Installation position, pin number. A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem).
< Example > (1) M-15 Abnormality in buzzer (2) (a) Buzzer does not sound when starting switch is turned ON (during self-check) (3)
(4) ! Before carrying out troubleshooting, check that all the related connectors are properly inserted. ! Always connect any disconnected connectors before going on to the next step.
20-120 1
WA700-3L
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
12 METHOD OF USING MATRIX TROUBLESHOOTING TABLES The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate the problems accurately and swiftly.
Step 2. Checks before troubleshooting Before starting the main troubleshooting and measuring the hydraulic pressure, first check the Checks before Starting items, and check for oil leaks and loose bolts. These checks may avoid time wasted on unnecessary troubleshooting. The items given under Checks before Starting are items which must be considered particularly for that symptom before starting troubleshooting. Step 3. Using cross-reference table 1.
2.
Operate the machine to carry out the checks in the troubleshooting item column. Mark the items where the results match the symptom. ★ It is not necessary to follow the troubleshooting checks in order; follow an order which is easiest to carry out troubleshooting. Find the appropriate cause from the cause column. If the symptom appears, the O marks on that line indicate the possible causes. (For item No. 2 in the table on the right, the possible causes are c or e.) If there is only one O: Carry out the other troubleshooting items (where the same cause is marked with check if the symptom appears, then repair. If there are two O: Go on to 4 to narrow down the possible causes.
WA700-3L
3.
Steering does not work
Symptom [Example]
Ask the operator about the following points. • Did the steering suddenly stop working? ➛ Breakage in steering equipment • Did the steering gradually become heavy? ➛ Internal wear of steering equipment, defective seal. Checks before starting [Example] • Is the oil level in the hydraulic tank correct? • Is the type of oil correct? • Are there any oil leaks from the steering control valve? • Has the safety bar been removed from the frame? [Example 1] Remedy
No. Problem
1 Steering does work to the left or right. as item 1, but abnormality in actuation of 2 Same work equipment. 3 Steering can only be operated to one side. 4 Steering wheel is heavy and cannot be turned. [Example 2]
Causes
Step 1. Questioning the operator The questions to ask the operator are given below the failure symptom. If the answers to the questions match the information given, follow the arrow to reach the probable cause of the failure. Consider the contents of the questions and consult the table while proceeding to Steps 2 and 3 to grasp the true cause.
Problems 1 2 3 4 5
Remedy
a b c d e X C
X
A X
O O O O ● ● O O O O O O
20-121 1
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
12 Operate the machine and check the troubleshooting items other than those in 1. Operate the machine and check the items in the same way as in 1 and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 6.
Causes
4.
Remedy
Narrow down the possible causes. There is one common cause among the causes located in 2 and 4. (One cause marked O, appears on the line for both items.) This cause is common to both the symptoms in troubleshooting 1 and 3. ★ The causes which are not common to both troubleshooting items (items which are not marked O for both symptoms) are unlikely causes, so ignore them. (In the example given on the right, the causes for Troubleshooting Item 2 are c or e, and the causes for Troubleshooting Item 5 are b or e, so cause e is common to both.)
7.
Repeat the operations in 4, 5 and 6 until one cause (one common cause) remains. ★ If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible.
8.
Remedy If the causes are narrowed down to one common cause, take the action given in the remedy column. The symbols given in the remedy column indicate the following: X: Replace : Repair A: Adjust C: Clean
20-122 1
1 2 3 4 5
X C X A X O O O O O ● O O O O ● ●
Applicable troubleshooting item located in Step 3). Applicable troubleshooting item located in Step 1).
Ignore these causes
Causes
6.
Problems
Find the appropriate cause from the cause column. In the same way as in Step 2, if the symptom appears, the O marks on that line indicate the possible causes. (For item No.5 in the table on the right, the possible causes are b or e.)
Remedy Problems 1 2 3 4 5
Remedy Problems 1 2 3 4 5
Common causes
a b c d e X C X A X O O O O ● ● O O O O ● ●
Causes
5.
a b c d e
a b c d e
Action to take
X C X A X O O O O O ● O O O O O ●
WA700-3L
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED CHARTS
12 METHOD OF USING ENGINE RELATED CHARTS Using troubleshooting charts for engine-related failure This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in (B) are items that can be obtained from the user, depending on the user’ level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right correspond to this. The service man narrows down the causes from information (A) that he has obtained from the user and the results of (C) that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in order of probability, starting with the causes that have been marked with having the highest probability from information gained from [Questions] and [Check items] Causes
Questions
(1) (2) (3)
(a) (b) (c)
Check items
(d) (e)
Troubleshooting
i
WA700-3L
O
ii iii
O
● ● ●
20-123 1
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED CHARTS
12 The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with O, and these, causes that have high probability are marked with a . Check each of the [Questions] and [Check items] in turn and mark the O or the in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to ake final confirmation of the cause. ❇1. For [Confirm recent repair history] in the [Questions Section, ask the user, and mark the Cause column with to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. ❇2. Use the in the Cause column as reference for [Degree of use (operated for long period)] in the [Questions] section as reference.As a rule do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
❇1
Confirm recent repair history
❇2
Degree of use
Defective injection pump (excessive injection)
Improper injection timing
Clogged seized injection nozzle
Worn piston ring, cylinder
Clogged air cleaner element
Seized turbocharger, interference
Causes
Operated for long period
(A)
(B) (C)
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WA700-3L
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED CHARTS
12
MEMORANDUM
WA700-3L
20-125 1
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED CHARTS
12• Example of troubleshooting when exhaust gas is black Let assume that [Clogged air cleaner] is taken to be the cause of the black gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pin point the most probable cause. S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel
O
O O O
O
O
O
O O O
O
Defective injection pump (rack, plunger seized)
Defective contact of valve, valve seat
Air leaks between turbo charger and head
Crushed clogged muffler
improper valve clearance
Defective injection pump (excessive injection)
Improper injection timing
O
O O
O
● ● ●
● ● ● ● ● ● Replace
Replace
Repair
Replace
Adjust
Adjust
Adjust
Replace
Replace
Replace
● Clean
Check items
20-126 1
O O
O O
Troubleshooting
Remedy
Clogged seized injection nozzle
Worn piston ring, cylinder
O O
Questions
: Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause Confirm recent repair history Degree of use Operated for long period Suddenly became black Color of exhaust gas Gradually became black Blue under light load Engine oil must be added more frequently Suddenly Power was lost Gradually Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Air leaks between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected, it is found to be clogged When compression pressure is measured, it is found to be low Speed of some cylinder does not change when operating on reduced cylinders When check is made using delivery method, timing found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked, it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal When control rack is pushed, it is found to be heavy or does not return
Clogged air cleaner element
Legend O: Possible causes (judging from questions and check items)
Seized turbocharger, interference
Causes
WA700-3L
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED CHARTS
12
Five causes
Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.
Three symptoms
Step 2 Add up the total of O and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element:----------------- O (2) Air leaks between turbocharger and head:--O O (3) Clogged, seized injection nozzle:------------O (4) Defective contact of valve, valve seat:------O (5) Worn piston ring, cylinder:-------------------O Step 3 The calculation in Step 2 show that the closet relationship is with [clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked â&#x2014;? The Remedy is given as [clean], so carry out cleaning, and the exhaust gas color should return to normal.
WA700-3L
20-127 1
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED CHARTS
12
MEMORANDUM
20-128 1
WA700-3L
TROUBLESHOOTING ELECTRICAL CONNECTORS CONNECTOR TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203 CONNECTOR PIN ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207 ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ACTION . . . . . . . . . . . . . . . . . . . . . . . . . 20-221 TRANSMISSION CONTROLLER LED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
WA700-3L
20-201 1
TROUBLESHOOTING 12
MEMORANDUM
20-202 1
WA700-3L
TROUBLESHOOTING
CONNECTOR TYPES
12 CONNECTOR TYPES
Type
No. of pins
CNA4
X
2
CNA5
SWP
2
CNA6
M
6
Air mix servo motor
CNC4
AMP040
12 J/S T/M Controller
CNA7
M
6
Blower motor, resistor
CNC5
AMP040
17 J/S T/M Controller
NA8A
S
Air conditioner relay intermediate 10 connector
CNE01
-
1
Slow blow fuse
CNA8B
S
8
Air conditioner relay intermediate connector
CNE02
-
1
GND
CNA14
X
2
Air conditioner Me switch
CNE03
X
2
Connector for starting motor
CNA15
Yazaki
2
Air conditioner Hi/Lo switch
CNE04
X
2
Connector for starting motor
CNB02
KESO
2
F window washer
CNE05
-
1
Alternator
CNB04
KESO
2
R window washer
CNE06
-
1
Alternator
CNB06
1-pin connector
1
Dust indicator
CNE07
-
1
Alternator
CNB07
1-pin connector
1
Dust indicator
CNE08
-
1
APS water temperature sensor
CNB08
1-pin connector
1
Dust indicator
CNE09
X
2
engine water temperature sensor (monitor)
CNB09
1-pin connector
1
Dust indicator
CNE10
X
2
Engine speed sensor B
CNB10
X
2
Air conditioner condenser left
CNE11
X
2
Engine water temperature sensor
CNB11
X
1
Air conditioner condenser left
CNE12
X
3
Governor solenoid
CNB12
X
2
Air conditioner condenser right
CNE13
X
2
Engine speed sensor A
Connector No.
No. of pins
Connector No.
Type
Air servo motor
CNC3A
AMP040
20 J/S T/M Controller
Air conditioner thermistor
CNC3B
AMP040
16 J/S T/M Controller
Description
Description
CNB13
X
2
Air conditioner condenser right
CNE14
X
4
Rack sensor
CNBC01
SWP
6
Intermediate connector
CNE15
X
2
Governor solenoid
CNBR1
SWP
Intermediate connector 12 (condensor, washers & dust indicators)
CNE16
X
3
Pre-stroke solenoid
CNC01
X
2
Torque converter oil filter sensor
CNE17
X
4
Connector for nozzle, glow
CNC03
X
2
Brake pressure switch
CNE18
-
1
Engine oil pressure switch
CNC04
X
2
Brake pressure switch
CNE19
X
1
Engine oil level sensor
CNC07
X
2
Emergency brake switch
CNE20
X
2
Fuel cut-off solenoid
Emergency brake switch
1
Air conditioner magnet clutch
CNC08
X
2
CNE21
X
CNCL1
S
12 Intermediate connector
CNER1
SWP
CNCL2
S
Air conditioner intermediate con10 nector
CNER2
X
CNCL3
S
10 Air conditioner intermediate connector
CNER3
SWP
12 Intermediate connector
CNCL4
M
6
CNER4
SWP
8
CNC1
MIC
13 J/S T/M Controller
CNEC1
MIC
17 Engine controller
CNC2
MIC
13 J/S T/M Controller
CNEC2
MIC
21 Engine controller
WA700-3L
Intermediate connector
12 Intermediate connector 4
Intermediate connector
Intermediate connector
20-203 1
TROUBLESHOOTING
CONNECTOR TYPES
12 Connector No.
Type
CNEC3A
AMP040
No. of pins
Connector No.
Type
No. of pins
20 Engine controller
CNG09
M
6
SWP
12 Intermediate connector
Description
Description Rear combination lamp left
CNEC3B
AMP040
16 Engine controller
CN GR1
CNEC5A
AMP040
20 Engine controller
CN GRE
SWP
6
When auto-greasing system is installed
CNEC5B
AMP040
16 Engine controller
GND
KES1
1
Ground
CNF01
M
4
Lamp intermediate connector
GND
KES1
1
Ground
CNF02
M
3
Turn signal, side lamp intermediate connector
CNIL1
1
Fwd LED
CNF03
M
3
Turn signal, side lamp intermediate connector
CNIL2
1
Fwd LED
CNF04
M
4
Lamp intermediate connector
CNIL3
1
Neutral LED
CNF05
X
3
Bucket proximity switch
CNIL4
1
Neutral LED
CNF06
X
3
Boom kick-out proximity switch
CNIL5
1
Reverse LED
1
Reverse LED
8
J/S Intermediate
CNF07
-
1
Horn (303 Hz)
CNIL6
CNF08
-
1
Horn (333 Hz)
CNJL1
CNF09
-
1
Horn (334 Hz)
CNJL2
S
8
J/S Intermediate
CNF10
-
1
Horn (303 Hz)
CNJS1
S
8
J/S Lever Switch
X
3
J/S Potentiometer
1
J/S System cut-off switch
CNF11
X
2
Parking brake solenoid
CNJS2
CNF12
X
2
Parking brake display switch
CNJS3
-
GND
CNF13
-
CNFR1
S
CNFR2 CNFS1
S
1
J/S System cut-off switch
10 Intermediate connector
CNJS5
CNJS4 X
3
J/S Neutral position switch
SWP
6
Intermediate connector
CNL01
SWP
6
Parking brake switch
L
2
Fuse box
CNL02
SWP
6
Lighting switch
CNFS2
S
12 Fuse box
CNL03
SWP
6
Turn signal, hazard switch
CNFS3
M
6
Fuse box
CNL04
SWP
14 Directional, speed switch
CNFS4
L
2
Fuse box
CNL05
AMP040
20 Main monitor
CNFS5
M
6
Fuse box
CNL06
AMP040
16 Main monitor
CNFS6
M
4
Fuse box
CNL07
AMP040
12 Main monitor
CNFS7
M
2
Fuse box
CNL08
AMP040
8
Main monitor
CNFS8
1
Fuse box
CNL09
M
6
Starting switch
CNFS9
1
Fuse box
CNL10
S
10 Wiper switch
CN FS10
1
Fuse box
CNL12
X
2
Transmission cut-off switch
CN FS11
1
Fuse box
CNL13
X
3
Accelerator pedal
X
3
Accelerator pedal
CNG01
M
6
Rear combination lamp right
CNL14
CNG02
M
2
Rear working lamp right
CNL15
M
2
Kickdown switch
CNG03
M
2
Radiator water level sensor
CNL16
KES1
2
Boom kick out solenoid
2
Bucket positioner solenoid
CNG04
-
1
Backup buzzer
CNL17
KES1
CNG05
-
1
Backup buzzer
CNL18
AMP040
16 Maintenance monitor
CNG06
X
2
Rear working lamp right
CNL19
AMP040
8
Maintenance monitor
CNG07
M
2
Rear working lamp left
CNL21
KES!
2
Maintenance monitor
CNG08
M
2
Rear working lamp left
20-204 1
WA700-3L
TROUBLESHOOTING
CONNECTOR TYPES
12 Connector No.
Type
No. of pins
Connector No.
Type
No. of pins
CNL22
KES1
2
Maintenance monitor
CN SEL3
M
2
Auto shift selector
CNL40
Yazaki
7
Power window right switch
CN SEL4
M
2
J/S Option select
CNL41
Yazaki
7
Power window left switch
CNT01
MS
10 Transmission valve solenoid
CNL42
1-pin connector
1
Alarm buzzer
CNT05
X
2
Speed sensor
CNL43
1-pin connector
1
Alarm buzzer
CNT06
X
2
Torque converter oil temperature sensor
CNL44
KESO
6
Wiper relay
CNTAC
-
1
Not used
CNL46
-
-
Flasher relay
CNTL1
SWP
CNL63
1-pin connector
1
Horn switch
CNL69
SWP
6
APS assisted
CNL71
MWP
6
APS control unit
CNL72
X
4
APS control unit
CNL74
KES1
2
Fuel cut switch
CNL74
KES1
4
Heater switch
CNL78
-
-
Emergency engine stop switch
CNL79
-
-
Emergency engine stop switch
Description
CNL81
X
2
Stop lamp switch
CNL82
KES1
2
J/S ON/OFF switch
CNL83
X
2
J/S LH solenoid
CNL84
X
2
J/S RH solenoid
CNLR1
SWP
12 Intermediate connector
CNLR2
SWP
14 Intermediate connector
CNLR3
X
CNLR4
SWP
4
CNLR5
X
4
Intermediate connector
CNLR6
L
2
Intermediate connector Intermediate connector
Intermediate connector 12 (transmission)
Intermediate connector
14 Intermediate connector
CNLR7
SWP
8
CNLR8
SWP
12 Intermediate connector
CNOP1
KES1
1
Option 24V, 10 amp
CNR01
-
-
Emergency steering switch
CNR05
X
2
Fuel level sensor
CNR06
-
-
30A fuse connection for rear harness
CNR07
-
-
30A fuse connection for rear harness
CNR08
-
-
80A fuse connection for rear harness
CNR09
-
-
80A fuse connection for rear harness
CNR10
-
1
GND
CN RA1
X
2
Intermediate connector
WA700-3L
Description
20-205 1
TROUBLESHOOTING
CONNECTOR PIN ARRANGEMENT
12
CONNECTOR PIN ARRANGEMENT See FOLDOUT 20-206-1 CONNECTOR PIN DIAGRAM (1/6) See FOLDOUT 20-206-2 CONNECTOR PIN DIAGRAM (2/6) See FOLDOUT 20-206-3 CONNECTOR PIN DIAGRAM (3/6) See FOLDOUT 20-206-4 CONNECTOR PIN DIAGRAM (4/6) See FOLDOUT 20-206-5 CONNECTOR PIN DIAGRAM (5/6) See FOLDOUT 20-206-6 CONNECTOR PIN DIAGRAM (6/6) (Joystick Steering Configuration) Remark FOLDOUTS are located in Section 90 of this Manual.
20-206 1
WA700-3L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS â&#x2DC;&#x2026; The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
WA700-3L
20-207 1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
20-208 1
WA700-3L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
WA700-3L
20-209 1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
20-210 1
WA700-3L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
WA700-3L
20-211 1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
20-212 1
WA700-3L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
WA700-3L
20-213 1
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
20-214 1
WA700-3L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
WA700-3L
20-215 1
TROUBLESHOOTING
ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM
12
ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM
20-216 1
WA700-3L
TROUBLESHOOTING
ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM
12 1. Functions of equipment at input end A. Working mode switch This detects the condition of operation of the working mode switch and inputs it to the controller as a digital (ON-OFF) signal. B. Accelerator sensor This detects the low idling position and angle (amount) of operation of the accelerator pedal and inputs the low idling position to the controller as a digital (ON-OFF) signal and the angle (amount) of operation as an analog (voltage) signal. C. Engine speed sensor A This detects the speed of the engine fly-wheel as engine speed A and inputs it to the controller as a pulse (rotation) signal. D. Engine speed sensor B This detects the speed of the engine fly-wheel as engine speed B and inputs it to the controller as a pulse (rotation) signal. E. Engine water temperature sensor This detects the temperature of the engine cooling water and inputs it to the controller as an analog (voltage) signal. F.
Rack position sensor This detects the rack position inside the fuel injection pump and inputs it to the controller as an analog (voltage) signal.
G. Starting switch (terminal C) This detects the condition of operation of the starting switch to the START position and inputs it to the controller through the neutral relay as a digital (ON-OFF) signal. 2.
Control functions of controller A. All-speed governor control: An analog (electric current) signal is out-put to the governor actuator to control the engine speed over the whole range according to the signal from the accelerator sensor. B. Sudden acceleration control (soft boost compensator): An analog (voltage) signal is output to the governor actuator to prevent the emission of black smoke by limiting the maximum rack position (= fuel injection amount) when accelerating suddenly. C. Automatic warming-up operation: An analog (voltage) signal is output to the governor actuator to automatically raise the engine speed and reduce the warming-up time when the engine water temperature is low according to the signal from the engine water temperature sensor. The automatic warming-up speed is set at two levels according to the engine water temperature. D. Fuel amount adjustment (start mode) function when starting: An analog (voltage) signal is output to the governor actuator to adjust the fuel injection amount and improve the ease of starting according to the engine water temperature when starting. When the engine speed goes above the set speed inside the controller and the starting is completed, the start mode is canceled and the system returns to normal control. E. Overrun prevention function: If the engine speed rises abnormally and exceeds the set speed of the accelerator sensor, it stops the output to the governor actuator to cut the fuel injection and prevent overrun. When the engine speed goes down below the set speed of the accelerator sensor, the system returns to normal control.
WA700-3L
20-217 1
TROUBLESHOOTING F.
ELECTRICAL ENGINE THROTTLE CONTROLLER SYSTEM
Self-diagnostic function: The controller always observes the condition to check that there is no abnormality in the accelerator sensor, engine speed sensor A, engine speed sensor B, engine water temperature sensor, and rack position sensor at the input end and the governor and pre-stroke control systems and the controller itself at the out-put end.
G. Network communication with main monitor: If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality as a digital (ON-OFF) signal to the main monitor. 3.
Functions of equipment at output end A. Governor actuator This receives the signal from the controller and controls the fuel injection pump control rack position to control the fuel injection amount smoothly between no injection and the maximum injection. B. Cut-off solenoid relay This receives the signal from the controller and drives the solenoid to open or close the hydraulic circuit before and after the valve.
4.
Main monitor display For details, see MAIN MONITOR SYSTEM.
20-218 1
WA700-3L
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
12 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 1.
Outline The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine controller uses a special parallel signal.)
2.
Display of failure action code This code informs the operator directly of the abnormality, and takes action, such as stopping the machine immediately. There are three types of action code: EOO, EOI + CALL (EOI and CALL are displayed alternately), and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer display.
3.
Failure code and time elapsed since failure The failures detected by each controller are changed to a code and displayed. It is possible to tell from this code which system in which controller has failed, so carry out troubleshooting for the applicable controller.
4.
Saving failure code The transmission controller writes the failure codes to memory. A. A total of 9 failure codes can be saved in memory. B. The data that is saved to memory is as follows: i.
Failure code
ii.
Time elapsed since failure (up to 1000 hours)
C. The failures are saved in the order that they occur. If a failure code already exists in the memory, the repeat failure code is not saved. D. If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved. â&#x2DC;&#x2026; It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the main monitor set switch.
WA700-3L
20-219 1
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
12 5. Switch operation procedure and actuation Switch operation
Actuation
Trouble data memory mode display 1.
Stop engine.
2.
Turn starting switch ON.
3.
Push operation mode switch (1) and head lamp switch (2) simultaneously and keep pressed for at least 5 seconds.
•
•
The failure code is displayed on the speedometer display and the time elapsed since failure is displayed on the action code display. If there is no failure, the speedometer display shows [CC] and the action code display shows [0000].
Going to nest failure code 4.
Press head lamp switch (2).
•
•
The failure code and time elapsed since failure are displayed in turn (when this is done, the failure code for the latest failure is displayed first). If the failure still exists, the display flashes; if the failure has been restored, the display lights up.
Clearing failure code 5.
Keep rear lamp switch (3) pressed for at least 2 seconds.
• •
The failure code and elapsed time on the display are cleared. If the failure still exists, the failure code is not cleared.
Quitting trouble data memory display mode 6.
Push operation mode switch (1) and head lamp switch (2) simultaneously and keep pressed for at least 5 seconds. Or start the engine.
20-220 1
•
The display returns to the normal display.
WA700-3L
TROUBLESHOOTING
CHART OF ACTION CODES AND FAILURE CODES, AND RE-AC-
12 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ACTION After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to reenact the problem as follows. Re-action marks. ★ : Turn stating switch ON (with engine stopped) ❏ : Start engine ■ : Carry out operation to actuate actuator.
1.
Transmission and joystick steering controller A. Transmission control system Main monitor action code
Failure code
None
10
Failed system Short circuit
Disconnection
Short circuit
Disconnection
Memory
Alarm buzzer
Back lamp relay
❍
❍
■
★
❍
X
12
F solenoid
❍
❍
■
★
❍
❍
13
R solenoid
❍
❍
■
★
❍
❍
14
1st solenoid
❍
❍
■
★
❍
❍
15
2nd solenoid
❍
❍
■
★
❍
❍
16
3rd solenoid
❍
❍
■
★
❍
❍
17
4th solenoid
❍
❍
■
★
❍
❍
E00
19
Joystick directional switch
❍
❍
■
■
❍
X
CALL
20
Directional switch signal
❍
❍
★
★
❍
❍
None
21
Range switch signal
❍
❍
★
★
❍
X
22
Travel speed sensor
X
❍
★
★
❍
❍
23
Engine speed sensor
❍
❍
❈
★
❍
X
Item
CALL
E00
❈
Re-action
E59 and E60 cannot be distinguished, so they are issued at the same time. Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
WA700-3L
20-221 1
TROUBLESHOOTING
CHART OF ACTION CODES AND FAILURE CODES, AND RE-AC-
12 B. Joystick control system After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to reenact the problem as follows. Re-action marks. ★ : Turn stating switch ON (with engine stopped) ❏ : Start engine ■ : Carry out operation to actuate actuator. Main monitor action code
Failure code
None
56
E00
20-222 1
Failed system
Re-action
Short circuit
Disconnection
Short circuit
Disconnection
Memory
Alarm buzzer
Joystick caution relay output
❍
❍
★
■
❍
X
57
Steering right solenoid (detent when output)
❍
❍
■
■
❍
❍
58
Steering left solenoid (detect when output)
❍
❍
■
■
❍
❍
59
Steering right solenoid (short circuit at HOT side)
❍
X
★
★
❍
❍
60
Steering left solenoid (short circuit at HOT side)
❍
X
★
★
❍
❍
61
Steering solenoid cut relay out put
❍
❍
★
■
❍
❍
62
Joystick neutral abnormal
❍
❍
★
★
❍
❍
63
Joystick potentiometer abnormal (other than 0.5 4.5 V)
❍
❍
★
★
❍
X
Item
switch
WA700-3L
TROUBLESHOOTING
CHART OF ACTION CODES AND FAILURE CODES, AND RE-AC-
12 2. Action code table Action code
E00
CALL
Transmission control system
Joystick control system
Problem system
Action of machine
Problem system
Action of machine
Disconnection in travel speed sensor system
Automatic gear shifting not carried out (changes to manual gear shifting) (OP)
---
---
Disconnection in engine speed sensor system
Gear shifting not carried out in Auto mode (OP)
---
---
---
---
Breakage, short circuit with chassis ground or short circuit of joystick FNR signal line
Set to neutral position (Can be changed to steering wheel mode)
Shift lever system disconnection, short circuit with GND, short circuit
Become neutral and cannot travel (Judges controller input as N)
---
---
F, R solenoid signal system disconnection, short circuit with GND, short circuit
Become neutral and cannot travel (Output off)
---
1st, 2nd, 3rd, 4th solenoid system disconnection, short circuit with GND, short circuit
WA700-3L
Become neutral and cannot travel (Output off)
Action buzzer
Action by operator
Normal operation possible at manual
No
Normal operation possible at manual
Normal operation possible at wheel steering mode
Stop travelling immediately ---
Yes
Turn starting switch OFF Call service after action above.
---
---
20-223 1
TROUBLESHOOTING
TRANSMISSION CONTROLLER LED DISPLAY
12
TRANSMISSION CONTROLLER LED DISPLAY The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and input/output errors. The display shows two characters at the same time, and changes these in turn to give the display. ★ When the engine is started, “Program part No. display mode” appears, followed by “Output speed range display mode”. If there is any abnormality in the controller, it changes to “Troubleshooting mode”. ★ The failure mode is saved to memory by the main monitor.
Table 1 (Output speed range display mode) Display
Content
Display
Content
0.1❍
Neutral, 1st
F.4❍
FORWARD, 4th
0.2❍
Neutral, 2nd
A.1❍
REVERSE, 1st
0.3❍
Neutral, 3rd
A.2❍
REVERSE, 2nd
0.4❍
Neutral, 4th
A.3❍
REVERSE, 3rd
F.1❍
FORWARD, 1st
A.4❍
REVERSE, 4th
F.2❍
FORWARD, 2nd E.0❍
Neutral safety condition or selection signal abnormal
F.3❍
20-224 1
FORWARD, 3rd
WA700-3L
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) E-1 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304 A. STARTING MOTOR DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304 B. STARTING MOTOR TURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310 E-2 ABNORMALITY IN APS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-313 A. WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOT LIGHT UP, BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP. . . . . . . . . . . . . . . . 20-315 B. WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 2O° C, PREHEATING LAMP FLASHES, BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316 C. AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START, BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL . 20-317 D. LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL . . . . . . . . . . . . . . . . . . . . . 20-318 E. LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL . . . . . . . . . . . . . . . . . . . . . 20-318 F. LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL . . . . . . . . . . . . . . . . . . . . . . 20-319 G. LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL . . . . . . . . . . . . . . . . . . . . . 20-319 H. LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL . . . . . . . . . . . . . . . . . . . . . 20-320 I. LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL . . . . . . . . . . . . . . . . . . . . . . 20-320 J. WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP . . . . . . . . . . . . . . . . . . 20-321 E-3 PARKING BRAKE DOES NOT HAVE EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322 A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON . . . . 20-322 B. PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS . . . . . . . . . . . . . . . . . . . . 20-322 E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324 E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON . . . . . . . . . . . . . . . 20-326 E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORKS NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326 E-7 TRANSMISSION DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328 A. ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330 B. NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 20-334 C. NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336 D. SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT . . . . . . . . . 20-338 E. ABNORMALITY IN SHIFT SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344 F. SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . 20-347 E-8 KICK-DOWN SWITCH DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352 E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON . . . . . . . . . . 20-355 E-10 KICK-DOWN ALWAYS WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356 E-11 KICK-DOWN SWICTH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND . . . . . . . . . . . . . 20-358 E-12 BOOM KICK-OUT DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360 E-13 DEFECTIVE BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362 E-14 POWER WINDOW DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364 A. WINDOW DOES NOT GO UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364 B. WINDOW DOES NOT GO DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-365 E-15 ABNORMALITY IN FRONT WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367 E-16 ABNORMALITY IN REAR WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367 E-L 7 ABNORMALITY IN TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367 E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
WA700-3L
20-301 1
TROUBLESHOOTING E-19 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
20-302 1
WA700-3L
TROUBLESHOOTING 12
MEMORANDUM
WA700-3L
20-303 1
TROUBLESHOOTING
E-1
12
E-1 ENGINE DOES NOT START ★ Before disconnecting or connecting connectors, always turn starting switch OFF. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. STARTING MOTOR DOES NOT TURN Yes
a
3 Yes Is voltage between starting motor terminal (B) and chassis normal? 1. 20 - 30 V 2. Turn starting switch OFF
5
Yes
b
Yes Is voltage between battery relay terminal M and 4 chassis normal? Dose battery relay make sound of No actuation?
1. 20 - 30 V 2. Turn starting switch ON
c No
1. Starting switch ON ↔ OFF
Yes d
2
6
Yes Is there continuity between starting motor terminal (E) and chassis?
No
1. Turn starting switch OFF
Is voltage between both connection terminals A02 and A05 of battery relay normal? 1. 20 - 30 V 2. Turn starting switch ON
e No
1 Is voltage between E03, E04 (female)(1) and chassis normal? 1. 20 - 30 V 2. Disconnect E03 and E04 3. directional lever: Neutral 4. Turn starting switch to START
f No
g No
20-304 1
WA700-3L
TROUBLESHOOTING
E-1
12
Cause
Remedy
a Defective starting motor assembly
Replace
b
Defective contact or disconnection in cable between battery relay and starting motor
Repair or replace
c
Defective battery relay or defective contact of wiring harness between battery and battery relay
Repair or replace
Defective battery relay
Replace
d
e
8
Yes
7 Yes Is resistance between A03, A05 - chassis Is voltage between normal? starting switch terminal BR and 1. Max. 1 â&#x201E;Ś chassis normal? 2. Turn starting switch OFF. 1. 20-30 V 3. Disconnect A03 2. Turn starting and A05. switch ON.
No
Defective contact or disconnection in wiring harness or between starting switch terminal BR - LO9 (2) - LR4 (9) - Repair replace R03 (diode) (2). (1) - RAl (1) -A02, A04 (female) Defective contact or disconnection in wiring harness between A03, A05 - RAl (2) -chassis ground
Repair or replace
Defective starting switch
Replace
Defective contact or disconnection in starting motor ground cable
Repair or replace
No f
g Go to A on next page
WA700-3L
20-305 1
TROUBLESHOOTING
E-1
12
Yes
From A
a
9
Yes
Does starting motor rotate when neutral relay is replaced? 1. Replace neutral relay L57 with stop lamp relay L53 2. Directional lever: Neutral 3. Turn starting switch to START
b
11 Yes Is voltage between L57 (female) (5) and chassis normal? 1. 20 - 30 V 2. Disconnect L57 3. Turn starting switch to START 10
Yes 12 Is voltage between starting switch No terminal B and chassis normal? 1. 20 - 30 V 2. Turn starting switch to OFF
13
Yes
c
Is voltage between starting switch terminal C and chassis normal? 1. 20 - 30 V 2. Turn starting switch to START
d No e
No 16
Is voltage between L57 (female)(1) No and (2) normal?
Yes
f
Yes Is voltage between L04(3) and chassis normal?
1. Disconnect L57 2. Directional lever: Neutral 3. Turn starting switch to START
15 Yes Is voltage between L04 (female)(1) and chassis normal? 1. 20 - 30 V 2. Disconnect L04 3. Turn starting switch ON
1. 20 - 30 V 2. Connect Tadapter to LO4. 3. Directional lever: Neutral 4. Turn starting switch ON
17 14
g No Yes
18 Yes h
Is voltage between battery relay terminal M and chassis normal? 1. 20 - 30 V 2. Turn starting switch to ON
1. Turn starting switch ON â&#x2020;&#x201D; OFF
1. Max. 1â&#x201E;Ś 2. Turn starting switch OFF 3.Disconnect L57
No
Yes j
Does battery relay make sound of No actuation?
Is resistance between L57 No (female)(2) and chassis normal?
i
19 Is voltage between both connection terminals A02 and A03 and connection No terminals A04 and A05 of battery relay normal? 1. 20 - 30 V 2. Turn starting switch to ON
k No
l No
20-306 1
WA700-3L
TROUBLESHOOTING
E-1
Cause
Remedy
a Defective neutral relay
Replace
b
Defective contact or disconnection in wiring harness between L57 (female)(3) - LR4 (8) - ER1(10) - E24(2) (1) - E04 (female)(1) or E22(2) - (1) - E03 (female)(1)
Repair or replace
c
Defective contact or disconnection in wiring harness between starting switch terminal C - L09(3) - L57 (female)(5)
Repair or replace
Defective starting switch
Replace
Defective contact or disconnection in wiring harness between starting switch terminal B - L09(1) - FS3(4) fuse - FS3(6) - LR5(1) - slow blow fuse 30 A - battery relay
Repair or replace
Defective contact or disconnection in wiring harness between L04 (female)(3) and L57 (female)(1)
Repair or replace
Defective directional lever switch
Replace
h
Defective contact or disconnection in wiring harness between battery relay - slow blow fuse 80 A - LR6(1) FS1(2) fuse - FS2(8) - L04 (female)(1)
Repair or replace
i
Defective battery relay or defective contact or disconnec- Repair or tion in wiring harness between battery and battery relay replace
d
e
f
g
j Defective battery relay 21
k
20 Yes Is resistance between A03, A05 - chassis Is voltage between normal? starting switch BR and chassis 1. Max. 1â&#x201E;Ś normal? 2. Turn starting switch OFF 1. 20 - 30 V 3. Disconnect A03 2. Turn starting and A05 switch ON No
Yes
No
Replace
Defective contact or disconnection in wiring harness or between Starting switch terminal BR - L09(2) - LR4(9) - Repair replace R03 (diode)(2), (1) - RA1(1) - A02, A04 (female) Defective contact or disconnection in wiring harness between A03, A05 - RA1(2) - chassis ground
Repair or replace
Defective starting switch
Replace
Defective contact or disconnection in wiring harness between L57 (female)(2) - LR5(2) - chassis ground
Repair or replace
l
WA700-3L
20-307 1
TROUBLESHOOTING
E-1
12 E-1 a. Related electrical circuit diagram
20-308 1
WA700-3L
TROUBLESHOOTING
E-1
MEMORANDUM
WA700-3L
20-309 1
TROUBLESHOOTING 12 B.
E-1
STARTING MOTOR TURNS Yes
a
3 Yes Is voltage between EC5B (female)(4) and chassis normal?
2
1. 20-30V 2. Disconnect EC5B 3. Turn starting switch ON
1. 20-30V 2. Disconnect EC1 3.Turn starting switch ON
Yes
1. Replace with other relay 2. Turn starting switch ON
c
d No
e No Yes
f
6 Does condition become normal No when governor cut relay L30 is replaced? 1. Replace with other relay 2. Turn starting switch ON
7
Yes
Is voltage between L30 (female)(1), (3) No - chassis normal? 1. 20 - 30V 2. Disconnect L30 3. Turn starting switch ON
20-310 1
5
1. Turn starting Does condition switch ON become normal 2. Turn fuel cut No when No-injection switch ON â&#x2020;&#x201D; OFF cranking relay L82 is replaced?
Is voltage between EC1 (female) (4) and chassis normal? 1. 20-30V 2. Disconnect EC1 3. Turn starting switch ON
b
4 When fuel cut switch is operated, No is No-injection cranking relay L82 actuated?
Yes Is voltage between EC1 (female) (9), (17) chassis normal?
1
Yes
g
h No
WA700-3L
TROUBLESHOOTING
E-1
12
Cause
Remedy
a
b
Defective electric engine throttle controller
Replace
Defective contact or disconnection in wiring harness between EC5B (female)(4) and L82 (female)(6)
Repair or replace
Defective No-injection cranking relay L82
Replace
c
d
Short circuit with wiring harness between L82 or (female)(1) - L73(2) - fuel cut switch or defective fuel cut Repair replace switch
e Defective contact or disconnection in wiring harness between EC1 (female)(9), (17) - FS7(2) - fuse - FS7(1) L09 (female)(5)
Repair or replace
Defective governor cut relay L30
Replace
Short circuit with wiring harness between EC2 (female)(1) and L30 (female)(6)
Repair or replace
Defective contact or disconnection in wiring harness between L30 (female)(1), (3) - FS7(2) - fuse - FS7(1) L09 (female)5)
Repair or replace
f
g
h
WA700-3L
20-311 1
TROUBLESHOOTING
E-1
12 E-1 b. Related electrical circuit diagram
20-312 1
WA700-3L
TROUBLESHOOTING
E-2
12 E-2 ABNORMALITY IN APS SYSTEM Preheating lamp and pilot LED on APS controller 1.
Preheating lamp ★ Preheating lamp shows normal or abnormal APS conditions as below, after turning starting switch ON, according to the time clasped.
2.
Pilot LED on APS controller ★ APS controller caries out self-checking for bad contact and short circuit to chassis ground in glow plug 1 circuit, glow plug 2 circuit and nozzle circuit, and then shows conditions as below. ★ All LED go out when there is short circuit or bad contact in power supply circuit. ★ APS controller does not carry out self-checking for APS water temperature switch circuit. LED No.
Color of LED
1
Red
2
Green
3
Red
4
Green
5
Red
6
Green
WA700-3L
Abnormal condition
When normal
When abnormal
❍ Light off
● Light on
Bad contact in glow plug 1 circuit
● Light on
❍ Light off
Short circuit to GND in glow plug 2 circuit
❍ Light off
● Light on
Bad contact in glow plug 2 circuit
● Light on
❍ Light off
Short circuit to GND in nozzle circuit
❍ Light off
● Light on
Bad contact in glow nozzle circuit
● Light on
❍ Light off
Short circuit to GND in glow plug 1 circuit
20-313 1
TROUBLESHOOTING
E-2
12 E-2 Electrical circuit diagram for APS system
20-314 1
WA700-3L
TROUBLESHOOTING
E-2
12 Abnormality in APS system ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. WHEN PREHEATING SWITCH IS TURNED AUTO, PREHEATING LAMP DOES NOT LIGHT UP, BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP. ★ ★ ★ ★
Check for power supply circuit. Check whether engine cranking is possible or not. In case cranking is impossible, check for E-l then check for E-4. Check whether fuse 9 is blown or not. If fuse 9 is blown, check for short circuit to GND in fuse 9 related circuit. When carrying out troubleshooting, turn preheating switch AUTO. Remedy
Cause 2
Yes
Yes Is resistance between L71 (female)(1) and chassis ground normal? 1 Is voltage between L72 (female)(1) and chassis ground normal?
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L71
1. 20 - 30V 2. Turn starting switch ON 3. Disconnect L72
3 Yes Is resistance between L74 (male)(3) and (4) normal? Is voltage between L74 (female)(3) and chassis ground 1. Max. 1 Ω No normal? 2. Turn starting switch OFF 1. 20 - 30V 3. Disconnect L74 2. Turn starting switch ON No 3. Disconnect L74
No
No 4 Yes
Defective APS controller
Replace
Defective contact or disconnection in wiring harness between L71 (female)(1), CL1(12) and chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between L74 (female)(4) and L72 (female)(1)
Repair or replace
Defective pre heater switch
Replace
Defective contact or disconnection in wiring harness between L74 (female)(3), FS6(3) and fuse II(9)
Repair or replace
E-2 a. Related APS controller electrical circuit diagram
WA700-3L
20-315 1
TROUBLESHOOTING
E-2
12 B.
WHEN PREHEATING SWITCH IS TURNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 2O°° C, PREHEATING LAMP FLASHES, BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL ★ Check APS water temperature switch circuit. ★ Check engine water temperature. 4
Yes
Is resistance between L74 (female)(1) and (2) normal?
2
1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L74, L71 and E08
Yes Is resistance between L74 (female)(2) and chassis ground 1 normal? Is resistance between E08 (male) and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect E08 3. When water temperature is below 20° C: Max. 1Ω 4. When water temperature is above 20° C: Min. 1Ω No
3
1. Turn starting switch OFF 2. Disconnect L71 and L74 3. Resistance must be the same as Section 1 No
Yes Is resistance between L74 (male)(1) and (2) normal? 1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L74
No
Cause
Remedy
Yes
No
Defective APS controller
Replace
Defective pre heater switch
Replace
Short circuit between L74 (female)(1) and L71 Repair or (female)(2) or between replace L74 (female)(2) and chassis ground
Defective contact or disconnection or short circuit with chassis ground Repair or in wiring harness between replace L71 (female)(2), LR4(2), ER1(8) and E08(female) Defective APS water tem- Replace perature sensor
E-2 b. Related electrical circuit diagram
20-316 1
WA700-3L
TROUBLESHOOTING
E-2
12 AFTER PREHEATING, FUEL IS NOT INJECTED FROM APS NOZZLE C. WHEN STARTING SWITCH IS TURNED START, BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL â&#x2DC;&#x2026; Check starting switch circuit. Cause 1
Remedy
Yes
Is voltage between L71 (female)(3) and chassis ground normal? 1. 20 - 30V No 2. Starting switch: START 3. Disconnect L71
Defective APS controller
Replace
Defective contact or disconnection in writing harness between L71 (female)(3) - L69(4) - L69(2) - L09(3) terminal C starting switch
Repair or replace
Defective starting switch
Replace
2 Is voltage between terminal C of starting switch and chassis ground normal? 1. 20 - 30V 2. Starting switch: START
Yes
No
E2 c. Related electrical circuit diagram
WA700-3L
20-317 1
TROUBLESHOOTING 12 D.
E-2
LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL Cause 2
Defective APS controller
Yes Is resistance between L72 (female)(2) and chassis ground normal? 1 Is resistance between terminal of glow plug 1 and chassis ground normal? 1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect plug terminal
1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect L72
Remedy
Yes
No
Replace
Short circuit with chassis ground in harness between L72 Repair or (female)(2) and terminal glow plug 1 replace
Defective glow plug 1
No
Replace
E. LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL Cause 2
Yes Defective APS controller
Yes Is resistance between L72 (female)(2) and chassis ground normal? 1 Is resistance between terminal of glow plug 1 and chassis ground normal? 1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect plug terminal
1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect L72 No
Remedy
No
Replace
Short circuit with chassis ground in harness between L72 Repair or (female)(2) and terminal glow plug 1 replace
Defective glow plug 1
Replace
E-2 d, e. Related electrical circuit diagram
20-318 1
WA700-3L
TROUBLESHOOTING
E-2
12 LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL F.
Cause 2
Defective APS controller
Yes Is resistance between L72 (female)(3) and chassis ground normal? 1 Is resistance between terminal of glow plug 2 and chassis ground normal? 1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect plug 2
1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect L72
Remedy
Yes Replace
Repair or replace No
Short circuit with chassis ground in harness between L72 (female)(2) and terminal glow plug 2
Replace Defective glow plug 2
No
G. LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL Cause 2
Defective APS controller
Yes Is resistance between L72 (female)(3) and chassis ground normal? 1 Is resistance between terminal of glow plug 2 and chassis ground normal? 1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect plug terminal
1. 0.8 - 1.3 Ω 2. Turn starting switch OFF 3. Disconnect L72
No
Remedy
Yes
No
Replace
Short circuit with chassis ground in harness between L72 Repair or (female)(2) and terminal glow plug 2 replace
Defective glow plug 2
Replace
E-2 f, g. Related electrical circuit diagram
WA700-3L
20-319 1
TROUBLESHOOTING 12 H.
E-2
LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL Cause 2
Defective APS controller
Yes Is resistance between L72 (female)(4) and chassis ground normal? 1 Is resistance between each nozzle terminal chassis ground normal? 1. 3 - 5 Ω 2. Turn starting switch OFF 3. Disconnect nozzle terminal
1. 1.5 - 2.5 Ω 2. Turn starting switch OFF 3. Disconnect L72
Remedy
Yes
No
Replace
Short circuit with chassis ground in harness between L72 Repair or (female)(4) and each nozzle terminal replace
Nozzle having improper resistance
No
Replace
I. LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL Cause 2
Defective APS controller
Yes Is resistance between L72 (female)(4) and chassis ground normal? 1 Is resistance between each nozzle terminal chassis ground normal? 1. 3 - 5 Ω 2. Turn starting switch OFF 3. Disconnect nozzle terminal
1. 1.5 - 2.5 Ω 2. Turn starting switch OFF 3. Disconnect L72
No
Remedy
Yes
No
Replace
Short circuit with chassis ground in harness between L72 Repair or (female)(4) and each nozzle terminal replace
Nozzle having improper resistance
Replace
E-2 h, i. Related electrical circuit diagram
20-320 1
WA700-3L
TROUBLESHOOTING
E-2
12 WHEN PREHEATING SWITCH IS OFF, PREHEATING LAMP LIGHTS UP J. ★ Before checking, turn preheating switch OFF Cause 1
Yes
1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L74
No
Is resistance between L74 (male)(3) and (4) normal?
Remedy
Short circuit with power source in wiring harness between Repair or L74 (female)(4) and L72 (female)(1) replace
Defective pre heater switch
Replace
E-2 j. Related electrical circuit diagram
WA700-3L
20-321 1
TROUBLESHOOTING
E-3
12
E-3 PARKING BRAKE DOES NOT HAVE EFFECT ★ ★ ★ ★
When carrying out troubleshooting of the brake system, stop the machine on flat ground. Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON Cause 1
Yes
Does condition become normal when L01 is disconnected?
2
1. Start engine (Charge brake oil pressure)
No
Yes
Is resistance between L01 (female)(2) and (3) normal? 1. Disconnect L01 2. Turn starting switch OFF 3. Disconnect L58 4. Disconnect L59
3
No
Yes
Is voltage between F11 (female)(1) and chassis normal? 1. Max. 1 Ω 2. Start engine (Charge brake oil pressure) 3. Turn parking brake switch ON
No
Remedy
Defective parking brake switch
Replace
Defective contact of wiring harness at L01 (female)(2) end and (3) end
Repair or replace
Defective parking brake solenoid
Replace
Defective contact of wiring harness at L01 (female)(2) end and (1) end
Repair or replace
B. PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS Cause 1
Yes
Is parking brake normal when C07 and C08 are disconnected? 1. Turn starting switch ON 2. turn parking brake switch ON, then OFF
20-322 1
No
Remedy
Defective emergency brake switch (C07, C08)
Replace
Defective parking brake solenoid
Replace
WA700-3L
TROUBLESHOOTING
E-3
12
MEMORANDUM
WA700-3L
20-323 1
TROUBLESHOOTING
E-4
12
E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING ★ ★ ★ ★
When carrying out troubleshooting of the brake system, stop the machine on flat ground. Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
2
Yes
a
Yes Is resistance between F11 (female)(2) and chassis normal?
b
1. Max. 1 Ω 2. Turn starting switch OFF
No Yes
c
1 Yes
Is voltage between F11 (female)(1) and chassis normal?
d
4 Yes Does condition become normal when parking brake safety relay is replace?
1. 20 - 30 V 2. Start engine (Charge brake oil pressure)
1. Replace parking brake safety relay L59 with stop lamp relay L53 2. Start engine (Charge brake oil pressure) 3 Is continuity of L01 (male)(1)(2)(3) as No shown in Table 1?
5 Does condition become normal when C07 and C08 No (female) are connected to short connector? 1. Connect short connector to C07 (female) and C08 (female) 2. Start engine (charge brake oil pressure)
1. Turn starting switch OFF 2. Operate parking brake switch ON/ OFF 3. Disconnect L01
7 Yes Is resistance between L59 (female)(1) and (3) normal? 6 Is voltage between L59 (female)(5) No and chassis normal?
e
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L59
1. 20 - 30 V 2. Turn starting switch ON 3. disconnect L59
g No h
No
Table 1 Operation
20-324 1
Between L01(2) - (3)
Between L01(1) - (3)
ON (Parking)
Min. 1 MΩ
Max. 1 Ω
OFF (Travel)
Max. 1 Ω
Min. 1 MΩ
WA700-3L
TROUBLESHOOTING
E-4
12
Cause a
b
c
d
Yes Yes Is voltage between C08 (female)(1) and 10 chassis normal? Yes Is voltage between C07 (female)(1) and 9 chassis normal? Yes Is resistance between L59 (female)(2) and 8 chassis normal? e
Is voltage between L59 (female)(1) and chassis normal?
1. Max. 1 Ω 2. Turn starting switch OFf 3. Disconnect L59
No
1. 20 - 30 V 2. Turn starting switch ON 3. Turn parking brake switch ON 4. Disconnect L59 No
f
1. 20 - 30 V 2. Turn starting switch ON 3. Turn parking brake switch ON ➞ Off 4. Disconnect C07
1. 20 - 30 V 2. Turn starting switch ON 3. Turn parking brake switch ON ↔ Off 4. Disconnect C08 No
No
Remedy
Defect parking brake solenoid
Replace
Defective contact or disconnection in wiring harness between F11 (female)(2) and chassis
Repair or replace
Defective parking brake safety relay
Replace
Defective emergency brake switch
Replace
Defective contact or disconnection in wiring harness between C08 (female)(2) - BC01(4) FR2(5) - F11 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between C07 (female)(2) and C08 (female)(1)
Repair or replace
Defective contact or disconnection in wiring Repair or harness between C07 replace (female)(1) - BC01(5) LR2(12) - L01 (female)(2) Defective contact or disconnection in wiring harness between L59 (female)(2) CL1(2) and chassis
Repair or replace
Defective contact or disconnection in wiring harness between L59 (female)(1) and L01 (female)(3) or between FS2 (female)(7) and L01 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between L59 (female)(1) and L59 (female)(3)
Repair or replace
g
Defective contact or disconnection in wiring Repair or harness between L59 replace (female)(5) - FS2(7) - fuse
h
Defective parking brake switch
WA700-3L
Replace
20-325 1
TROUBLESHOOTING
E-5
12
E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON ★ Before disconnecting or connecting connectors, always turn starting switch OFF. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Yes
Is problem removed when parking safety relay L59 is replaced
2
1. Replace parkNo ing safety relay L59 with stop lamp relay L53 2. Turn starting switch ON 3. Start engine (Stop engine after charging brake oil pressure)
Yes
Does it become normal when L01 is disconnected 1. Disconnect L01 2. Turn starting switch ON No 3. Start engine (Stop engine after charging brake oil pressure)
3
Yes
Is there continuity between L59 (female)(3) and (5) 1. Disconnect L59 2. Turn starting switch OFF 3. Turn parking brake switch OFF
No
Remedy
Defective parking safety relay
Replace
Defective parking brake switch
Replace
Defective contact of wiring harness between Replace L59(5) and (female)(3)(1) Defective contact of wiring harness between L01 (female)(1) and (2)
Repair or replace
E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORKS NORMALLY Cause 1
Remedy
Yes Defective neutralizer relay Replace
Is voltage between neutralizer relay L58 (female)(5) chassis normal? 1. max. 1 V 2. Disconnect neutralizer relay L58 3. turn starting switch ON 4. Shift directional lever between F, N and R, and check each voltage
20-326 1
No
Short circuit with power source in wiring harness between L58 (female)(5)
Repair or replace
WA700-3L
TROUBLESHOOTING
E-6
E-3, E-4, E-5, E-6 Related electrical circuit diagram
WA700-3L
20-327 1
TROUBLESHOOTING
E-7
12
E-7 TRANSMISSION DOES NOT WORK PROPERLY ★ Before disconnecting or connecting connectors, make sure to turn starting switch OFF. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Perform tester check of the transmission solenoid control circuit according to the following procedure. WARNING! Stop the machine on flat ground and put blocks under the tires.
1.
Install a T-adopter (or socket adopter) to transmission connector T01, then check the voltage between the pins in Table 1 and chassis ground.
2.
Turn starting switch ON. WARNING! Do not start the engine.
3.
Turn the parking brake switch ON, then OFF (release) again.
4.
If required, press the right-hand foot brake pedal. ★ If the left-hand brake pedal is pressed, the transmission is cut off and cannot be checked.
5.
Check the voltage and continuity according to Table 1. Then, go to the troubleshooting shown in the right columns of Table 2 and Table 3 according to the inspection result shown in those tables.
Table 1 - Normal operation table of transmission Pin No.
Gear shift lever
FR lever
Operation of lever
T01 (1) H
(2) G
(3) F
(4) E
(F) D
(R) C
(GND) B
(GND) A
Forward (F)
●
❍
❍
Reverse (R)
❍
●
❍
Remedy
Go to Table 2
1st
●
❍
❍
❍
❍
2nd
❍
●
❍
❍
❍
3rd
❍
❍
●
❍
❍
4th
❍
❍
❍
●
❍
Go to Table 3
❍: 0 - 0.5 V (Continuity) ●: 20 - 30 V (Battery voltage)
20-328 1
WA700-3L
TROUBLESHOOTING
E-7
12 Table 2 - Result of check during operation of directional lever Check result
Cause
Troubleshooting
● Battery voltage is zero
Defective transmission cut-off switch, parking brake or neutralizer relay circuit
Go to E7-a
❍ There is not continuity (Forward side)
Defective circuit on forward side
Go to E7-b
❍ There is not continuity (Reverse side)
Defective circuit on reverse side
Go to E7-c
❍ Continuity is higher than specification
Contact of circuits on forward and reverse sides with each other
Go to E7-d
Table 3 - Result of check during operation of gear shift lever Check result
Cause
● Battery voltage is zero
Defective power supply circuit
❍ There is not continuity
Defective circuit on gear shifting side
❍ Continuity is higher than specification
Contact of circuits on gear shifting side
WA700-3L
Troubleshooting Go to E7-e Go to E7-f
20-329 1
TROUBLESHOOTING
E-7
12 A.
ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT
3 Yes 2 Yes Does condition become normal when transmission cut-off selector switch to turn OFF? 1. Start engine
Is resistance between L12 (male)(1) and (2) normal?
Yes
a
b No Yes
c
4 Does condition become normal No when replacing neutralizer relay is replaced
Yes
d
5
Yes e Does condition become normal No when parking brake 7 1. Replace neutralizer relay safety relay is L58 with stop lamp replaced Yes Is voltage between relay L53 L58 (female)(1) 2. Start engine 1. Replace parking 6 and chassis ground brake relay L59 normal? with stop lamp Is resistance of L01 relay L53 2. Start engine No (male)(1), (2) and 1. 20 - 30 V f (3) conformed to 2. Turn starting Table 1 switch ON No 3. Disconnect L58 4. Turn on park1. Turn starting ing brake switch, switch OFF then release it 2. Disconnect L01 g
1 Is resistance between L04 (female)(10) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L04
No
h No
Table 1 Operation
Terminals (1) - (3)
Terminals (3) - (2)
ON (Parking)
Max. 1 Ω
Min. 1 Ω
OFF (Travel)
Min. 1 Ω
Max. 1 Ω
20-330 1
WA700-3L
TROUBLESHOOTING
E-7
12
Cause a
Remedy
Defective contact or disconnection in writing harness or between L12 (female)(1) and L58 (female)(5) or between Repair replace L12 (female)(2) and L65 (female)(5)
b Defective transmission cut-off switch
Replace
Defective neutralizer relay
Replace
Defective parking brake safety relay
Replace
c
d
e
Defective contact or disconnection in wiring harness or between L58 (female)(3) and FS2 (female)(8) or between Repair replace L58 (female)(2), CL1 (female)(12) and chassis ground 9
f
g
Is resistance between L01 (female)(3) and L59 (female)(1) and (3) normal? 1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L01 and L59
h
WA700-3L
Yes
8 Yes Is voltage between L59 (female)(5) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 3. Disconnect L59 No
No
Defective contact or disconnection in wiring harness between L59 (female)(2), CL1(12) and chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between L59 (female)(5) and FS2 (female)(7)
Repair or replace
Defective contact or disconnection in wiring harness between L01 (female)(3) and L59 (female)(1) and (3)
Repair or replace
Defective parking brake switch
Replace
Defective contact or disconnection in wiring harness between L04 (female)(10), LR5(3) and chassis ground
Repair or replace
20-331 1
TROUBLESHOOTING
E-7
12 E-7 a. Related electrical circuit diagram
20-332 1
WA700-3L
TROUBLESHOOTING
E-7
12
MEMORANDUM
WA700-3L
20-333 1
TROUBLESHOOTING 12 B.
E-7
NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT
2 Yes Is resistance between T01 (female)(A) and chassis ground 1 normal Is voltage between T01 (female) (D) and chassis ground normal?
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
Yes
a
b No Yes
c
5
Yes
1. 20 - 30 V 3 Yes Is voltage between 2. Turn starting L66 (female)(5) switch ON and chassis ground Does condition 3. Disconnect normal? become normal T01 when relay is No replace? 4 1. 20 - 30 V 6 4. Release 2. Turn starting parking brake switch ON 1. Replace forward (Turn switch ON, Is voltage between 3. Disconnect L66 relay L66 with Is resistance then OFF) (female)(1) 4. Set directional reverse relay L67 No L04 between L66 5. Set and chassis ground lever to 2. Start engine No (female)(6) and directional lever normal? FORWARD 3. Release parking chassis ground to FORWARD brake normal? 1. 20 - 30 V 4. Set directional 2. Turn starting lever to switch OFF 1. Max. 1 Ω FORWARD 3. Disconnect L04 2. Turn starting switch OFF 3. Disconnect L66
d
Yes
e
f No
g No
E-7 b. Related electrical circuit diagram
20-334 1
WA700-3L
TROUBLESHOOTING
E-7
12
Cause
Remedy
a
b
Defective forward solenoid
Replace
Defective contact or disconnection in wiring harness between T01 (female)(A), TL1(7), CL1(12) and chassis ground
Repair or replace
Defective forward relay
Replace
c
d See E7-a
---
e
Defective directional lever or defective contact or discon- Repair or nection in wiring harness between L04 (female)(2) and replace L66 (female)(5)
f
Defective contact or disconnection in wiring harness between L04 (female)(1), FS2(8) and fuse
Repair or replace
g
Defective contact or disconnection in wiring harness between L66 (female)(6), CL1(12) and chassis ground
Repair or replace
WA700-3L
20-335 1
TROUBLESHOOTING 12 C.
E-7
NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT
2 Yes Is resistance between T01 (female)(A) and chassis ground 1 normal Is voltage between T01 (female) (C) and chassis ground normal?
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
Yes
a
b No Yes
c
5
Yes
1. 20 - 30 V 3 Yes Is voltage between 2. Turn starting L67 (female)(5) switch ON and chassis ground Does condition 3. Disconnect normal? become normal T01 when relay is No replace? 4 1. 20 - 30 V 6 4. Release 2. Turn starting parking brake switch ON 1. Replace reverse (Turn switch ON, Is voltage between 3. Disconnect L67 relay L67 with Is resistance then OFF) (female)(1) 4. Set directional foward relay L66 No L04 between L67 5. Set and chassis ground lever to 2. Start engine No (female)(6) and directional lever normal? REVERSE 3. Release parking chassis ground to REVERSE brake normal? 1. 20 - 30 V 4. Set directional 2. Turn starting lever to switch OFF 1. Max. 1 Ω REVERSE 3. Disconnect L04 2. Turn starting switch OFF 3. Disconnect L67
d
Yes
e
f No
g No
E-7 c. Related electrical circuit diagram
20-336 1
WA700-3L
TROUBLESHOOTING
E-7
12
Cause
Remedy
a
b
Defective reverse solenoid
Replace
Defective contact or disconnection in wiring harness between T01 (female)(A), TL1(7), CL1(12) and chassis ground
Repair or replace
Defective reverse relay
Replace
c
d See E7-a
---
e
Defective directional lever or defective contact or discon- Repair or nection in wiring harness between L04 (female)(4) and replace L67 (female)(5)
f
Defective contact or disconnection in wiring harness between L04 (female)(1), FS2(8) and fuse
Repair or replace
g
Defective contact or disconnection in wiring harness between L67 (female)(6), CL1(12) and chassis ground
Repair or replace
WA700-3L
20-337 1
TROUBLESHOOTING
E-7
12 D.
SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT 1.
Short circuit to chassis ground in travel FORWARD circuit Yes a 6
Yes Is resistance between TL1 (male)(5) and 3 chassis ground normal?
Yes Is resistance between T01 1 (female) (D) and connector body normal? 1. Is resistance between T01 1. Min. 1 MΩ (male) (D) and 2. Turn starting chassis ground switch OFF normal? 3. Disconnect T01 and TL1 2. Is resistance between (A), (B), (F), (G), (H) and chassis ground No normal?
Yes Is resistance between TL1 2 (female)(5) and (1), (2), (3), (4), (6), (7) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
Yes Is resistance between L04 4 (male)(2) and (4), (5), (6), (7), (8) normal?
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect TL1, L04 and L66
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04 4. Set directional lever to N or F
Yes Is resistance between L04 5 (male)(2) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04
No b
c
No
d No e
No f
No g
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01
20-338 1
WA700-3L
TROUBLESHOOTING
E-7
12
Cause 7 a
b
Is resistance between L04 (male)(2) and chassis ground normal? 1. Min. 1 Mâ&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L04 and L66
c
d
e
f
g
WA700-3L
Yes
No
Remedy
Short circuit between forward solenoid relay L66 (male)(1) and (2)
Replace
Short circuit with chassis or ground wire in harness between L04 (female)(2) and L66 (female)(5)
Repair or replace
Defective transmission control switch
Replace
Defective transmission control switch
Replace
Short circuit with chassis or ground wire in harness between TL1 (male)(5) and L66 (male)(2)
Repair or replace
Short circuit of harness between TL1 (female)(5) and T01 (female) (D) and Repair or harness between TL1 (female)(1), (2), (3), (4), replace (6), (7) and T01 (female) (A), (C), (E), (F), (G) and (H) with each other Defective insulation or between T01 (female) (D) Repair replace and connector body Defective insulation between T01 (male) (D) and connector body or short circuit of harness and Repair or chassis ground with T01 replace (D) in control valve and defective insulation among pins of T01
20-339 1
TROUBLESHOOTING
E-7
12 2.
Short circuit to chassis ground in travel REVERSE circuit Yes a 6
4 Yes Is resistance between TL1 (male)(6) and 3 chassis ground normal?
1 1. Is resistance between T01 (male) (C) and chassis ground normal? 2. Is resistance between (A), (B), (D), (E), (F), (G), (H) and chassis ground normal?
Yes Is resistance between T01 (female) (C) and connector body normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
Yes Is resistance between TL1 2 (female)(6) and (1), (2), (3), (4), (5), (7) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect TL1, L04 and L67
Yes Is resistance between L04 (male)(2) and (4), (5), (6), (7), (8) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04 4. Set directional lever to N or F
Yes Is resistance between L04 5 (male)(4) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04
No b
c
No
d No e
No f
No g
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01
20-340 1
WA700-3L
TROUBLESHOOTING
E-7
Cause 7 a
b
Is resistance between L04 (male)(4) and chassis ground normal? 1. Min. 1 Mâ&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L04 and L67
c
d
e
f
g
WA700-3L
Yes
No
Remedy
Short circuit between forward solenoid relay L67 (male)(1) and (2)
Replace
Short circuit with chassis or ground wire in harness between L04 (female)(4) and L67 (female)(5)
Repair or replace
Defective transmission control switch
Replace
Defective transmission control switch
Replace
Short circuit with chassis or ground wire in harness between TL1 (male)(6) and L67 (male)(2)
Repair or replace
Short circuit of harness between TL1 (female)(6) and T01 (female) (C) and harness between TL1 Repair or (female)(1), (2), (3), (4), replace (5), (7) and T01 (female) (A), (D), (E), (F), (G) and (H) with each other Defective insulation or between T01 (female) (C) Repair replace and connector body Defective insulation between T01 (male) (C) and connector body or short circuit of harness and Repair or chassis ground with T01 replace (C) in control valve and defective insulation among pins of T01
20-341 1
TROUBLESHOOTING
E-7
12 E-7 d. Related electrical circuit diagram
20-342 1
WA700-3L
TROUBLESHOOTING
E-7
12
MEMORANDUM
WA700-3L
20-343 1
TROUBLESHOOTING 12 E.
E-7
ABNORMALITY IN SHIFT SOLENOID CIRCUIT 5 Yes a
1st
4 Yes Is voltage between T01 (female) (H) and chassis ground Is voltage between normal? L04(5) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 1. 20 - 30 V 3. Disconnect T01 2. Turn starting 4. Set gear shift switch ON lever to 1st 3. Connect T-adapter to L04 No 4. Set gear shift lever to 1st
b No
c
7 Yes d
2nd
Yes
Go to defective transmission range
6 Yes Is voltage between L76 (female) (3) and chassis ground Is voltage between normal? L04(6) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 1. 20 - 30 V 3. Disconnect L76 2. Turn starting 4. Set gear shift switch ON lever to 2nd 3. Connect T-adapter to L04 4. Set gear shift lever to 2nd No
e No f
11 Yes g
3rd
3
1
20-344 1
4th
1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect 01
1. 20 - 30 V 2. Turn starting switch ON 3. Disconnect L04
No i
12 Yes Is voltage between T01 (female) (E) and chassis ground Is voltage between normal? L04(8) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 1. 20 - 30 V 3. Disconnect T01 2. Turn starting 4. Set gear shift switch ON lever to 4th 3. Connect T-adapter to L04 4. Set gear shift lever to 4th No
k No l m
No
Is resistance between L04 (female)(10) and chassis ground normal? 1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L04
h
13 Yes j
Yes Is resistance between T01 (female) (B) and chassis ground normal? 2 Yes Is voltage between L04 (female)(1) and chassis ground normal?
10 Yes Is voltage between T01 (female) (F) and chassis ground Is voltage between normal? L04(7) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 1. 20 - 30 V 3. Disconnect T01 2. Turn starting 4. Set gear shift switch ON lever to 3rd 3. Connect T-adapter to L04 4. Set gear shift lever to 3rd No
n No o No
WA700-3L
TROUBLESHOOTING
E-7
12
Cause
Remedy
a Defective 1st solenoid
Replace
Defective contact or disconnection in wiring harness between L04 (female)(5), TL1(1) and T01 (female) (H)
Repair or replace
Defective gear shift lever switch
Replace
Defective 2nd - 1st selector relay
Replace
Defective 2nd solenoid
Replace
Defective contact or disconnection in wiring harness between L76 (female)(6), TL1(2) and T01 (female) (G)
Repair or replace
Defective contact or disconnection in wiring harness between L04 (female)(6) and L76 (female)(3)
Repair or replace
Defective gear shift lever switch
Replace
Defective 3rd solenoid
Replace
Defective contact or disconnection in wiring harness between L04 (female)(7), TL1(3) and T01 (female) (F)
Repair or replace
Defective gear shift lever switch
Replace
Defective 4th solenoid
Replace
Defective contact or disconnection in wiring harness between L04 (female)(8), TL1(4) and T01 (female) (E)
Repair or replace
Defective gear shift lever switch
Replace
m
Defective contact or disconnection in wiring harness between T01 (female) (B), TL1(7), CL1(12) and chassis ground
Repair or replace
n
Defective contact or disconnection in wiring harness between L04 (female)(1), FS2(8) and fuse I (9)
Repair or replace
o
Defective contact or disconnection in wiring harness between L04 (female)(10), LR5(3) and chassis ground
Repair or replace
b
c
8 d
Yes
Does condition become normal when relay is replaced? 1. Replace 2nd-1st selector relay L76 with stop 1 amp No relay L53 2. Start engine
e
9
Yes
1. 20 - 30 V 2. Turn starting switch ON 3. Disconnect T01 4. Set gear shift lever to 2nd
No
Is voltage between T01 (female) (G) and chassis ground normal?
f
g
h
i
j
k
l
WA700-3L
20-345 1
TROUBLESHOOTING
E-7
12 E-7 e. Related electrical circuit diagram
20-346 1
WA700-3L
TROUBLESHOOTING
E-7
12 SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT F. 1.
Short circuit to chassis ground in 1st solenoid circuit Cause
Remedy
Yes To A
4 Yes
3 Yes Is voltage between TL1 (male)(1) and chassis ground normal? 2 Yes
1
Is resistance between T01 (female) (H) and (A), (B), (C), (E), (F), (G) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
1. Is resistance between T01 (male) (H) and chassis ground normal? 2. Is resistance between (A), (B), (C), (D), (E), (F), (G) and chassis ground normal?
No
Yes 5 A
Is resistance between L04 (female)(5) and (2), (4), (6) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
WA700-3L
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
No
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01
From
1. 0 - 0.5 V 2. Disconnect TL1, L04 and L76 3. Turn starting switch ON
Is resistance between TL1 (male)(1) and (2), (3), (4), (5), (6), (7) normal?
No
---
Short circuit with harness between following couples in harness between TL1 (male)(1) and L04 (female)(5); TLl (male) (2) and L76(female) (6), TL1 (male)(3) and L04 Repair or (female)(7), TLl (male)(4) replace and L04 (female) (8), TLl (male)(5) and L66 (female)(2), TLl (male)(6) and L67 (female)(2), TL1 (male)(7) and chassis ground Short circuit with power source in wiring harness between TL1 (male)(1), L04 (female)(5) and L76 (female)(5)
Repair or replace
Short circuit with harness between T01 (female) (H) and TL1 (female)(1) in Repair or harness between T01 replace (female) (A) - (G) and TL1 (female)(2) - (7) Defective insulation between T01 (male) (H) and connector body or short circuit of harness and Repair or chassis ground with T01 replace (H) in control valve and defective insulation among pins of T01 Defective transmission control switch
Replace
Short circuit with harness between following couples in harness between L04 (female)(5) and TL1 (male)(1); L04 (female)(2) Repair or and L66 (female)(5), L04 replace (female)(4) and L67 (female)(5), L04 (female)(6) and L76 (female)(3)
20-347 1
TROUBLESHOOTING
E-7
12 2. Short circuit to chassis ground in 2nd solenoid circuit Cause
Remedy
Yes To A
4 Yes
3 Yes Is voltage between TL1 (male)(2) and chassis ground normal? 2 Yes
1
Is resistance between T01 (female) (G) and (A), (B), (C), (D), (E), (F) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
1. Is resistance between T01 (male) (G) and chassis ground normal? 2. Is resistance between (A), (B), (C), (D), (E), (F), (H) and chassis ground normal?
No
Yes 5 A
Is resistance between L04 (female)(6) and (2), (4), (5) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
20-348 1
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
No
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01
From
1. 0 - 0.5 V 2. Disconnect TL1, L04 and L76 3. Turn starting switch ON
Is resistance between TL1 (male)(2) and (1), (3), (4), (5), (6), (7) normal?
No
---
Short circuit with harness between following couples in harness between TL1 (male)(2) and L76 (female)(6); TLl (male) (1) and L76(female) (5), TL1 (male)(3) and L04 Repair or (female)(7), TLl (male)(4) replace and L04 (female) (8), TLl (male)(5) and L66 (female)(2), TLl (male)(6) and L67 (female)(2), TL1 (male)(7) and chassis ground Short circuit with power source in wiring harness between TL1 (male)(2), L04 (female)(5) and L76 (female)(6)
Repair or replace
Short circuit with harness between T01 (female) (G) and TL1 (female)(2) in Repair or harness between T01 replace (female) (A) - (F), (H) and TL1 (female)(1), (3) - (7) Defective insulation between T01 (male) (G) and connector body or short circuit of harness and Repair or chassis ground with T01 replace (G) in control valve and defective insulation among pins of T01 Defective transmission control switch
Replace
Short circuit with harness between following couples in harness between L04 (female)(6) and L76 (female)(3); L04 Repair or (female)(2) and L66 replace (female)(5), L04 (female)(4) and L67 (female)(5), L04 (female)(5) and TL1 (male)(1)
WA700-3L
TROUBLESHOOTING
E-7
12 3. Short circuit to chassis ground in 3rd solenoid circuit Cause
Remedy
Yes To A
4 Yes
3 Yes Is voltage between TL1 (male)(3) and chassis ground normal? 2 Yes
1
Is resistance between T01 (female) (F) and (A), (B), (C), (D), (E), (G) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
1. Is resistance between T01 (male) (F) and chassis ground normal? 2. Is resistance between (A), (B), (C), (D), (E), (F), (H) and chassis ground normal?
No
Yes 5 A
Is resistance between L04 (female)(7) and (2), (4), (5), (6) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
WA700-3L
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
No
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01
From
1. 0 - 0.5 V 2. Disconnect TL1, L04 and L76 3. Turn starting switch ON
Is resistance between TL1 (male)(3) and (1), (2), (4), (5), (6), (7) normal?
No
---
Short circuit with harness between following couples in harness between TL1 (male)(3) and L04 (female)(7); TLl (male) (1) and L76(female) (5), TL1 (male)(2) and L76 Repair or (female)(6), TLl (male)(4) replace and L04 (female) (8), TLl (male)(5) and L66 (female)(2), TLl (male)(6) and L67 (female)(2), TL1 (male)(7) and chassis ground Short circuit with power source in wiring harness between TL1 (male)(3), L04 (female)(7)
Repair or replace
Short circuit with harness between T01 (female) (F) and TL1 (female)(3) in Repair or harness between T01 replace (female) (A) - (E), (G), (H) and TL1 (female)(1), (2), (4), (5), (6), (7) Defective insulation between T01 (male) (F) and connector body or short circuit of harness and Repair or chassis ground with T01 replace (F) in control valve and defective insulation among pins of T01 Defective transmission control switch
Replace
Short circuit with harness between following couples in harness between L04 (female)(7) and TL1 (male)(3); L04 (female)(2) Repair or and L66 (female)(5), L04 replace (female)(4) and L67 (female)(5), L04 (female)(5) and TL1 (male)(1), L04 (female)(6) and L76 (female)(3)
20-349 1
TROUBLESHOOTING
E-7
12 4. Short circuit to chassis ground in 4th solenoid circuit Cause
Remedy
Yes To A
4 Yes
3 Yes Is voltage between TL1 (male)(4) and chassis ground normal? 2 Yes
1
Is resistance between T01 (female) (E) and (A), (B), (C), (D), (F), (G) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01 and TL1
1. Is resistance between T01 (male) (E) and chassis ground normal? 2. Is resistance between (A), (B), (C), (D), (F), (G), (H) and chassis ground normal?
No
Yes 5 A
Is resistance between L04 (female)(8) and (2), (4), (5), (6) normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
20-350 1
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L04, TL1 and L76
No
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect T01
From
1. 0 - 0.5 V 2. Disconnect TL1, L04 and L76 3. Turn starting switch ON
Is resistance between TL1 (male)(4) and (1), (2), (3), (5), (6), (7) normal?
No
---
Short circuit with harness between following couples in harness between TL1 (male)(4) and L04 (female)(8); TLl (male) (1) and L76(female) (5), TL1 (male)(2) and L76 Repair or (female)(6), TLl (male)(3) replace and L04 (female) (7), TLl (male)(5) and L66 (female)(2), TLl (male)(6) and L67 (female)(2), TL1 (male)(7) and chassis ground Short circuit with power source in wiring harness between TL1 (male)(4), L04 (female)(8)
Repair or replace
Short circuit with harness between T01 (female) (E) and TL1 (female)(4) in harness between T01 Repair or (female) (A) - (D), (F), replace (G), (H) and TL1 (female)(1), (2), (3), (5), (6), (7) Defective insulation between T01 (male) (E) and connector body or short circuit of harness and Repair or chassis ground with T01 replace (E) in control valve and defective insulation among pins of T01 Defective transmission control switch
Replace
Short circuit with harness between following couples in harness between L04 (female)(8) and TL1 (male)(4); L04 (female)(2) Repair or and L66 (female)(5), L04 replace (female)(4) and L67 (female)(5), L04 (female)(5) and TL1 (male)(1), L04 (female)(6) and L76 (female)(3)
WA700-3L
TROUBLESHOOTING
E-7
12 E-7 f. Related electrical circuit diagram
WA700-3L
20-351 1
TROUBLESHOOTING
E-8
12
E-8 KICK-DOWN SWITCH DOES NOT WORK (Shift works correctly during normal gear shift operations F1 - F4) ★ Before disconnecting or connecting connectors, always turn starting switch OFF. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Yes
a
2 Yes Does condition become normal when kick-down relay is replaced?
Yes 3
1. Replace kick-down relay L68 with reverse relay L67 2. Start engine
Does condition become normal when forward relay is replaced? 1. Replace forward relay L66 with reverse relay L67 2. Start engine
1
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Press kick-down switch L15
c
4 Does condition become normal when 2nd-1st selector relay is replaced? 1. Replace 2nd-1st selector relay L76 with stop lamp relay L53 2. Start engine
Is resistance betweenL15 (male)(1) and (2) normal?
b
6 Yes d
5 Is resistance between L68 (female)(6) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L68
Yes Is resistance between L15 (female)(2) and L68 (female)(5) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L15 and L68
e No
f No g No 11 From A
Is resistance between L76 (female)(5) and TL1 (male)(1) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L76 and TL1
20-352 1
Yes
h
i No
WA700-3L
TROUBLESHOOTING
E-8
12
Cause
Remedy
a Defective kick-down relay Replace b Defective forward relay c
Defective 2nd-1st selector Replace relay 10
Yes To A (previous page)
Yes Is resistance between L68 (female)(4) and L76 (female)(1) normal? 9
d
Replace
8 Yes Is voltage between L68 (female)(3) and chassis ground Is voltage between normal? Yes L66 (female)(3) and chassis ground 7 1. 20 - 30 V normal? 2. Turn starting switch ON 1. 20 - 30 V Is resistance 3. Disconnect L68 2. Turn starting between L66 switch ON (female)(4) and 3. Disconnect L66 L68 (female)(1) 4. Set gear shift lever normal? 2nd 1. Max. 1 â&#x201E;Ś No 2. Turn starting switch OFF 3. Disconnect L66 No
e
f
g
h
i
WA700-3L
1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L66 and L76 No
No
---
Defective contact or disconnection in wiring harness between L68 (female)(4) and L76 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between FS2 (female)(8) and L68 (female)(3)
Repair or replace
Defective contact or disconnection in wiring harness between L76 (female)(3) and L66 (female)(3)
Repair or replace
Defective contact or disconnection in wiring harness between L66 (female)(4) and L68 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between L15 (female)(2) and L68 (female)(5)
Repair or replace
Defective contact or disconnection in wiring harness between L68 (female)(6), CL1(12) and chassis ground
Repair or replace
Defective kick-down switch
Replace
Defective contact or disconnection in wiring harness between L76 (female)(2), CL1(12) and chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between L76 (female)(5) and TL1 (male)(1)
Repair or replace
20-353 1
TROUBLESHOOTING
E-8
12 E-8 Related electrical circuit diagram
20-354 1
WA700-3L
TROUBLESHOOTING
E-9
12 E-9 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON (Kick-down switch does not carry out self-hold operation) ★ Before disconnecting or connecting connectors, always turn starting switch OFF. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Remedy
Yes Defective kick-down relay Replace
Does condition become normal when kick-down relay is replaced 1. Replace kickNo down relay L68 with reverse relay L67 2. Start engine
2
Yes
Is resistance between L66 (female)(1) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L66 and L68
No
Defective contact or disconnection in wiring harness between L68 (female)(2) and (5)
Repair or replace
Defective contact or disconnection in wiring harness between L66 (female)(4) and L68 (female)(1)
Repair or replace
E-9 Related electrical circuit diagram
WA700-3L
20-355 1
TROUBLESHOOTING
E-10
12
E-10 KICK-DOWN ALWAYS WORKS ★ Before disconnecting or connecting connectors, surely turn starting switch OFF. ★ Before carrying out troubleshooting, check that all related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause Yes
Defective 2nd-1st selector Replace relay
1 Yes Kick-down is not reset when directional lever is returned from FORWARD to NEUTRAL or REVESE
Does condition become normal when 2nd-1st selector relay is replaced? 1. Replace 2nd-1st selector relay L76 with stop lamp relay L53. 2. Start engine
2
Go to defective part No
No
3 Kick-down is not reset when gear shift lever is set from 2nd to another speed
5
Yes
Yes Is resistance between L68 (female)(1) and (2) normal?
Is resistance between L68 (female)(3) and (4) normal?
1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L68 No
1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L68 No
20-356 1
Defective forward relay
Replace
Short circuit in harness between L66 (female)(3) and (4)
Repair or replace
Yes Defective kick-down relay Replace
Does condition become normal when replacing kick-down relay? 1. Replace kickdown relay L68 with reverse relay L67 2. Start engine
4
Yes
Does condition become normal when forward relay is replaced? 1. Replace forward relay L66 with reverse relay L67 2. Start engine
No
From A
Remedy
No
To A
---
Short circuit with harness between L68 (female)(1) and L66 (female)(4) in harness between L68 (female)(4) and L76 (female)(1)
Repair or replace
Short circuit with harness between L68 (female)(1) and L66 (female)(4) in harness between L68 (female)(2) and L68 (female)(5)
Repair or replace
Short circuit with harness between L68 (female)(3) and FS2 (female)(8) in harness between L68 (female)(4) and L76 (female)(1)
Repair or replace
WA700-3L
TROUBLESHOOTING
E-10
12 E-10 Related electrical circuit diagram
WA700-3L
20-357 1
TROUBLESHOOTING
E-11
12
E-11 KICK-DOWN SWICTH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND ★ Before disconnecting or connecting connectors, surely turn starting switch OFF. ★ Before carrying out troubleshooting, check that all related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause Yes
Defective 2nd-1st selector Replace relay
3 Yes Does condition become normal when 2nd-1st selector relay is replaced? Yes Is resistance between L68 (male)(1) and (2) and between (3) and (4) normal? 1 Is resistance between L15 (female)(1) and (2) normal?
1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L68
1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L15 4. Do not press kick-down switch
1. Replace 2nd-1st No selector relay L76 with stop lamp relay L53 2. Start engine
No
No
Yes 5 From A Is resistance between L68 (female)(1) and (2) normal? 1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L68
20-358 1
No
Remedy
4
Yes To A
---
Is resistance between L15 (female)(1) and (2) normal? 1. Min. 1 Ω 2. Turn starting switch OFF 3. Disconnect L15
No
Short circuit with harness between L15 (female)(1) and L66 (female)(4) in harness between L15 (female)(2) and L68 (female)(5)
Repair or replace
or Defective kick-down relay Repair replace Defective kick-down switch
Replace
Short circuit with harness between L68 (female)(3) and FS2 (female)(8) in harness between L68 (female)(4) and L76 (female)(1)
Repair or replace
Short circuit with harness between l68 (female)(1) and L15 (female)(1) in harness between L68 (female)(2) and L15 (female)(2)
Repair or replace
WA700-3L
TROUBLESHOOTING
E-11
12 E-11 Related electrical circuit diagram
WA700-3L
20-359 1
TROUBLESHOOTING
E-12
12
E-12 BOOM KICK-OUT DOES NOT WORK ★ Before carrying out troubleshooting, check that all related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Check that fuse (10) is not blown. Yes
a
Yes b 1
6
Does condition become normal when boom relay with another relay is replaced?
5 Yes
1. Replace boom relay L49 with bucket relay L48
4
Yes 2 Is voltage between No each two pins of F06 conformed to Table 1?
Is resistance between L16 (male)(1) and (2) normal? 1. 19 - 23 Ω 2. Disconnect L16
Yes Is resistance between F06 3 (female)(3) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect F06
Is voltage between F06 (female)(1) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Yes Is voltage between F06 (female)(2) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 3. Disconnect F06
c No d
No e
No
f
1. See Table 1 2. Turn starting switch ON
No g No
Table 1 When screw driver is close to proxity switch
When screw driver is not close to proxity switch
Between (1) and (2)
20 - 30 V
Below 3 V
Between (1) and (3)
20 - 30 V
0 - 30 V
Between (2) and (3)
Below 3 V
20 - 30 V
20-360 1
WA700-3L
TROUBLESHOOTING
E-12
12 Cause
Remedy
a Defective boom relay
Replace
Defective contact or disconnection in wiring harness between L49 (female)(5) and L16 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between L16 (female)(2), CL1(12) and chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between F06 (female)(2), FR2(2), LR2(2) and L49 (female)(2)
Repair or replace
d
Defective contact or disconnection in wiring harness between FS2 (female)(10), LR2(1), FR2(1) and F06 (female)(1)
Repair or replace
e
Defective contact or disconnection in wiring harness between F06 (female)(3) and chassis ground
Repair or replace
Defective boom kick-out solenoid
Replace
Defective boom proximity switch
Replace
7 b
c
Yes
Is resistance between L16 (female)(2) and chassis ground normal? 1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L16
No
f
g
E-12 Related electrical circuit diagram
WA700-3L
20-361 1
TROUBLESHOOTING
E-13
12
E-13 DEFECTIVE BUCKET POSITIONER ★ Before carrying out troubleshooting, check that all related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Check that fuse (10) is not blown. Yes
a
Yes b 1
6
Does condition become normal when bucket relay with another relay is replaced?
5 Yes
1. Replace boom relay L48 with bucket relay L49
4
Yes 2 Is voltage between No each two pins of F05 conformed to Table 1?
Is resistance between L17 (male)(1) and (2) normal? 1. 19 - 23 Ω 2. Disconnect L17
Yes Is resistance between F05 3 (female)(3) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect F05
Is voltage between F05 (female)(1) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Yes Is voltage between F05 (female)(2) and chassis ground normal? 1. 20 - 30 V 2. Disconnect F05 3. Turn starting switch ON
c No d
No e
No
f
1. See Table 1 2. Turn starting switch ON
No g No
Table 1 When screw driver is close to proxity switch
When screw driver is not close to proxity switch
Between (1) and (2)
20 - 30 V
Below 3 V
Between (1) and (3)
20 - 30 V
0 - 30 V
Between (2) and (3)
Below 3 V
20 - 30 V
20-362 1
WA700-3L
TROUBLESHOOTING
E-13
12 Cause
Remedy
a Defective bucket relay
Replace
Defective contact or disconnection in wiring harness between L48 (female)(6) and L17 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between L17 (female)(2), CL1(12) and chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between F05 (female)(2), FR2(3), LR2(3) and L48 (female)(2)
Repair or replace
d
Defective contact or disconnection in wiring harness between FS2 (female)(10), LR2(1), FR2(1) and F05 (female)(1)
Repair or replace
e
Defective contact or disconnection in wiring harness between F05 (female)(3) and chassis ground
Repair or replace
Defective bucket positioner solenoid
Replace
Defective bucket proximity switch
Replace
7 b
c
Yes
Is resistance between L16 (female)(2) and chassis ground normal? 1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L17
No
f
g
E-12 Related electrical circuit diagram
WA700-3L
20-363 1
TROUBLESHOOTING
E-14
12
E-14 POWER WINDOW DOES NOT WORK ★ ★ ★ ★
Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuse (12) is not blown.
A. WINDOW DOES NOT GO UP (This troubleshooting flowchart shows the troubleshooting procedure for the left power window) Cause 4
Yes
Yes Is resistance between L75 (female)(6) and 3 chassis normal? Yes Is resistance between PWL2 (female) and L75 (female)(3) normal? 2 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect PWL2 and L75
Yes Is voltage between PWL1 and chassis normal? 1. 20 - 30 V 2. Turn starting switch ON 3 Left power window switch: UP
1 Is there continuity between PWL1 (female) and PWL2 (male)?
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect PWL2 and L75
1. Turn starting switch OFF 2. Disconnect PWL1 and PWL2
No
No
No
6
Yes
7 Is voltage between L70 (female)(1) and chassis normal?
10
8
No
Is resistance between L41 (male)(1) and (5) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L41 4. Left power window switch: UP
Yes Is voltage between L41 (female)(1) and chassis normal?
1. 20 - 30 V 2. Disconnect L70 3. Turn starting switch ON
1. 20 - 30 V 2. Disconnect L41 3. Turn starting switch ON NO
No
20-364 1
Yes
Yes Is voltage between L70 (female)(5) and chassis normal? 9
1. 20 - 30 V 2. Turn starting switch ON 3 Left power window switch: UP
Replace
Defective contact or disconnection in wiring harness between L75 (female)(6) - CL1(12) chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between PWL2 (female) - CL4(2) - L75 (female)(3)
Repair or replace
Defective relay L70
Replace
Go to A
No
From
Defective relay L75
Yes
5 Yes Does condition become normal when relay is Is resistance between replaced? PWL1 (male) and L70 (female)(3) 1. Replace L70 left normal? UP relay with L80 right UP relay 1. Max. 1 Ω 2. Turn starting 2. Turn starting switch ON switch OFF 3.Left power 3. Disconnect PWL1 window switch: UP and L70 No
A
Remedy
No
---
Defective contact or disconnection in wiring harness between PWL1 (male) - CL4(1) - L70 (female)(3)
Repair or replace
Defective power window motor
Replace
Defective contact or disconnection in wiring harness between L70 (female)(2) - CL1(12) chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between L41 (female)(5) and L70 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between FS8 (male)(1) and L70 (female)(5)
Repair or replace
Defective contact or disconnection in wiring harness between L41 (female)(1) and FS8 (male)(1)
Repair or replace
Defective switch L41
Replace
WA700-3L
TROUBLESHOOTING 12 ★ ★ ★ ★
E-14
Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuse (12) is not blown.
B. WINDOW DOES NOT GO DOWN (This troubleshooting flowchart shows the troubleshooting procedure for the left power window) Cause 4
Yes
Yes Is resistance between L75 (female)(6) and 3 chassis normal? Yes Is resistance between PWL1 (male) and L70 (female)(3) normal? 2 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect PWL1 and L70
Yes Is voltage between PWL2 and chassis normal? 1. 20 - 30 V 2. Turn starting switch ON 3 Left power window switch: DOWN
1 Is there continuity between PWL1 (female) and PWL2 (male)?
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L70 and L75
No
No
6
1. Turn starting switch OFF 2. Disconnect PWL1 and PWL2
No
Remedy
Defective relay L70
Replace
Defective contact or disconnection in wiring harness between L70 (female)(6) - CL1(12) chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between PWL1 (male) - CL4(2) - L70 (female)(3)
Repair or replace
Defective relay L75
Replace
Yes
5 Yes Does condition become normal when relay is Is resistance between replaced? PWL2 (male) and L75 (female)(3) 1. Replace L75 left normal? DOWN relay with L77 right DOWN 1. Max. 1 Ω relay 2. Turn starting 2. Turn starting switch OFF switch ON 3. Disconnect PWL2 3.Left power and L75 window switch: DOWN
Go to A
---
Defective contact or disconnection in wiring harness between PWL2 (female) - CL4(2) - L75 (female)(3)
Repair or replace
Defective power window motor
Replace
Defective contact or disconnection in wiring harness between L75 (female)(2) - CL1(12) chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between L41 (female)(6) and L75 (female)(1)
Repair or replace
Defective contact or disconnection in wiring harness between FS8 (male)(1) and L75 (female)(5)
Repair or replace
Defective contact or disconnection in wiring harness between L41 (female)(1) and FS8 (male)(1)
Repair or replace
Defective switch L41
Replace
No
No Yes
7
From
A
Is voltage between L75 (female)(1) and chassis normal?
10 Yes Is voltage between L75 (female)(5) and chassis normal? 9
1. 20 - 30 V 2. Disconnect L75 3. Turn starting switch ON 4. Left power window switch: DOWN
Yes Is voltage between L41 (female)(1) and 8 chassis normal?
No
Is resistance between L41 (male)(1) and (6) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L41 4. Left power window switch: DOWN
WA700-3L
Yes
1. 20 - 30 V 2. Disconnect L75 3. Turn starting switch ON
1. 20 - 30 V 2. Disconnect L41 3. Turn starting switch ON NO
No
No
20-365 1
TROUBLESHOOTING
E-14
12 E-14 Related electrical circuit diagram
20-366 1
WA700-3L
TROUBLESHOOTING
E-15
12 E-15 ABNORMALITY IN FRONT WORKING LAMP ★ Go to Troubleshooting M-8.
E-16 ABNORMALITY IN REAR WORKING LAMP ★ Go to Troubleshooting M-9.
E-17 ABNORMALITY IN TRANSMISSION CUT-OFF ★ Go to Troubleshooting M-10.
E-18 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ★ Go to Troubleshooting M-l 1, M-12.
E-19 ABNORMALITY IN BUZZER ★ Go to Troubleshooting M-13.
WA700-3L
20-367 1
TROUBLESHOOTING
E-19
12
MEMORANDUM
20-368 1
WA700-3L
TROUBLESHOOTING OF ELECTRIC ENGINE THROTTLE & APS CONTROLLERS (G MODE) 2 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS . . . . . . . . . . . 20-403 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-405 ACTION TAKEN BY CONTROLLER AND CONDITIONS FOR RESETTING WHEN ABNORMALITY OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412 JUDGEMENT TABLE FOR ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414 G-1 [90] [OFF or 101] ABNORMALITY IN POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-415 G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-415 G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416 G-4 [90] [56] ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM . . . . . . . . . . 20-416 G-5 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 20-417 G-6 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418 G-7 [91] [14] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419 G-8 [91] [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420 G-9 [91] [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421 G-10 [91] [1d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422 G-11 [92] [12] ABNORMALITY IN RACK SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-423 G-12 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . 20-424 G-13 [93] [1b] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 20-425 G-14 [94] [1c] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 20-426 G-15 [93, 94] [1b, 1c] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM . . . . . . . . . . . . . . . . 20-427 G-16 [95] [40] ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM . . . . . . . . . . . . . . . . . . 20-427 G-17 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428 G-18 [99] [22] ENGINE OVERRUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430 G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430 G-20 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432 G-21 ENGINE DOES NOT STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435 G-22 DEFECTIVE ACTUATION OF APS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436 A. PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE ALSO OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436 B. 1. PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20°C WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY) . . . 20-438 B. 2. PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20°C WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY) . . . 20-438 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438 D. APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439 E. APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439 F. APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440 G. APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
WA700-3L
20-401➀
TROUBLESHOOTING H. APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) GIVES ABNORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-441 I. APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-441
20-402 1
WA700-3L
TROUBLESHOOTING
JUDGEMENT TABLE
12 JUDGEMENT TABLE
Difficulty in starting engine
Engine stopped during operation Engine lacks power, acceleration is poor Engine speed stays at low idling, does 1 not change when accelerator pedal is 2 depressed 1 Engine accelerates to high idling 2
Controller solenoid power source system
Controller back-up power source system
Controller switch poser source system
Failure code Engine does not start
90 10 LED built into controller (OFF) ● Exhaust smoke comes out but engine does not 1 start, difficult to start ● 2 No exhaust smoke comes out
Controller connection system
Failure code displayed by monitor
Controller system
Error code
Controller power source system
ENGINE CONTROLLER AND ENGINE RELATED PARTS
90
90
90
90
90
a b
11
21
56
58
59
c
●
●
●
●
d e
●
●
Exhaust gas is normal (operator’s judgement)
f g h i
Exhaust smoke is abnormally black
j
Accelerated at same time as abnormality display Accelerated while abnormality display was showing change in low idling speed does not match operation 1 Exhaust gas is normal (operator’s judgement) High fuel consumption 2 Exhaust smoke is abnormally black Engine speed does not change to high 1 Does not reach high idling idling 2 Reaches high idling but returns to low idling Defective automatic warming-up operation 1 Engine continues to run at high speed Engine does not stop Engine continues to run at low idling even when 2 starting switch is turned OFF 1 Engine rotation is unstable at low idling There is hunting of engine 2 Engine rotation is unstable at high idling High oil consumption or exhaust smoke is blue Oil becomes dirty quickly Oil in cooling water Oil pressure lamp lights up Oil level raises Water temperature rises too high (overheating) Abnormal noise is generated Excessive vibration Trouble shooting code when abnormality display is given G1 G2 G3 ●: Check the error code display. If there is no display, go to the right side; if there is a display, go to bottom.
WA700-3L
●
k l m n o p q r s t
G4
G5
G6
u v w x y z aa bb cc dd ee
20-403 1
TROUBLESHOOTING
JUDGEMENT TABLE
19 1d
12
18
97
99
31
22
Governor servo system
Engine does not start
14 16
94
Engine overrun
c
93 95 94 1b 1b 1c 40 1c ● ● ● ● 93
Accelerator sensor system
92
Water temperature sensor system
92
Engine speed sensor A, B system
91 91
Engine speed sensor B system
Rack sensor system
91 91
Engine speed sensor A system
Pre-stroke solenoid system
b
Governor cut relay system
a
Governor solenoid system
Rack sensor power source system
12
Troubleshooting code if no abnormality display is given
● ● ● ● See engine shop manual d e ● ● ● See engine shop manual f ● ● ● g See engine shop manual h ● ● ● ● ● See engine shop manual i G17 ● ● j See engine shop manual k ● ● --l ● G17 m n See engine shop manual o ● See engine shop manual p ● ● ● ● ● G13, G14, G17 q ● --r ● --s G21 t u See engine shop manual v ● w See engine shop manual x See engine shop manual y See engine shop manual z See engine shop manual aa See engine shop manual bb See engine shop manual cc See engine shop manual dd See engine shop manual ee G7 G8 G9 G10 G11 G12 G13 G14 G15 G16 G17 G18 G19 ●: Check the error code display. If there is no display, go to the right side; if there is a display, go to bottom.
20-404 1
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12 CONTROLLER ACTIONS DURING ABNOMALITY
Main Engine monitor controller error code error code
System with abnormality
Nature of abnormality
90
10
Abnormality in power source system
1. Occurs at same time as 58 and 59.
90
11
Abnormality in controller system
1. Defective engine controller.
90
21
Mistaken connection of connector
1. Disconnection in wiring harness between controller EC5A (1) GND (chassis ground). 2. Defective engine controller. 1. Defective contact or disconnection inside governor cut relay.
90
56
Abnormality in controller solenoid power source system
2. Defective contact or disconnection in wiring harness between starting switch ACC terminal - governor cut relay. 3. Short circuit with ground, defective contact or disconnection in wiring harness between governor cut relay - controller EC2 (1). 4. Defective engine controller. 1. Back-up power voltage has dropped more than 5V from switch power voltage.
90
58
Abnormality in controller back-up power source system
2. Short circuit with ground, defective contact or disconnection in wiring harness between fuse box - controller EC1 (7). 3. Defective contact or disconnection in wiring harness between controller EC1 (16) - chassis ground. 4. Defective engine controller. 1. Switch power voltage has dropped more than 5V from back-up power voltage.
90
59
Abnormality in controller switch power source system
2. Short circuit with ground, defective contact or disconnection in wiring harness between fuse box - controller EC1 (9)(17). 3. Defective contact or disconnection in wiring harness between controller EC1 (8)(16) - chassis ground. 4. Defective engine controller. 1. Short circuit, short circuit with ground, defective contact or disconnection inside governor control solenoid. 2. Short circuit with ground, short circuit with power source, defective contact or disconnection in wiring harness between controller EC2 (7) governor control solenoid CNE12 (2) (No. 1 (+) end).
91
14
Abnormality in governor solenoid system
3. Short circuit with ground, short circuit with power source, defective contact or disconnection in wiring harness between controller EC2 (4) - governor control solenoid CNE15 (2) (No. 2 (+) end). 4. Short circuit with ground, short circuit with power source, defective contact or disconnection in wiring harness between controller EC2 (17) - governor control solenoid CNE12 (1) (No. 1 (-) end). 5. Short circuit with ground, short circuit with power source, defective contact or disconnection in wiring harness between controller EC2 (15) - governor control solenoid CNE15 (1) (No. 2 (-) end). 6. Defective engine controller.
WA700-3L
20-405 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
Condition when normal (voltage, current, resistance) Same as 58 and 59.
Action by controller when abnormality is detected 1. Stops engine.
1. Stops engine.
Voltage between EC5A (1) chassis: Less than 0.5 V
1. Normal control (when operating). 2. Stops engine (when engine is started).
Voltage between EC2 (1) chassis: 20 - 30 V
1. Engine stops. ★ If the abnormality is restored by the vibration of the machine, it resets automatically.
Voltage between EC1 (7) (16): 20 - 30 V
1. Operates under normal control. ★ If the abnormality is restored by the vibration of the machine, it resets automatically.
Problem that appears on machine when there is abnormality 1. Engine stops during operation. 2. Engine cannot be started. 1. Engine stops during operation. 2. Engine cannot be started. 1. When traveling: same condition is maintained. 2. When starting: engine cannot be started.
1. Engine stops during operation. 2. Engine cannot be started.
1. Operates under normal control. Voltage between EC1 (9)(17) - ★ If the abnormality is restored by the (8)(16): 20 - 30 V vibration of the machine, it resets automatically.
1. Engine stops during operation. Solenoid resistance value: 10 - 1. Sets output to governor control solenoid to 2. Engine cannot be started. 21 Ω 0 (stops engine).
20-406 1
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
Main Engine monitor controller error code error code
System with abnormality
Nature of abnormality 1. Defective contact or disconnection inside governor cut relay. 2. Short circuit with ground, defective contact or disconnection in wiring harness between starting switch ACC terminal - governor cut relay.
91
16
Abnormality in governor cut relay system
3. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC1 (4) - governor cut relay. 4. Short circuit inside governor cut relay. 5. Short circuit with power source in wiring harness between controller EC1 (4) - governor cut relay. 6. Defective engine controller 1. Defective governor control solenoid system or rack sensor system (governor command value and rack sensor signal do not match).
91
19
Abnormality in governor servo system
2. Abnormality in solenoid power source system 3. Defective engine controller 4. Defective part related to fuel injection pump 1. Short circuit, short circuit with ground, defective contact or disconnection inside pre-stroke control solenoid. 2. Defective contact or disconnection in wiring harness between controller EC2 (9) - pre-stroke control solenoid CNE18 (2) ((+) pin).
91
1d
Abnormality in pre-stroke solenoid system
3. Defective contact or disconnection in wiring harness between controller EC2 (19) - pre-stroke control solenoid CNE18 (1) ((-) pin). 4. Short circuit with ground, short circuit with power source in wiring harness between controller EC2 (9) - pre-stroke control solenoid CNEl8 (1) ((+) pin). 5. Short circuit with power source in wiring harness between controller EC2 (19) - pre-stroke control solenoid CNE18 (2) ((-) pin). 6. Defective controller. 1. Defect inside rack sensor.
92
12
Abnormality in rack sensor system
2. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (7) - rack sensor CNE14 (3) ((+) pin). 3. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (17) - rack sensor CNE14 (4) ((-) pin). 4. Defective engine controller. 1. Defect inside rack sensor.
92
18
Abnormality in rack sensor power source system
2. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC2 (16) - rack sensor CNE14 (1) 3. Defective contact or disconnection in wiring harness between rack sensor CNE14 (2) - chassis ground. 4. Defective engine controller.
WA700-3L
20-407 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
Condition when normal (voltage, current, resistance)
Solenoid resistance value: 200 - 900 â&#x201E;Ś
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. Operates under normal control.
1. Engine stops during operation. 2. Engine cannot be started.
1. Engine stops.
1. Engine stops during operation. 2. Engine cannot be started.
Solenoid resistance value: 10 - 21 â&#x201E;Ś
1. Sets output to pre-stroke control solenoid to 0. 2. Operates with restricted output
1. Feels that there is lack of power during operation. 2. Engine does not pick up smoothly. 3. Amount of black smoke increases. 4. Starting performance is poor.
Voltage between ECSA (7) (17): 0.1 - 4.5 V
1. Operates under open control. (limits output)
1. Feels that there is lack of power during operation. 2. Engine does not pick up smoothly. 3. Starting performance is poor.
Voltage between EC2 (16) chassis: 4.6 - 5.4 V
1. Operates under open control. (limits output)
1. Feels that there is lack of power during operation. 2. Engine does not pick up smoothly. 3. Starting performance is poor.
20-408 1
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12 Main Engine monitor controller error code error code
System with abnormality
Nature of abnormality 1. Defect inside engine speed sensor A or defective adjustment.
93
1b
Abnormality in engine speed Sensor A system
2. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (2) - engine speed sensor A - CNE13 (1). 3. Defective contact or disconnection in wiring harness between engine speed sensor A - CNE13 (2) - chassis ground 4. Defective engine controller. 1. Defect inside engine speed sensor B or defective adjustment.
94
1c
2. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (3) - engine speed sensor Abnormality in engine speed sensor B system B - CNE10 (1). 3. Defective contact or disconnection in wiring harness between engine speed sensor B - CNE10 (2) - chassis ground.
93 94
1b 1c
Abnormality in engine speed sensor A, B system
4. Defective engine controller. 1. 1b and 1c occur at same time. 1. Short circuit, defective contact or disconnection inside water temperature sensor.
95
40
Abnormality in engine water temperature sensor system
2. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3B (9) - water temperature sensor CNE11 (1) (signal end). 3. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (16) - water temperature sensor CNE11 (2) (GND end). 4. Defective engine controller. 1. Short circuit, defective contact or disconnection inside accelerator sensor. 2. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (6) - accelerator sensor CNL13 (3) ((+) end).
97
31
Abnormality in accelerator sensor system
3. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3A (16) - accelerator sensor CNL13 (2) ((-) end). 4. Short circuit with ground, defective contact or disconnection in wiring harness between controller EC3B (11) - accelerator sensor CNL13 (1) (signal end).
99
WA700-3L
22
Engine overrun
5. Defective engine controller. 1. Engine speed exceeded operating range.
20-409 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12 Condition when normal (voltage, current, resistance)
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. Operates with restricted output.
1. Feels that there is lack of power during operation. 2. Engine does not pick up smoothly. 3. Engine stops during operation and cannot be started again.
Sensor resistance value: 500 - 1000 Ω
1. Operates with restricted output.
1. Feels that there is lack of power during operation. 2. Engine does not pick up smoothly. 3. Engine stops during operation and cannot be started again.
Same as lb and lc.
1. Stops engine.
1. Engine stops during operation. 2. Engine cannot be started.
Resistance value between EC3B (9) - EC3A (16): Below several Ω or infinity is abnormal
1. Operates under normal control. ★ If the abnormality is restored by the vibration of the machine, it resets automatically.
Sensor resistance value: 500 − 1000 Ω
1. Does not carry out warming-up operation. 2. Does not stop warming-up operation.
Voltage between EC3A (6) 1. Low idling operation (16) (power source): 4.6 - 5.4 V ★ If the abnormality is restored by the vibration of the machine, it resets Voltage between EC3B (11) automatically. EC3A (16) (signal): 0.5 - 4.4 V
1. Sets fuel injection amount to 0. ★ If the abnormality is restored by the vibration of the machine, it resets automatically.
20-410 1
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS FOR RESETTING ABNORMALITY
12 CONTROLLER ACTIONS FOR RESETTING ABNORMALITY
Failure code Monitor Engine panel controller
System with abnormality
11
Abnormality in power source system Abnormality in controller system
21
Mistaken connection of connector
10
90 56 58 59 14 16 91 19 1d 12 92
18
93
1b
94
1c
93, 94
1b, 1c
95
40
97
31
99
22 00
WA700-3L
Abnormality in solenoid power source system Abnormality in back-up power source system Abnormality in switch power source system Abnormality in governor solenoid system Abnormality in governor cut relay system Abnormality in governor servo system Abnormality in pre-stroke solenoid system Abnormality in rack sensor system Abnormality in rack sensor power source system Abnormality in engine speed sensor A system Abnormality in engine speed sensor B system Abnormality in engine speed sensor A, B system Abnormality in engine water temperature sensor system Abnormality in accelerator sensor system Engine overrun Normal
Action by controller when abnormality is detected
Conditions for resetting
Stops engine
Power source in normal range
Stops engine When traveling: same condition is maintained When stopped: engine cannot be started
Turn on power again
Engine stops
Turn on power again
Normal operation
Power source in normal range
Normal operation
Power source in normal range
Engine stops
Turn on power again
Normal operation
Turn on power again
Engine stops
Turn on power again
Turn on power again
Pre-stroke OFF + 20% reduction in Turn on power again fuel Open loop control Turn on power again Open loop control
Turn on power again
Output restricted 50%
Turn on power again
Output restricted 50%
Turn on power again
Stops engine
Input rotation
Normal operation
Power source in normal range
Low idling
Power source in normal range
No injection
Below 1500 rpm
20-411 1
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING 1.
Points to remember if abnormality returns to normal by itself: If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure, and the error code is no longer displayed, or if the monitor display returns to normal, the abnormality has probably returned to normal. However, there is a high probability that the same problem will occur again, so it is desirable to follow up this problem carefully.
2.
Handling error code: A. For details of the abnormality, in addition to the main monitor display, it is necessary to check the LED display built into the engine controller before carrying out troubleshooting. (The main monitor error code shows a large system category, so it is necessary to check the code on the LED display built into the engine controller to check the detailed category.) B. The engine controller error code stores the errors that have occurred in the past, so pay careful attention to the display pattern below when proceeding with the troubleshooting operation. C. After completing troubleshooting, erase all the error codes from the engine controller memory.
3.
Details of LED display built into engine controller: A. Display schedule After controller is turned ON 88 ➞ Checks LED ➞ XX ➞ XX ➞ XX ➞ XX Displays content of controller ➞ -- ➞ ➞ XX ➞ ... ➞ XX Displays errors in memory ➞ E ➞ XX ➞ E ➞ XX Displays existing errors ➞ 00 Displays when normal Checks LED: Displays content of controller:
Displays errors in memory:
Displays existing errors:
20-412 1
Displays 88 when checking LED Displays 88 when checking LED Displays content of engine controller program (displays codes for program) XX ➞ XX ➞ XX ➞ XX 2 digits * 4 Displays error codes in controller memory for errors that occurred in past XX ➞ . . . ➞ XX errors in memory are displayed Displays errors that are occurring now E ➞ XX displays E in front of the error code, displays number of occurrences Error display continues for 5 minutes even after condition causing error has been removed.If the condition is normal, 00 is displayed.
WA700-3L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
12 4. Controller
1. Case 2. Self-diagnostic display window 3. Print board
OUTLINE This receives the signals from the accelerator sensor, low idling selector switch, and other sensors and switches mounted on the machine. It then outputs the signals to control the fuel injection pump for the engine. The controller has a self-diagnostic function. If there is any abnormality, it sends the ON/ OFF signal to the main monitor and displays characters on the built-in segments.
WA700-3L
20-413 1
TROUBLESHOOTING
JUDGEMENT TABLE FOR ENGINE CONTROLLER
12
JUDGEMENT TABLE FOR ENGINE CONTROLLER
Display code for monitor panel G-1
90
Displays abnormality in controller system and power source system
Display code for LED built into controller 10
Abnormality in power source system
G-2
11
Abnormality in controller system
G-3
21
Mistaken connection of connector
G-4
56
Abnormality in solenoid power source system
G-5
58
Abnormality in back-up power source system
G-6
59
Abnormality in switch power source system
14
Abnormality in governor solenoid system
G-8
16
Abnormality in governor cut relay system
G-9
19
Abnormality in governor servo system
G-10
1d
Abnormality in pre-stroke solenoid system
12
Abnormality in rack sensor system
18
Abnormality in rack sensor power source system
G-7
91
G-11
92
Displays abnormality in governor and pre-stroke control system
Displays abnormality in rack sensor system
G-12 G-13
93
Displays abnormality in engine speed sensor A system
1b
Abnormality in engine speed sensor A system
G-14
94
Displays abnormality in engine speed sensor B system
1c
Abnormality in engine speed sensor B system
G-15
93, 94
G-16
95
G-17 G-18
Displays abnormality in engine speed sensor A, B system
1b, 1c
Abnormality in engine speed sensor A, B system
Displays abnormality in engine water temperature sensor system
40
Abnormality in engine water temperature sensor system
97
Displays abnormality in accelerator sensor system
31
Abnormality in accelerator sensor signal system
99
Displays engine overrun
22
Engine overrun
G-19 G-20
Engine does not start
G-21
Engine does not stop
20-414 1
WA700-3L
TROUBLESHOOTING
G-1
12 G-1 [90] [OFF OR 101] ABNORMALITY IN POWER SOURCE SYSTEM ★ If this abnormality occurs, carry out troubleshooting G-5 and G-6.
G-2 [90] [11] ABNORMALITY IN CONTROLLER SYSTEM ★ When the battery is normal. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 1
Remedy
Yes Defective controller
Is voltage between EC11(9) - (8), EC1(17) - (16) normal? 1. 20 - 30 V 2. Turn starting switch ON
No
Replace
Check wiring harness. For details, see section on abnormality in power source
---
G-2 Related electrical circuit diagram
WA700-3L
20-415 1
TROUBLESHOOTING
G-3
12
G-3 [90] [21] MISTAKEN CONNECTION OF CONNECTOR ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause
Is voltage between EC5A(1) and GND less than 0.5 V? 1. Turn starting switch ON 2. Disconnect CN5A 3. Check that CN3A(1) is OPEN (wiring harness is not connected)
Remedy
Defective controller
Replace
Defective contact or disconnection in wiring harness between EC5A (female)(1) and GND
Repair or replace
G-3 Related electrical circuit diagram
G-4 G-4 [90] [56] ABNORMALITY IN CONTROLLER SOLENOID POWER SOURCE SYSTEM ★ If this abnormality occurs, carry out troubleshooting G-7 and G-10.
20-416 1
WA700-3L
TROUBLESHOOTING
G-5
12 G-5 [90] [58] ABNORMALITY IN BACK-UP POWER SOURCE SYSTEM ★ Check that the fuse is not blown. If it is blown, check for a short circuit with the ground inside the controller and in the wiring harness between the fuse and the controller. ★ When the battery is normal. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause
Remedy
Yes 1 Is voltage between EC1 (7) and EC1 (16) normal?
Yes
1. 20 -30 V 2. Turn starting switch ON
2
No
Is voltage between CNFS2 (female) (11) and chassis normal?
Yes
1. 20 -30 V 2. Turn starting switch ON
3
No
Is voltage between CNFS3 (male)(6) and chassis normal? 1. 20 -30 V 2. Turn starting switch ON
4
No
Yes
Is voltage between CNLR5 (male) (1) and chassis normal? 1. 20 -30 V 2. Turn starting switch ON
No
Defective controller
Replace
Defective contact or disconnection in wiring harness between CNFS2 (female) (11) - EC1 (female)(7) or EC1 (female) (16) - battery terminal (-)
Repair or replace
Defective contact or disconnection in wiring harness between CNFS2 (male) (11) and CNFS3 (female) (6)
Repair or replace
Defective contact or disconnection in wiring harness between CNLR5 (male) (1) and battery terminal (+)
Repair or replace
Defective contact or disconnection in wiring harness between EC1 (female) (16) and battery terminal (-)
Repair or replace
G-5 Related electrical circuit diagram
WA700-3L
20-417 1
TROUBLESHOOTING
G-6
12
G-6 [90] [59] ABNORMALITY IN SWITCH POWER SOURCE SYSTEM ★ Check that the fuse is not blown. If it is blown, check for a short circuit with the ground inside the controller and in the wiring harness between the fuse and the controller. ★ When the battery is normal. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause
Remedy
Yes 1 Is voltage between EC1 (9) - (8). EC1 (17) - (16) normal? 1. 20 - 30 V 2. Turn starting switch ON
Defective controller
Replace
Defective contact or disconnection in wiring harness between CNFS7 (female) (1) - EC1 (female) (9), (17) or EC1 (female) (8). (16) - battery terminal (-)
Repair or replace
Defective contact or disconnection in wiring harness between CNFS7 (male) (1) and CN09 (female) (5)
Repair or replace
Defective contact or disconnection in wiring harness between CNL09 (male) (5) -starting switch - battery terminal (+)
Replace
Yes 2
No
Is voltage between CNFS7 (female) (1) and chassis normal? 1. 20 - 30 V 2. Turn starting switch ON
3 Yes
No
Is voltage between CNL09 (male) (5) and chassis normal? 1. 20 - 30 V 2. Turn starting switch ON
No
G-6 Related electrical circuit diagram
20-418 1
WA700-3L
TROUBLESHOOTING
G-7
12 G-7 [91] [14] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 3
Defective controller
Yes Is resistance between EC2 (female)(4), (7) - chassis and EC2 (female) (15), (17) chassis normal? 2
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect EC2
Yes Is resistance between EC2 (female)(4), (7) - (15), (17) normal?
1
4
No
Yes
Is voltage between EC1 (4) -chassis, between EC2 (1) and chassis normal?
5
1. 20 - 30 V 2. Turn starting switch ON
No
Is resistance between CNE12 (male)(1) and (2) normal? 1. 10 - 21 Ω 2. Turn starting switch OFF. 3. Disconnect CNE15 and CNEl2
Yes
Is resistance between CNE12 (male)(1) chassis and CNE12 (male) (2) - chassis normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect CNE12 and CNE15.
1. 10 - 21 Ω 2. Turn starting switch OFF. 3. Disconnect EC2
No
No
Replace
Short circuit with chassis ground in wiring harness between EC2 (female) (4). (7) - CNE15 (female) (2), Repair or replace CNEl2 (female) (2) or EC2 (female) (15). (17) CNE15 (female) (1). CNEl2 (female) 11) Defective governor solenoid
Replace
Defective governor solenoid or Defective contact or disconnection in wiring harness between EC2 (female) (4). (7) Repair or CNE15 (female1 (2). replace CNE12 (female) (2) or EC2 (female) (15). (17) CNE15 (female) (1). CNE12 (female) (1) Defective governor solenoid Go to G-8
No
Remedy
Yes
Replace
---
Between EC2 (female) (4), (7) - chassis Between EC2 (female) (15), (17) - chassis
Min. 1 MΩ
Engine controller Between CNE12 (female) - chassis
Min. 1 MΩ
Between CNE12 (female) (2) - chassis
G-7 Related electrical circuit diagram
WA700-3L
20-419 1
TROUBLESHOOTING
G-8
12
G-8 [91] [16] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM ★ Check that the fuse is not blown. If it is blown, check for a short circuit with the ground inside the controller and in the wiring harness between the fuse and the controller. ★ When the battery is normal. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause
Remedy
Yes Defective controller
2
1
Yes Is voltage between EC1 (4) and chassis normal?
Is voltage between EC2 (1) and chassis normal?
Yes
No
Is resistance between (1) and (2) inside relay normal?
1. 200 - 900 Ω 2. Turn starting switch OFF 4 Yes 3. Disconnect relay No
Is resistance between (3) and (6) inside relay normal? 1. MAX. 1 Ω 2. Turn starting switch OFF 3. Disconnect relay
Defective contact or disconnection in wiring harness Repair or between EC1 (female) (4) - relay - CNFS7 - power source replace
3
1. 20 - 30 V 2. Turn starting switch ON.
1. 20 - 30 V 2. Turn starting switch ON.
Replace
No
No
Defective governor cut relay
Replace
Defective contact or disconnection in wiring harness Repair or between EC2 (female) (1) - relay - CNFS7 - power source replace
Defective governor cut relay
Replace
G-8 Related electrical circuit diagram
20-420 1
WA700-3L
TROUBLESHOOTING
G-9
12 G-9 [91] [19] ABNORMALITY IN GOVERNOR SERVO SYSTEM â&#x2DC;&#x2026; Before carrying out troubleshooting, check that all the related connectors are properly inserted. â&#x2DC;&#x2026; Always connect any disconnected connectors before going on the next step. Cause 2
Defective fuel injection pump related part (see Engine Shop Manual)
voltage between Yes Is EC3A (7) and (17) normal? 1 Is voltage between EC2 (1) and chassis normal? 1. 20 - 30 V 2. Turn starting switch ON.
1. 0.1 - 4.5 V 2. Turn starting switch ON.
No
Remedy
Yes
No
---
Defective contact or disconnection in wiring harness between EC3A (female) (7), (17) - CNE14 (female) (3). (4)
Repair or replace wiring harness
Defective contact or disconnection in wiring harness between EC2 (female) (1) -governor cut relay
Repair or replace wiring harness
G-9 Related electrical circuit diagram
WA700-3L
20-421 1
TROUBLESHOOTING
G-10
12
G-10 [91] [1D] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 2
Defective controller
Yes Is resistance between EC2 (female) (9) and chassis normal? 1
1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect EC2
Is resistance between EC2 (female) (9) and (19) normal? 1. 10 - 21 Ω 2. Turn starting switch OFF 3. Disconnect EC2
3 Yes
No
4 Yes
No
Is resistance between CNE16 (male) (2) and chassis normal? 1. Max. 1 M Ω 2. Turn starting switch OFF 3. Disconnect CNE16.
Is resistance between CNE16 (male) (1) and (2) normal? 1. 10 - 21 Ω 2. Turn starting switch OFF 3. Disconnect CNE16
Remedy
Yes
No
No
Replace
Short circuit in wiring harness between EC2 (female) (9) - Repair or CNE16 (female) (2), (1) - EC2 (female) (19) replace
Defective pre-stroke solenoid
Replace
Defective contact or disconnection in wiring harness between EC2 (female) (9) - CNE16 (female) (2), (1) EC2 (female) (19)
Repair or replace
Defective pre-stroke solenoid
Replace
G-10 Related electrical circuit diagram
20-422 1
WA700-3L
TROUBLESHOOTING
G-11
12 G-11 [92] [12] ABNORMALITY IN RACK SENSOR SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause
Remedy
Yes 2 Yes Is voltage between EC3A(7) and (17) normal?
1
Yes
1. 0.1 - 4.5 V 2. Turn starting switch ON
Is voltage between EC2 (16) and EC3A (14) normal?
3
No
Is voltage between CNE14 (3) and (4) normal? 1. 0.l - 4.5 V 2. Turn starting switch ON 3. Disconnect EC3A No
1. 4.6 - 5.4 V 2. Turn starting switch ON
4
No
Replace
Defective contact or disconnection in wiring harness between EC3A (female) (7) - CNE14 (female) (3) or between EC3A (female) (17) CNE14 (female) (4)
Repair or replace
Defective rack sensor
Replace
Yes
Is resistance between CNE14 (female) (2) - (3), (2) - (4) normal? 1. 50 kΩ - 1 MΩ 2. Turn starting switch OFF 3. Disconnect CNE14 and EC3A.
Defective controller
No
Short circuit with chassis ground in wiring harness between EC3A (female) Repair or (7) - CNE14 (female) (3) replace or between EC3A (female) (17) - CNE14 (female) (4) Go to G-12
---
G-l 1 Related electrical circuit diagram
WA700-3L
20-423 1
TROUBLESHOOTING
G-12
12
G-12 [92] [18] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM ★ Before carrying out troubleshooting, check that all the related connector’s are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 3
Defective rack sensor
Yes Is voltage between CNE14 (female) (1) and (2) normal? 2 Yes Is voltage between EC2 (male) (16) and GND normal? 1 Is resistance between EC2 (female) (16) and EC3A (female) (14) normal?
1. 4.6 - 5.4 V 2. Turn starting switch ON 3. Disconnect EC2 and connect T-adapter to male end only
1. Min. 500 kΩ 2. Turn starting switch OFF 3. Disconnect EC2 and EC3A.
No
4
No
1. 4.6 - 5.4 V 2. Turn starting switch ON
Yes
Is resistance between CNE14 (male) (1) and (2) normal? 1. Min. 500 kΩ 2. Turn starting switch OFF. 3. Disconnect CNE14.
No
Remedy
Yes
No
Replace
Defective wiring harness between EC2 (female) or (16) - CNE14 (female) (1) Repair replace or EC3A (female) (14) CNE14 (female) (2)
Defective controller
Replace
Defective wiring harness between EC2 (female) or (16) - CNE14 (female) (1) Repair and between EC1 (female) replace (8) - CNE14 (female) (2)
Defective rack sensor
Replace
G-12 Related electrical circuit diagram
20-424 1
WA700-3L
TROUBLESHOOTING
G-13
12 G-13 [93] [1B] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 3
Yes
Yes Does condition become norman when speed sensor A 2 is adjusted? Yes Is resistance between EC3A (female) (2) and chassis normal? 1
1. See TESTING AND ADJUSTING 4
1. Min. 1 MΩ 2. Turn starting switch OFF No 3. Disconnect EC3A
Is resistance between EC3A (female) (2) and (14) normal? 1. 500 - 1000 Ω 2.Turn starting switch OFF 3. Disconnect EC3A
5 Yes
No
Is resistance between CNE13 (male)(1) and (2) normal? 1. 500 - 1000 Ω 2. Turn starting switch OFF 3. Disconnect CNE13
No
Defective adjustment of speed sensor A
---
Defective controller
Replace
Short circuit with chassis ground in wiring harness between EC3A (female) (2) - CNE13 (female) (l), (2) - EC3A (female) (14)
Repair or replace
Defective speed sensor A
Replace
Defective contact or disconnection in wiring harness between EC3A (female) (2) - CNE13 (female) (1), (2) - EC3A (female) (14)
Repair or replace
Defective speed sensor A
Replace
No Yes
Is resistance between CNE13 (male) (1) and chassis normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect CNE13
Remedy
No
G-13 Related electrical circuit diagram
WA700-3L
20-425 1
TROUBLESHOOTING
G-14
12
G-14 [94] [1C] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 3
Yes
Yes Does condition become norman when speed sensor B 2 is adjusted? Yes Is resistance between EC3A (female) (3) and chassis normal? 1
1. See TESTING AND ADJUSTING 4
1. Min. 1 MΩ 2. Turn starting switch OFF No 3. Disconnect EC3A
Is resistance between EC3A (female) (3) and (14) normal? 1. 500 - 1000 Ω 2.Turn starting switch OFF 3. Disconnect EC3A
5 Yes
No
Is resistance between CNE10 (male)(1) and (2) normal? 1. 500 - 1000 Ω 2. Turn starting switch OFF 3. Disconnect CNE10
No
Defective adjustment of speed sensor B
---
Defective controller
Replace
Short circuit with chassis ground in wiring harness between EC3A (female) (3) - CNE10 (female) (l), (2) - EC3A (female) (14)
Repair or replace
Defective speed sensor B
Replace
Defective contact or disconnection in wiring harness between EC3A (female) (3) - CNE10 (female) (1), (2) - EC3A (female) (14)
Repair or replace
Defective speed sensor B
Replace
No Yes
Is resistance between CNE10 (male) (1) and chassis normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect CNE10
Remedy
No
G-14 Related electrical circuit diagram
20-426 1
WA700-3L
TROUBLESHOOTING
G-15
12 G-15 [93, 94] [1B, 1C] ABNORMALITY IN ENGINE SPEED SENSOR A, B SYSTEM ★ If this abnormality occurs, carry out troubleshooting G-13 and G-14.
G-16 [95] [40] ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 1
Remedy
Yes
Is resistance between EC3B (female) (9) and EC3A (female) (16) normal? 1. Abnormal if resistance is below several Ω or infinity 2. Turn starting No switch OFF 3. Disconnect EC3A and EC3B
Yes 2 Is resistance between CNE11 (male)(1) and (2) normal? 1. Abnormal if resistance is below several Ω or infinity 2. Turn starting switch OFF 3. Disconnect CNE11
No
Defective controller
Replace
Short circuit, disconnection between EC3B (female) (9) CNE11 (female) (1) or between EC3A (female) (16) - CNE11 (female) (21)
Repair or replace
Defective water temperature sensor
Replace
G-16 Related electrical circuit diagram
WA700-3L
20-427 1
TROUBLESHOOTING
G-17
12
G-17 [97] [31] ABNORMALITY IN ACCELERATOR SENSOR SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause 2
Remedy
Yes
Yes Does voltage between EC3B(11) 1 and EC3A(16) change according to angle of accelerator Is voltage between pedal as shown in EC3A(6) and No Fig. 1? EC3A(16) normal? 1. Turn starting switch ON 2. Operate 1. 4.6 - 5.4 V accelerator pedal 2. Turn starting switch ON
3
Defective controller
Replace
Defective adjustment of accelerator sensor
Adjust (see TESTING and ADJUST ING)
Defective controller
Replace
Yes
On item 2, does voltage change but is outside specified value?
Go to A No
Yes 8
No
9
Is resistance between EC3A (female)(6) (16), (6) - chassis normal? 1. Between (6) No (16): 4.6 - 5.4 kΩ Between (6) chassis: Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect EC3A
Is resistance between accelerator sensor (male) (5V) and GND and resistance between accelerator sensor (male) (5V) and chassis normal?
Yes
1.Between (5V) GND: 4.6 - 5.4 kΩ Between (5V) chassis: Min. 1 MΩ 2. Turn starting switch OFF. 3. Disconnect sensor.
No
Short circuit in wiring harness between EC3A (female) (6) - CNLl3 or (female) (3) (5V), CNLl3 Repair (1) GND - EC3A (female) replace (16). contact with other wiring harness
Yes 5 Does voltage between accelerator Yes sensor (Sig) and GND change according to angle of accelerator pedal as shown in Fig. 1? 4
From
A
Is voltage between accelerator sensor (5V) - GND normal?
1. Turn starting switch ON 2. Operate accelerator pedal
1. 4.6 - 5.4 V 2. Turn starting switch ON
No
20-428 1
7
No
Does resistance between accelerator Yes sensor (Sig) and GND change according to angle of 6 accelerator pedal as shown in Fig 2? Is resistance between accelerator sensor (5V) - GND normal? 1. Turn starting switch OFF 2. Disconnect sensor 1. 4.6 - 5.4 kΩ 2. Turn starting switch OFF 3. Disconnect sensor No
Yes
No
Defective accelerator sensor
Replace
Defective contact or disconnection in wiring harness between EC3B (female) (11) and CNL13 (female) (Sig)
Repair or replace
Defective contact or disconnection in wiring harness between EC3B (female) (11) and CNL13 (female) (Sig)
Repair or replace
Disconnected accelerator Repair or sensor linkage or defective replace sensor
Defective accelerator sensor
Replace
Defective contact or disconnection in wiring harness between EC3A Repair or (female) (6) - CNL13 (female) (3) (5V), CNL13 replace (1) GND - EC3A (female) (16)
WA700-3L
TROUBLESHOOTING
G-17
12 G-17 Related electrical circuit diagram
WA700-3L
20-429 1
TROUBLESHOOTING
G-18
12
G-18 [99] [22] ENGINE OVERRUN Cause
Remedy
Carry out troubleshooting of abnorProblem probably caused by abnormality that occurred at mality the same time that occurred at the same time
Yes 1 Did any other abnormality occur at the same time?
for Problem probably caused by external abnormality and not Look other by electric engine throttle controller cause
No
G-19 ENGINE DOES NOT START (CONTROLLER RELATED ONLY) ★ When starting motor cranks but engine does not start. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause Yes
Carry out troubleshooting Problem probably caused by abnormality that is displayed of displayed abnormality
1 Is there any abnormality displayed? 2
No
Yes See engine shop manual
Is resistance between EC5B(4) and EC1(16) normal? 1. Min. 1 MΩ 2. Turn starting switch ON
Remedy
No
---
Defective fuel cut switch or APS assister or relay short circuit in wiring harness between EC5B(4) - relay - APS assister - fuel cut switch
Repair or replace
G-19 Related electrical circuit diagram
20-430 1
WA700-3L
TROUBLESHOOTING
G-19
12
MEMORANDUM
WA700-3L
20-431 1
TROUBLESHOOTING
G-20
12
G-20 ENGINE DOES NOT START ★ ★ ★ ★
Check that the fuse is not blown. (If it is blown, check for a short circuit with the ground in the circuit related to the fuse.) Check that the wiring harness between battery relay terminal B - battery (+) - battery (-) - chassis is connected securely. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. 4
Yes
a
Yes Is voltage between starting motor terminal B and chassis ground normal? 3 Yes
b
1. Turn starting switch ON 2. 20 - 30 V
No
6
7 Yes d
starting motor terminal R and chassis ground normal?
1. Turn starting switch ON ↔ START
5
Is voltage between alternator terminal R and chassis ground No normal?
1. Turn starting switch ON 2. Max. 1 V
1. Disconnect wiring 2. Turn starting switch ON 3. Max. 1 V
Is voltage between starting motor terminal C and chassis ground No normal?
8
Yes
1. Turn starting switch to START 2. 20 - 30 V
1. Turn starting switch to START 2. Disconnect CNL09 3. Max. 1 Ω
1. Turn starting switch OFF ↔ ON 10
9 Is voltage between battery relay t No terminal BR and chassis ground normal?
1. Turn starting switch OFF 2. Voltage: Min. 24 V 3. Specific gravity: Min. 1.26
1. Turn starting switch ON 2. 20 - 30 V
No
f
g No
Yes
h
Yes Is resistance between battery relay terminal E and chassis ground normal?
1
e
Is resistance between starting No switch terminal B and terminal C normal?
Yes Is sound of actuation heard from battery relay?
Are voltage and specific gravity of battery normal?
c
Yes Is voltage between
Is there sound of starting motor pinion engaging?
2
Yes
1. Turn starting switch ON 2. 20 - 30 V
i No
Yes
j
11 Is voltage between starting switch terminal BR and chassis ground No normal? 1. Turn starting switch ON 2. 20 - 30 V
12
Yes
Is resistance between starting No switch terminal B and terminal BR normal? 1. Turn starting switch to START 2. Disconnect CNL09 3. Max. 1 Ω
k
l No
m
No
20-432 1
WA700-3L
TROUBLESHOOTING
G-20
12
Cause
Remedy
a
b
Defective starting motor
Replace
Defective contact or disconnection in wiring harness between starting motor terminal B and battery relay termnal
Repair or replace
Defective starting motor
Replace
c
d
Short circuit with power source in wiring harness between Repair or starting motor terminal C - CNE22 - 25 (female)(2) or replace short circuit in diode CNE22 - 25
e Defective alternator
Replace
Defective contact or disconnection in wiring harness between starting switch terminal C and starting motor terminal C
Repair or replace
Defective starting switch
Replace
Defective battery relay
Replace
i
Defective contact or disconnection in wiring harness between battery relay terminal E and chassis ground
Repair or replace
j
Defective contact or disconnection in wiring harness between starting switch terminal BR and battery relay terminal BR
Repair or replace
k
Defective contact or disconnection in wiring harness between starting switch terminal B and battery relay terminal B
Repair or replace
Defective starting switch
Replace
Lack of battery capacity
Charge or replace
f
g
h
l
m
WA700-3L
20-433 1
TROUBLESHOOTING
G-20
12 G-20 Related electrical circuit diagram
20-434 1
WA700-3L
TROUBLESHOOTING
G-21
12 G-21 ENGINE DOES NOT STOP ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step. Cause Yes
Defective fuel injection pump or defective engine controller
1 Is voltage between EC1(9)(17) and chassis normal? 1. Max. 1 V 2. Turn starting switch OFF
2
No
Yes
Is resistance between starting switch terminal B and ACC terminal normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect connector connecting to controller
Remedy
No
See engine shop manual Replace
Short circuit in wiring harness between EC1(9) (17) Repair or - starting switch ACC replace terminal Defective starting switch
Replace
G-21 Related electrical circuit diagram
WA700-3L
20-435 1
TROUBLESHOOTING
G-22
12
G-22 DEFECTIVE ACTUATION OF APS ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step.
A. PREHEATING LAMP SWITCH DOES NOT LIGHT UP WHEN APS SWITCH IS ON (ALL APS CONTROLLER LEDS ARE ALSO OFF) ★ Carry out troubleshooting of the power system. ★ Check that the engine can be cranked (if the engine cannot be cranked, carry out troubleshooting G-19 and G-20 first). ★ Check that the fuse is normal. (If it is blown, check for a short circuit with the ground in the related circuits for the fuse). ★ Carry out troubleshooting with the APS switch ON. 2
Yes
Yes Is resistance between CNL71 (female)(1) and chassis ground 1 normal? Is voltage between CNL72 (1) and chassis ground normal?
1. Turn starting switch OFF 2. Disconnect CNL71 3. Max. 1 Ω
1. Turn starting switch ON 2. 20 - 30 V
a
b No
c
Yes
6 Yes 5
3
Yes Is there continuity between CNL82 (female)(2) and chassis ground?
When No-injection cranking (CNL82) is interchanged with other relay, No does voltage in item 1 become normal? 1. Turn starting switch ON 2. 20 - 30 V
d 7 Yes e
Is voltage between CNL82 (3) and chassis ground normal?
Is there continuity No between starting switch terminals B and ACC?
1. Turn starting switch ON 2. 20 - 30 V
1. Turn starting switch OFF 2. Disconnect CNL82
Yes
f No
1. Turn starting switch OFF
4
Yes
g No
Is voltage between CNL82 (1) and chassis ground normal? 1. Turn starting switch ON 2. 20 - 30 V
9
Yes
h
Yes Is there continuity between CNL09 8 (male)(3) and (4)? Is voltage between No CNL09 (female)(3) and chassis ground normal?
1. Turn starting switch OFF 2. Disconnect CNL09 3. Turn heater switch ON
i No
1. Turn starting switch ON 2. 20 - 30 V
j No
20-436 1
WA700-3L
TROUBLESHOOTING
G-22
12
Cause
Remedy
a
b
Defective APS controller
Replace
Defective contact or disconnection in wiring harness between CNL7l (female) (1) and chassis ground
Repair or replace
c Defective No-injection cranking relay for APS controller Replace d
Defective contact, disconnection. or short circuit with chassis ground in wiring harness between CNL82 (female) (6) and CNEC5B (female) (4)
e
Defective contact, disconnection or short circuit with or chassis ground in wiring harness between starting switch Repair replace terminal ACC and CNL82 (female) (3)
Repair or replace
f Defective starting switch
Replace
g
Defective contact or disconnection in wiring harness between CNL82 (female) (2) and chassis ground
Repair or replace
h
Defective contact or disconnection in wiring harness between CNL09 (female) (2) - CNL82 (female) (2)
Repair or replace
Defective heater switch
Replace
Defective contact or disconnection in wiring harness between fuse and CNL09 (female) (3)
Repair or replace
i
j
WA700-3L
20-437 1
TROUBLESHOOTING
G-22
12 B.
1. PREHEATING PILOT LAMP FLASHES WHEN WATER TEMPERATURE IS BELOW 20°C WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY) B. 2. PREHEATING PILOT LAMP LIGHTS UP WHEN WATER TEMPERATURE IS ABOVE 20°C WHEN APS SWITCH IS ON (CONTROLLER LEDS ALL GIVE NORMAL DISPLAY) ★ Carry out troubleshooting of the APS water temperature sensor system. ★ Check the engine water temperature. Remedy
Cause 2
Yes
Yes Is resistance between CNL71 (female) (2) and chassis ground 1 normal? Is resistance between CNE08 (male) and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect CNE08 3. Water temperature below 20°C: Max. 1 Ω 3. Water temperature above 20°C: Min. 1 MΩ
1. Turn starting switch OFF 2. Disconnect CNL71 3. Same as item 1
No
Defective APS controller
Repair
Defective contact, disconnection, or short circuit with chassis ground in wiring harness between CNL71 (female) (2) and CNE08 (female)
Repair or replace
Defective APS water temperature sensor
Replace
No
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) ★ Carry out troubleshooting of the starting motor signal (terminal C) system. ★ Check that the injection nozzle stop valve is open. Cause
Remedy
Yes Defective APS controller
1 Is voltage between CNL71(3) and chassis ground normal? 1. Turn starting switch to START 2. 20 - 30 V
2
No
Is voltage between starting switch terminal C and chassis ground normal?
Yes
No
Repair
Defective contact or disconnection in wiring harness Repair or between CN71 (female) (3) and starting switch terminal C replace
Defective starting switch
Replace
1. Turn starting switch ON 2. 20 - 30 V
20-438 1
WA700-3L
TROUBLESHOOTING
G-22
12 APS CONTROLLER LED 1 (SHORT CIRCUIT IN GLOW PLUG 1 SYSTEM) D. GIVES ABNORMAL DISPLAY
Cause 2 1 Yes Is resistance between CNL72 (female)(2) and chassis ground Is resistance normal? between glow plug 1 terminal and 1. Turn starting chassis ground switch OFF normal? 2. Disconnect CNL72 1. Turn starting 3. 0.8 - 1.3 Ω switch OFF 2. Disconnect plug No terminal 3. 0.8 - 1.3 Ω
Remedy
Yes
No
Defective APS controller
Repair
Short circuit with chassis ground in wiring harness between CNL72 (female) (2) and glow plug 1 terminal
Repair or replace
Defective glow plug 1
Replace
E. APS CONTROLLER LED 2 (DISCONNECTION IN GLOW PLUG 1 SYSTEM) GIVES ABNORMAL DISPLAY Cause 2 1 Yes Is resistance between CNL72 (female)(2) and chassis ground Is resistance normal? between glow plug 1 terminal and 1. Turn starting chassis ground switch OFF normal? 2. Disconnect CNL72 1. Turn starting 3. 0.8 - 1.3 Ω switch OFF 2. Disconnect plug No terminal 3. 0.8 - 1.3 Ω
WA700-3L
Remedy
Yes
No
Defective APS controller
Repair
Defective contact or disconnection in wiring harness between CNL72 (female) (2) and glow plug 1 terminal
Repair or replace
Defective glow plug 1
Replace
20-439 1
TROUBLESHOOTING
G-22
12 F.
APS CONTROLLER LED 3 (SHORT CIRCUIT IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY Cause 2 1 Yes Is resistance between CNL72 (female)(3) and chassis ground Is resistance normal? between glow plug 2 terminal and 1. Turn starting chassis ground switch OFF normal? 2. Disconnect CNL72 1. Turn starting 3. 0.8 - 1.3 Ω switch OFF 2. Disconnect plug No terminal 3. 0.8 - 1.3 Ω
Remedy
Yes
No
Defective APS controller
Repair
Short circuit with chassis ground in wiring harness between CNL72 (female) (3) and glow plug 2 terminal
Repair or replace
Defective glow plug 2
Replace
G. APS CONTROLLER LED 4 (DISCONNECTION IN GLOW PLUG 2 SYSTEM) GIVES ABNORMAL DISPLAY Cause 2 1 Yes Is resistance between CNL72 (female)(3) and chassis ground Is resistance normal? between glow plug 2 terminal and 1. Turn starting chassis ground switch OFF normal? 2. Disconnect CNL72 1. Turn starting 3. 0.8 - 1.3 Ω switch OFF 2. Disconnect plug No terminal 3. 0.8 - 1.3 Ω
20-440 1
Remedy
Yes
No
Defective APS controller
Repair
Defective contact or disconnection in wiring harness between CNL72 (female) (3) and glow plug 2 terminal
Repair or replace
Defective glow plug 2
Replace
WA700-3L
TROUBLESHOOTING
G-22
12 APS CONTROLLER LED 5 (SHORT CIRCUIT WITH GROUND IN NOZZLE) H. GIVES ABNORMAL DISPLAY
Cause 2
Is resistance between each nozzle and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect nozzle terminal 3. 3 - 5 Ω
1 Yes Is resistance between CNL72 (female)(4) and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect CNL72 3. 1.5 - 2.5 Ω
Remedy
Yes
No
Defective APS controller
Repair
Short circuit with chassis ground in wiring harness between CNL72 (female) (4) and each nozzle
Repair or replace
Defective nozzle (nozzle with defective resistance)
Replace
No
I. APS CONTROLLER LED 6 (DISCONNECTION IN NOZZLE) GIVES ABNORMAL DISPLAY Cause 2
Is resistance between each nozzle and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect nozzle terminal 3. 3 - 5 Ω
WA700-3L
Yes
1 Yes Is resistance between CNL72 (female)(4) and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect CNL72 3. 1.5 - 2.5 Ω
Remedy
No
Defective APS controller
Repair
Short circuit with chassis ground in wiring harness between CNL72 (female) (4) and each nozzle
Repair or replace
Defective nozzle (nozzle with defective resistance)
Replace
No
20-441 1
TROUBLESHOOTING
G-22
12 G-22 Related electrical circuit diagram
20-442 1
WA700-3L
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 12 POWER TRAIN H-1 MACHINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-503 H-2 MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES) . . . . . . . 20-504 H-3 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR . . . . . . . . . . . . . . . . . . . . . 20-505 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506 STEERING H-5 STEERING DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507 H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK] . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508 H-7 TURNING, RESPONSE OF STEERING IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-509 H-8 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK] . . . . . . . . . . . . 20-510 H-9 STEERING IS HEAVY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512 H-10 STEERING WHEEL SHAKES OR JERKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513 H-11 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK] . . . 20-514 H-12 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514 BRAKES H-13 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR . . . . . . . . . . . . . . . . . . . . 20-515 H-14 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG . . . . . . . . . . . . . . . . . . . . . . . . . . 20-517 H-15 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR . . . . . . . . . . . . . . . . . 20-518 H-16 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-519 WORK EQUIPMENT H-17 NEITHER BOOM NOR BUCKET MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520 H-18 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521 H-19 BOOM DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522 H-20 BOOM IS SLOW OR BOOM LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523 H-21 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT . . . . . . . . 20-524 H-22 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524 H-23 EXCESSIVE HYDRAULIC DRIFT OF BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525 H-24 BUCKET DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526 H-25 BUCKET IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527 H-26 EXCESSIVE HYDRAULIC DRIFT OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-528
WA700-3L
20-501â&#x17E;&#x20AC;
TROUBLESHOOTING 12
MEMORANDUM
20-502 1
WA700-3L
TROUBLESHOOTING
POWER TRAIN
12 POWER TRAIN
H-1 MACHINE DOES NOT START Ask the operator the following questions • Did the problem suddenly happen? Yes = Internal seizure, damage When this happened, was there any abnormal noise? Yes = Broken part Checks before troubleshooting • Is the oil level in the transmission case correct? • Is the monitor display correct? • Is the drive shaft broken?
Tank - Pump
Defective operation of solenoid valve
Breakage inside transmission
Defective shaft seal ring in (3rd) speed clutch circuit
Defective operation of solenoid valve
Breakage inside transmission
defective shaft seal ring in (3rd) speed clutch circuit
Defective (3rd) speed clutch (defective oil tightness)
Seized transmission clutch
Transmission
Torque converter
A
●: Items to confirm the cause
Remedy
X X
No.
Defective transmission clutch seal ring, groove
Deterioration, defective operation of pilot reducing valve spring
Defective operation of modulating valve, spool
Defective operation of modulating relief valve
Defective operation of modulating main relief valve
Defective pump
Air sucked in at suction side of pump
Causes
Problems
1
Abnormal noise comes from between pump and filter
2
Machine does not start in any speed range (item 1 normal)
3
Machine starts normally in certain speed range
4
When torque converter oil temperature rises, machine stops moving
5
Transmission relief pressure is low
6
Transmission modulation pressure is low - low at every speed range
7
Transmission modulation pressure is low - Becomes lower at certain speed range
8
Transmission modulation pressure is low - Indicator is unstable and fluctuates excessively
9
Lack of pilot pressure (items 5 - 8 are normal)
a
b
c
X d
●
X
X
e
f
X
X
X
X
g
h
i
j
●
●
●
●
●
●
●
●
●
●
X
X
X
X
k
l
m
n
●
●
●
●
●
●
X o
● ●
●
●
●
●
●
●
● ●
●
●
●
● ●
10 Torque converter relief valve pressure is low (items 5 - 9 are normal)
●
●
11 Torque converter outlet port pressure is low (items 5 - 9 are normal) Legend: X: Replace : Correct A: Adjust C: Clean
●
●
Remark Cause m is when the solenoid valve and oil pressure are normal but the valve spool does not move. Remark If the transmission clutch pressure is low but the cause cannot be found in the table above, there may be a crack in the valve or transmission.
WA700-3L
20-503 1
TROUBLESHOOTING
POWER TRAIN
12 H-2
MACHINE LACKS POWER OR SPEED WHEN TRAVELING (ALL SPEED RANGES)
Tank - Pump
---
Breakage inside torque converter (turbine rivet broken)
Defective operation of torque converter relief valve, deteriorated spring
Excessive leakage inside torque converter (defective seal ring, loose plug)
Defective pilot reducing valve
Deterioration, defective operation of modulation valve spring
Defective operation of transmission main relieve valve
Engine
Torque converter
A
●: Items to confirm the cause No.
Drop in performance of engine
Defective pump
Causes
Air sucked in at suction side of pump
Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage from the piping or valve joints? • Is there any dragging of the parking brake or service brake? Checking for abnormalities • Engine high idling speed • Torque converter stall speed • Machine travel speed • Transmission clutch (both high pressure and low pressure) • Pump outlet port pressure • Pilot reducing pressure
Remedy
X
Problems
a
b
●
●
c
X
X
d
e
●
●
X f
X
X
X
g
h
i
●
●
1
Abnormal noise comes from between pump and filter
2
Torque converter stall speed is low
3
Torque converter stall speed is high
4
Transmission main relief valve pressure is low
5
Transmission modulation pressure is low - Low at every speed range (item 2 abnormal)
●
6
Transmission modulation pressure is low - Indicator is unstable and fluctuate excessively
●
7
Pressure in pilot reducing pressure circuit is low (items 4 - 6 are normal)
8
Torque converter relief valve pressure is low (items 4 - 7 are normal)
●
●
●
9
Torque converter outlet port pressure is low (items 4 - 7 are normal)
●
●
●
● ●
20-504 1
●
● ●
●
10 Pieces of iron and aluminium stuck to strainer or transmission case 11 When oil temperature rises, modulating pressure drops Legend: X: Replace : Correct A: Adjust
●
● ●
C: Clean
WA700-3L
TROUBLESHOOTING
POWER TRAIN
12 H-3 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR
Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage from the piping or valve joints?
Problems
X a
X
X
c
d
e
●
●
●
●
●
Transmission modulating pressure is low when placed in any speed range
●
●
●
●
5
In item 4, indicator is unstable and fluctuates excessively
●
6
Torque converter oil temperature goes above operating range Legend: X: Replace : Correct A: Adjust
Abnormal noise comes from between pump and filter
●
2
There is time lag when transmission is placed in any speed range
3
Machine starts normally in certain speed range
4
WA700-3L
●
Defective transmission clutch seal ring, groove X
X
X
f
g
h
●
●
●
Transmission
b
1
Defective shaft seal ring in speed clutch circuit
No.
Remedy
Defective speed clutch defective oil tightness)
Tank - Pump
●: Items to confirm the cause
Defective operation of quick return valve spool
Blocked throttle hole in quick return valve
Deterioration, defective operation of modulating valve spring
Defective pump
Air sucked in at suction side of pump
Causes
●
C: Clean
20-505 1
TROUBLESHOOTING
TORQUE CONVERTER OIL TEMPERATURE IS HIGH Ask the operator the following questions. • Does oil temperature go up when torque converter is stalled and go down when torque converter is not stalled? Yes = Normal (incorrect selection of speed range) Checks before troubleshooting • Is oil level in transmission case correct? • Is filter clogged? Checking for abnormalities
Tank - Pump
●: Items to confirm the cause No.
Remedy Problems
1
Pump makes abnormal noise when oil temperature is low
2
High idling and low idling speeds are low
3
Transmission modulating pressure is low
4
Torque converter inlet port oil pressure is low
5 Torque converter outlet port oil pressure is low Legend: X: Replace : Correct A: Adjust
20-506 1
X a
X b
Oil leakage inside torque converter (defective seal ring), loose plug, pump (crack in turbine)
Defective operation of torque converter relief valve
If oil temperature is normal but oil temperature gauge on machine goes above operating range -> defective oil temperature gauge Air sucked in at suction side of pump
★
Causes
Defective pump
12 H-4
POWER TRAIN
Transmission
X
X
c
d
● ● ●
● ●
●
●
●
C: Clean
WA700-3L
TROUBLESHOOTING
STEERING
12 STEERING
H-5 STEERING DOES NOT TURN
X
X
Orbit-roll
Stop valve
X
X
X
X
X
e
f
g
●
●
No.
Problems
a
b
c
d
1
Steering wheel does not turn in both directions (left and right)
●
●
●
●
2
Steering wheel turns in one direction (left or right)
3
Steering wheel is heavy in both directions (left and right)
●
4
Work equipment moves
●
5
Work equipment does not move
●
●
6
Abnormal noise comes from around PTO
●
●
7
Abnormal noise comes from around PPC pump or hydraulic tank
8
When steering relief pressure is measured -- Oil pressure is low or zero in both directions (left and right)
9
When steering relief pressure is measured -- Oil pressure is low or zero in one direction (left or right)
Steering valve
●
Defective piston seal
PPC relief valve
Defective safety-suction valve
Defective actuation of steering spool
Defective actuation of demand spool
Defective stop valve
Remedy
Defective orbit-roll
Hydraulic pump
●: Items to confirm the cause
Defective PPC relief valve
Defective PPC pump
Causes Defective steering and switch pump
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken • Was there any abnormal noise when this happened? Where did the noise come from? Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct? • Is the steering shaft broken? • Is the stop valve stopper properly adjusted? • Has the safety bar been removed from the frame?
Cylinder
X
X
h
i ●
● ●
●
● ●
●
●
●
● ●
●
●
●
● ●
10 Measured orbit-roll output pressure is low or zero
●
●
●
11 When PPC valve (orbit-roll) basic pressure is measured -- Oil pressure is low
●
●
●
12 When PPC valve (orbit-roll) basic pressure is measured -- Oil ● pressure is zero Legend: X: Replace : Correct A: Adjust C: Clean
●
●
● ●
●
★ There is close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, also check the operation of the work equipment.
WA700-3L
20-507 1
TROUBLESHOOTING
STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]
●: Items to confirm the cause No. 1
Remedy Problems
X
X a
b
c
X
C X
X
d
e
f
g
●
●
Defective safety-suction valve
Defective actuation of steering spool
Defective actuation of demand spool
Steering valve
X
Defective piston seal
Stop valve
Valve
Cylinder
X
X
X
X
h
i
j
k
l
m
●
●
●
●
●
●
●
● ●
●
●
●
●
2
When steering mode switch is switched - Steering does not move (Joystick mode only)
3
When steering mode switch is switched - Steering does not move in either mode
●
●
●
●
4
Steering wheel does not turn in both directions (left and right) ●
●
●
●
5
Steering wheel turns only in one direction (left or right)
6
Steering wheel is heavy in both directions (left and right)
7
Steering wheel is heavy in one direction (left or right)
8
Work equipment moves
9
Work equipment does not move
●
●
● ●
●
●
● ●
● ●
●
●
●
●
●
●
● ●
●
12 When steering relief pressure is measured - Oil pressure is low ● or there is no pressure in both directions (left and right)
●
●
●
●
●
●
13 When steering relief pressure is measured - Oil pressure is low or there is no pressure in one directions (left or right)
● ●
●
●
●
●
15 When joystick solenoid valve output pressure is measured, oil ● pressure is found to be low or there is no oil pressure
●
●
●
16 When PPC valve (orbit-roll) basic pressure is measured - Oil pressure low
●
●
●
17 When PPC valve (orbit-roll) basic pressure is measured ● ● There is no oil pressure Legend: X: Replace : Correct A: Adjust C: Clean
●
●
●
●
●
11 Abnormal noise comes from around PPC pump or hydraulic tank
14 When orbit-roll output pressure is measured, oil pressure is found to be low or there is no oil pressure
Defective actuation of stop valve
Defective actuation of joystick solenoid valve
Clogged filter
Joystick
X
When steering mode switch is switched - Steering does not move (steering wheel mode only)
10 Abnormal noise comes from around PTO
Orbitroll
Defective 2-way restrictor valve
relief Hydraulic pump PPC valve
Defective Orbit-roll
Defective PPC relief valve
Defective PPC pump
Causes
Air sucked in at suction end of pump
Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken. • Was there any abnormal noise when this happened? Where did the noise come from? Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is the type of oil correct? • Is the steering shaft broken? • Is the stop valve stopper properly adjusted? • Has the safety bar been removed from the frame? • Is the operation of the steering and the steering mode switch correct?
Defective PTO
12 H-6
STEERING
●
● ●
● ●
●
★ There is close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, also check the operation of the work equipment.
20-508 1
WA700-3L
TROUBLESHOOTING
STEERING
12 H-7 TURNING, RESPONSE OF STEERING IS POOR
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Was there any symptom of difficulty in steering? Yes ➞ Wear of related equipment, defective seal Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct?
No. 1
Remedy
X
Problems Turning, response of steering is poor in both directions (left and right)
2
Turning, response of steering is poor in one directions (left or right)
3
Steering wheel is heavy in both directions (left and right)
4
Steering wheel is heavy in one directions (left or right)
5
Work equipment moves normally
6
Work equipment speed is low Abnormal noise comes from around PTO
Stop valve
X
X
X
X
X
X
h
i
j
k
●
●
●
X
X
a
b
c
d
e
f
g
●
●
●
●
●
●
●
●
Steering valve
●
Defective piston seal
orbit-roll
Defective safety-suction valve
Defective actuation of steering spool
Defective main relief valve
Defective actuation of demand spool
Defective actuation of stop valve
PPC relief valve
X
Cylinder
X l
X m ●
●
●
● ●
● ●
●
●
● Abnormal noise comes from around steering pump or ● ● hydraulic tank 9 Abnormal noise comes from around switch pump or hydraulic ● ● tank 10 When steering relief pressure is measured - Oil pressure is ● ● ● ● low or zero in both directions (left and right) When steering relief pressure is measured Oil pressure is 11 low or zero in one direction (left or right) 7
Defective orbit-roll
●: Items to confirm the cause
Defective PPC relief valve
Hydraulic pump
Defective switch pump
Defective steering pump
Defective PPC pump
Air sucked in at suction end of pump
Defective PTO
Causes
●
●
●
●
●
●
●
●
●
8
●
● ●
12 Measured orbit-roll output pressure is low
●
●
13 Measured PPC valve (orbit-roll) basic pressure is low Legend: X: Replace : Correct A: Adjust
●
●
●
● ●
●
C: Clean
★ There is close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, also check the operation of the work equipment.
WA700-3L
20-509 1
TROUBLESHOOTING
STEERING
12 H-8
TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK] Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Was there any symptom of difficulty in steering? Yes ➞ Wear of related equipment, defective seal Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct?
●: Items to confirm the cause
Remedy
No.
Problems
1
When steering mode switch is switched - Abnormality only in steering wheel mode
X a
b
X
X
X
c
d
e
X
X
C X
X
f
g
h
i
●
●
Joystick
Defective actuation of stop valve
Orbit-roll
Stop valve
X j
●
2
When steering mode switch is switched - Abnormality only in joystick mode
3
When steering mode switch is switched - Abnormality in both ● modes
●
●
●
●
●
●
4
Turning, response of steering is poor in both directions (left and right)
●
●
●
●
●
●
5
Turning, response of steering is poor in one directions (left or right)
6
Steering wheel is heavy in both directions (left and right)
7
Steering wheel is heavy in one directions (left or right)
8
Work equipment moves
9
Work equipment does not moves
10 Abnormal noise comes from around PTO
Defective actuation of joystick solenoid valve
PPC relief valve
Clogged filter
Defective orbit-roll
Hydraulic pump
Defective PPC relief valve
Defective switch pump
Defective steering pump
Defective PPC pump
Air sucked in at suction end of pump
Defective PTO
Causes
●
● ●
● ●
● ● ●
●
●
●
●
●
●
●
●
●
●
●
●
●
11 Abnormal noise comes from around steering pump or hydraulic tank
●
12 Abnormal noise comes from around switch pump or hydraulic tank
●
13 When steering relief pressure is measured - Oil pressure is low ● in both directions (left and right)
●
● ● ●
●
●
●
14 When steering relief pressure is measured - Oil pressure is low in one directions (left or right)
●
15 When orbit-roll output pressure is measured, oil pressure is found to be low
●
●
16 When joystick solenoid valve output pressure is measured, oil pressure is found to be low
●
●
17 When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found to be low Legend: X: Replace : Correct A: Adjust C: Clean
●
●
● ●
●
★ There is close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, also check the operation of the work equipment.
20-510 1
WA700-3L
No.
8
13 ●
6
●
●
5
●
14
WA700-3L 1
2 X X X X X
k l m n o p
3 ● ● ● ● ● ●
4 ● ● ● X
● Defective piston seal
Steering valve
Defective 2-way restrictor valve
Defective safety-suction valve
Defective actuation of steering spool
Defective main relief valve
Defective actuation of demand spool
TROUBLESHOOTING
Valve Cylinder
7 ● ● ●
● ●
●
STEERING
12
●: Items to confirm the cause
Causes
●
9 ●
10
11
12
●
●
15
16
17
20-511 1
TROUBLESHOOTING
STEERING IS HEAVY
Problems Steering is heavy in both directions (left and right)
2
Steering is heavy in one directions (left or right)
3
Steering is heavy even when joint between steering shaft and orbit-roll is disconnected
4
When steering relief pressure is measured - Oil pressure is low in both directions (left and right)
5
When steering relief pressure is measured - Oil pressure is low in one directions (left or right)
20-512 1
A: Adjust
Orbit-roll
Stop valve
Steering valve
Others
X
X
X
X
a
b
c
d
●
●
●
1
6 Measured orbit-roll output pressure is low Legend: X: Replace : Correct
Interference of steering wheel or steering shaft
No.
Remedy
Defective actuation of steering spool
●: Items to confirm the cause
Causes
Defective actuation of stop valve
Checking for abnormalities • Is the steering difficult to turn? Yes ➞ Go to H-7 • Measure the operating effort and turning speed, and check the STANDARD VALUE TABLE to see if they are normal. Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken • Was there previously any symptom, such as heavy steering? Yes ➞ Wear of related equipment, defective seal Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct? • Is the tire inflation pressure correct?
Defective orbit-roll
12 H-9
STEERING
● ● ●
● C: Clean
● ● ●
WA700-3L
TROUBLESHOOTING
STEERING
12 H-10 STEERING WHEEL SHAKES OR JERKS
Problems
X
X
X
X
X
a
b
c
d
e
f
●
●
●
●
●
2
Steering wheel shakes or jerks in one directions (left or right)
3
During operations or when traveling (when steering), steering wheel shakes or jerks in both directions (left and right)
4
During operations or when traveling (when steering), steering wheel shakes or jerks in one directions (left or right)
5
Steering wheel jerks or there is excessive shock when steering is operated to end of its stroke
6
Work equipment also jerks
●
7
When steering relief pressure is measured - Oil pressure is unstable in both directions (left and right)
●
8
When steering relief pressure is measured - Oil pressure is unstable in one directions (left or right)
9
When orbit-roll output pressure is measured - Oil pressure is unstable in both directions (left and right)
Steering valve
●
Defective piston seal
X
Defective safety-suction valve
Stop valve
Steering wheel shakes or jerks in both directions (left and right)
Cylinder
X g
X h ●
● ●
● ●
● ● ●
● ●
●
10 When orbit-roll output pressure is measured - Oil pressure is unstable in one directions (left or right)
WA700-3L
Defective actuation of steering spool
Orbit-roll
Defective main relief valve
PPC relief valve
1
11 When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found to be stable Legend: X: Replace : Correct A: Adjust C: Clean
Defective actuation of demand spool
Defective actuation of stop valve
No.
Remedy
Defective orbit-roll
●: Items to confirm the cause
Causes
Defective PPC relief valve
Checking for abnormalities • Is the steering difficult to turn? Yes = Go to H-7 • Is there any abnormal noise from around the steering equipment? Checks before troubleshooting • Is the steering wheel play correct? • Is there any abnormality in the connection between the steering shaft and the orbit-roll? • Is the tire inflation pressure correct?
●
●
● ●
● ●
●
20-513 1
TROUBLESHOOTING
STEERING
H-11 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]
X
X
X
X
X
X
a
b
c
d
e
f
g
●
●
●
●
●
●
●
When steering mode switch is switched - Abnormality only in joystick mode
3
When steering mode switch is switched - Abnormality only in both modes
●
4
Steering wheel shakes or jerks in both directions (left and right)
●
5
Steering wheel shakes or jerks in one directions (left or right)
6
During operations or when traveling (when steering), steering wheel shakes or jerks in both directions (left and right)
7
During operations or when traveling (when steering), steering wheel shakes or jerks in one directions (left or right)
8
Steering wheel jerks or there is excessive shock when steering is operated to end of its stroke
9
Confirm recent repair
●
● ●
X
i
j
●
●
● ●
●
● ●
●
●
● ● ●
●
●
● ●
●
●
●
● ●
●
● ●
●
15 When joystick solenoid output pressure is measured - Oil pressure is unstable in one directions (left or right) 16 When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found to be stable Legend: X: Replace : Correct A: Adjust C: Clean
X
h
●
13 When orbit-roll output pressure is measured - Oil pressure is unstable in one directions (left or right) 14 When joystick solenoid output pressure is measured - Oil pressure is unstable in both directions (left and right)
X
●
11 When steering relief pressure is measured - Oil pressure is unstable in one directions (left or right) 12 When orbit-roll output pressure is measured - Oil pressure is unstable in both directions (left and right)
Cylinder
Steering valve
●
2
10 When steering relief pressure is measured - Oil pressure is unstable in both directions (left and right)
Valve
Defective safety-suction valve
X
Defective actuation of steering spool
Stop valve
Defective main relief valve
Joystick
Defective actuation of demand spool
Orbit-roll
Defective piston seal
1
When steering mode switch is switched - Abnormality only in steering wheel mode
PPC relief valve
Defective 2-way restrictor valve
Problems
Defective actuation of stop valve
No.
Defective actuation of joystick solenoid valve
Remedy
Defective orbit-roll
●: Items to confirm the cause
Causes
Defective PPC relief valve
Checking for abnormalities • Is the steering difficult to turn? Yes = Go to H-8 • Is there any abnormal noise from around the steering equipment? Checks before troubleshooting • Is any failure code for the electrical system displayed on the main monitor? • Is the steering wheel play correct? • Is there any abnormality in the connection between the steering shaft and the Orbit-roll? • Is the tire inflation pressure correct?
● ●
●
H-12 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING Causes and Remedy • Defective adjustment of stop valve ( )
20-514 1
WA700-3L
TROUBLESHOOTING
BRAKES
12 BRAKES
PPC pump
●: Items to confirm the cause No.
Remedy Problems
X
X
Charge Accumulator valve
X
X
a
b
c
d
X e
Brake valve
Stack adjuster
Breakage inside brake
Defective brake piston seal
Defective slack adjuster
Defective right brake valve
Defective left brake valve
Defective piston seal or defective bleeding of gas from accumulator
Defective accumulator charge valve
Defective PPC pump
Air sucked in at suction end of pump
Defective PTO
Checking for abnormalities • Measure the actual brake performance, and check if there is actually an abnormality or whether it is just the feeling of the operator. For details, see TESTING AND ADJUSTING, “Measuring brake performance”. Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken. Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes ➞ Wear of related parts, defective seal . Checks before troubleshooting Causes • Is the oil level in the hydraulic tank correct? • Is the type of oil correct? • Is the brake pedal play correct? • Is there any leakage of oil from the brake tube? • Is there any deformation of the tube? • Are the tire inflation pressure and tread pattern correct?
Defective actuation of brake piston
H-13 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
Wheel brakes
X
X
X
X
X
X
f
g
h
i
j
k
●
1
Brake has no effect only when left brake pedal is depressed
2
Left brake pedal is light when it is depressed
●
●
●
●
3
Right brake pedal is light when it is depressed
●
●
●
●
4
Left brake pedal is heavy when it is depressed
5
Right brake pedal is heavy when it is depressed
6
Abnormally large operating force is needed to obtain specified braking force
7
Abnormal noise is heard from brake when brake is applied
8
Work equipment and steering do not work either
9
Movement of work equipment and steering is slow
●
●
●
●
●
● ● ●
●
●
●
● ●
●
● ●
●
●
●
●
●
●
●
10 Abnormal noise comes from around PTO 11 Abnormal noise comes from around hydraulic tank or PPC pump 12 Many metal particles are found in oil drained from axle case 13 Measured accumulator charge pressure is low
● ●
14 Braking effect is lost immediately after engine is stopped
●
15 There is time lag before brake takes effect
●
16 Measured brake oil pressure is low ●
17 Measured drop in brake piston pressure is excessive
●
18 Measured wear of brake disc is excessive 19 When air is bled from brake line, air comes out Legend: X: Replace : Correct
●
A: Adjust
C: Clean
★ The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of the work equipment and steering (the circuit set pressure is different).
WA700-3L
20-515 1
TROUBLESHOOTING
BRAKES
12
Wheel brakes
Others
X
X No.
l
Defective axle oil
Air in brake circuit
Wear of brake disc
Causes
m
n
1 2
●
3
●
4 5 6 7
●
●
8 9 10 11 12
●
13 14 ●
15 16 17 18
●
19
20-516 1
●
WA700-3L
TROUBLESHOOTING
BRAKES
12 H-14 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
Ask the operator the following questions. • Did the problem suddenly start? ➞ Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Checks before troubleshooting • Does the brake pedal come back fully? • Is the parking brake still applied?
Brake valve
●: Items to confirm the cause No. 1
Remedy Problems
Machine cannot travel at all
2
Machine can travel a small amount
3
When remaining pressure is released from brake accumulator circuit with left brake pedal only, brake is released
4
When remaining pressure is released from brake accumulator circuit with right brake pedal only, break is released
5
When air bleed plug in wheel portion is loosened, oil flows out and brake is released
6
When air bleed plug is loosened, a large amount of oil flows out
7
When wear of brake disc is measured and brake pedal is released, piston returns
8
When wear of brake disc is measured and brake pedal is released, piston does not return Legend: X: Replace : Correct A: Adjust C: Clean
WA700-3L
X
Slack adjuster
Seized brake disc, plate
Defective actuation of brake piston
Defective actuation of slack adjuster
Defective right brake valve
Defective left brake valve
Causes
Wheel brake
X
X
X
X
a
b
c
d
e
●
● ●
●
●
● ● ● ●
● ● ●
●
20-517 1
TROUBLESHOOTING
PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken. Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes ➞ Wear of related parts, defective seal.
SOL
●: Items to confirm the cause No. 1 2 3
4
Remedy Problems
X a
Parking brake does not work when engine is stopped
Parking brake
X
X
b
c
d
●
● ●
Measured parking brake disc thickness is less than specified value ● ●
When parking brake solenoid valve output pressure is measured - There is no oil pressure when parking brake switch is ON (normal) When parking brake solenoid valve output pressure is measured - There is oil pressure when parking brake switch is ON Legend: X: Replace : Correct A: Adjust C: Clean
20-518 1
X
●
When parking brake inlet port pressure is measured - There is no oil pressure when parking brake switch is ON (normal) When parking brake inlet port pressure is measured - There is oil pressure when parking brake switch is ON
Worn brake disc or pad
Defective actuation of parking brake piston
Defective parking brake solenoid valve
Causes
Defective brake spring
12 H-15
BRAKES
●
● ●
●
WA700-3L
TROUBLESHOOTING
BRAKES
12 H-16 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS
1
Remedy Problems
X a
X
b
c
d
●
●
●
When parking brake switch is OFF, oil leaks from spring cylinder or cylinder rod does not return to end
2
When parking brake switch is OFF, parking brake is not released
3
Spring cylinder operates normally and rod and lever return, but brake drags Legend: X: Replace : Correct A: Adjust
WA700-3L
X
C
●: Items to confirm the cause No.
X
Damage of parking brake linkage or wrong adjustment
If it is below 37 ± 5 kgf/cm 2 (526.2 ± 71.1 lbf/in2), the parking brake solenoid valve operates automatically to apply the parking brake.
Defective internal parts of parking brake (Flaked and caught pad)
Checking before troubleshooting • Is the brake circuit pressure in the specified range?
Defective internal parts of spring cylinder (Piston seal)
Defective internal parts of parking brake solenoid valve (Valve seat)
Causes
● C: Clean
20-519 1
TROUBLESHOOTING
WORK EQUIPMENT
12
WORK EQUIPMENT H-17 NEITHER BOOM NOR BUCKET MOVE Ask the operator the following questions. • Did the problem suddenly start? ➞ Related equipment broken. Was there any abnormal noise when this happened? Where did the noise come from? Checks before troubleshooting • Is the oil level in the hydraulic tank correct? Is the type of oil correct?
●: Items to confirm the cause No.
Remedy Problems
X
X
X
X
b
c
d
e
●
●
●
●
●
●
●
Steering also does not work
●
Abnormal noise comes from around PTO
●
Abnormal noise comes from around hydraulic tank or PPC pump Measured PPC valve output pressure is normal
5
Measured PPC valve (orbit-roll) basic pressure is low or zero Legend: X: Replace : Correct A: Adjust C: Clean
Control valve
a
2 3
PCC relief valve
X
1
4
Defective main relief valve
Hydraulic pump
Defective PPC relief valve
Defective PPC pump
Air sucked in at suction end of pump
Defective PTO
Causes
● ●
●
★ There is close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the work equipment, also check the operation of the steering.
20-520 1
WA700-3L
TROUBLESHOOTING
WORK EQUIPMENT
12 H-18 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes ➞ Wear of related parts, defective seal
No.
Remedy Problems
X
X
a
b
X
X
e
f
g
2
Boom and bucket movement takes approximately 3 times standard value
●
●
3
Steering works normally
●
●
4
Response of steering is also poor
●
●
●
5
Abnormal noise comes from around PTO
● ●
●
●
●
8
Measured PPC valve (orbit-roll) basic pressure is low Legend: X: Replace : Correct A: Adjust
X
X
d
●
Abnormal noise comes from around hydraulic tank or hydraulic pump
Steering valve
X
●
Measured PPC valve output pressure is normal
Control valve
c
Boom and bucket movement takes approximately 1.5 times standard value
6
PPC relief valve
X
1
7
Defective actuation of demand spool
●: Items to confirm the cause
Defective main relief valve
Hydraulic pump
Defective PPC relief valve
Defective switch pump
Defective Work equipment pump
Defective PPC pump
Air sucked in at suction end of pump
Defective PTO
Causes
●
h ●
● ● ● ●
●
●
● ●
●
●
C: Clean
★ There is close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the work equipment, also check the operation of the steering.
WA700-3L
20-521 1
TROUBLESHOOTING
BOOM DOES NOT MOVE
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
●: Items to confirm the cause No.
Remedy Problems
X a
X
X
X
X e
b
c
d
●
●
●
Defective control lever linkage
Defective suction valve
Defective unload valve
Control valve
Defective cylinder seal
PPC valve
defective actuation of load check valve
Defective PPC valve
Causes Defective actuation of boom spool
12 H-19
WORK EQUIPMENT
Boom
Others
X
A
f
g
●
●
1
Does not move in both directions (RAISE and LOWER)
2
Does not move in one direction (RAISE or LOWER)
3
When boom relief pressure is measured - Oil pressure is low or zero in both directions (RAISE and LOWER)
4
When boom relief pressure is measured - Oil pressure is low or zero in one direction (RAISE or LOWER)
5
Measured PPC valve output pressure is low or zero
●
●
6
Measured operating effort of boom control lever is heavy
●
●
7
Measured travel of boom control lever is short Legend: X: Replace : Correct
20-522 1
●
● ●
●
●
●
● ●
● A: Adjust
C: Clean
WA700-3L
TROUBLESHOOTING
WORK EQUIPMENT
12 H-20 BOOM IS SLOW OR BOOM LACKS POWER
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken. • Did the problem gradually appear? Yes ➞ Wear of related parts, defective seal
PPC valve
●: Items to confirm the cause No.
Remedy Problems
X a
1
Does not move in both directions (RAISE and LOWER)
2
Does not move in one direction (RAISE or LOWER)
3
When boom relief pressure is measured - Oil pressure is low or zero in both directions (RAISE and LOWER)
4
When boom relief pressure is measured - Oil pressure is low or zero in one direction (RAISE or LOWER)
●
5
Measured PPC valve output pressure is low
●
6
Measured hydraulic drift of boom is excessive
7
Measured operating effort of boom control lever is heavy
8
Measured travel of boom control lever is short Legend: X: Replace
WA700-3L
Control valve
X
X
X e
b
c
d
●
●
●
Defective control lever linkage
Cylinder Others
X
●
Defective cylinder seal
Defective suction valve
Defective Unload valve
Defective actuation of load check valve
Defective actuation of boom spool
Defective PPC valve
Causes
X
A
f
g
●
●
●
●
● ●
●
● ●
● ●
● ●
: Correct
A: Adjust
C: Clean
20-523 1
TROUBLESHOOTING
WORK EQUIPMENT
12 H-21
BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT
PPC valve
●: Items to confirm the cause No. 1 2 3 4 5
Remedy
X
Problems
a
When PPC valve output pressure is measured (boom control lever Oil pressure is normal at FLOAT position) Oil pressure is low When PPC valve output pressure is measured (boom control lever Oil pressure is normal at LOWER position) Oil pressure is low Measured travel of boom control lever is short Legend: X: Replace
Control valve
X
X
b
c
●
●
●
●
● ●
Defective control lever linkage
Defective actuation of unload valve
Defective actuation of float selector valve
Causes
Defective PPC valve
Ask the operator the following questions. • Did the problem suddenly start? Yes ➞ Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes ➞ Wear of related parts, defective seal. Checks before troubleshooting • Can other operations of boom (RAISE, HOLD, LOWER) be carried out normally?
Others
A d ● ● ●
: Correct
A: Adjust
C: Clean
H-22 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE Checking for abnormalities • With the engine running at low idling, if the boom control lever is gradually moved from HOLD to RAISE, the boom moves down momentarily under its own weight. • If the control lever is operated fully to the RAISE position, the condition becomes normal. Causes and Remedy • Defective throttling for control valve boom spool (C).
20-524 1
WA700-3L
TROUBLESHOOTING
WORK EQUIPMENT
12 H-23 EXCESSIVE HYDRAULIC DRIFT OF BOOM
Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken. • Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal
●: Items to confirm the cause
Remedy
No.
Problems
1
When boom control lever is operated in RAISE direction from boom maximum raise with engine stopped (See remark) - Hydraulic drift increases
2
When boom control lever is operated in RAISE direction from boom maximum raise with engine stopped (See remark) - No change in hydraulic drift Legend: X: Replace : Correct A: Adjust C: Clean
Defective oil tightness of boom spool
Defective piston seal
Causes
Control valve
Cylinder
X a
X b ●
●
Remark Before starting troubleshooting, the PPC accumulator must be charged, run the engine at low idling for 5 - 10 seconds, then stop the engine.
WA700-3L
20-525 1
TROUBLESHOOTING
BUCKET DOES NOT MOVE
Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken • Was there any abnormal noise when this happened? Where did the noise come from?
No.
Remedy Problems
X a
1
Does not move both directions (TILT and DUMP)
2
Does not move one direction (TILT or DUMP)
3
When bucket relief pressure is measured - Oil pressure is low or there is no pressure in both directions (TILT and DUMP)
4
When bucket relief pressure is measured - Oil pressure is low or there is no pressure in one direction (TILT or DUMP)
●
5
When PPC valve output pressure is measured, oil pressure is found to be low or there is no pressure
●
6
When operating effort of bucket control lever is measured, lever is found to be heavy
●
7
When travel of bucket control lever is measured, it is found to be short Legend: X: Replace : Correct A: Adjust
20-526 1
X
X
b
c
●
●
●
X d
Defective control lever linkage
Defective safety-suction valve
Control valve
Defective cylinder seal
PPC valve
●: Items to confirm the cause
Defective actuation of load check valve
Defective PPC valve
Causes Defective actuation of bucket spool
12 H-24
WORK EQUIPMENT
Cylinder
Others
X
A
e
f
●
●
●
●
● ●
● ●
●
● ●
C: Clean
WA700-3L
TROUBLESHOOTING
WORK EQUIPMENT
12 H-25 BUCKET IS SLOW OR LACKS POWER
Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken. • Was there any abnormal noise when this happened? Where did the noise come from? • Did the problem gradually appear? Yes = Wear of related parts, defective seal
No. 1
Remedy Problems
X a
Does not move in both directions (TILT and DUMP)
X
Does not move in one direction (TILT or DUMP) When bucket relief pressure is measured - Oil pressure is low or there is no pressure in both directions (TILT and DUMP)
4
When bucket relief pressure is measured - Oil pressure is low or there is no pressure in one direction (TILT or DUMP)
● ●
5
When PPC valve output pressure is measured, oil pressure is found to be low
6
When hydraulic drift or bucket is measured, it is found to be excessive
7
When operating effort of bucket control lever is measured, lever is found to be heavy
8
When travel of bucket control lever is measured, it is found to be short Legend: X: Replace : Correct A: Adjust
b
c
●
●
X d
Defective control lever linkage
Defective safety-suction valve
Defective actuation of load check valve X
●
2 3
WA700-3L
Control valve
Defective cylinder seal
PPC valve
●: Items to confirm the cause
Defective actuation of bucket spool
Defective PPC valve
Causes
Cylinder
Others
X
A
e
f
●
●
●
●
● ●
● ●
● ●
●
● ●
C: Clean
20-527 1
TROUBLESHOOTING
EXCESSIVE HYDRAULIC DRIFT OF BUCKET Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken. • Did the problem gradually appear? Yes = Wear of related parts, defective seal.
●: Items to confirm the cause
Remedy
No.
Problems
1
When bucket control lever is operated in DUMP direction with engine stopped (See remark) - Hydraulic drift increases
2
When bucket control lever is operated in DUMP direction with engine stopped (See remark) - No change in hydraulic drift Legend: X: Replace : Correct A: Adjust C: Clean
Defective piston seal
Causes Defective oil thightness of bucket spool
12 H-26
WORK EQUIPMENT
Control valve
Cylinder
X a
X b ●
●
Remark Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10 seconds, then stop the engine.
20-528 1
WA700-3L
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE) 12 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS . . . . . . . . . . . . . . . 20-603 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-604 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 20-608 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616 J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20-618 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619 J-12 DISCONNECTION IN STEERING LEFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
WA700-3L
20-601â&#x17E;&#x20AC;
TROUBLESHOOTING 12
MEMORANDUM
20-602 1
WA700-3L
TROUBLESHOOTING
JUDGEMENT TABLE
12 JUDGEMENT TABLE
FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS
Abnormality in joystick ON-OFF signal system
Abnormality in power source, voltage
Short circuit, disconnection in joystick potentiometer
Short circuit, disconnection in joystick steering neutral switch
Short circuit, disconnection in steering solenoid cut relay output
Short circuit in steering left solenoid (HOT end)
Short circuit in steering right solenoid (HOT end)
Short circuit in steering left solenoid (detected when output)
Short circuit in steering right solenoid (detected when output)
Short circuit, disconnection in joystick caution relay output
Location of failure Self-diagnostic display (abnormality display)
Troubleshooting code when no abnormality display is given
Transmission & joystick steering controller
●: Items to confirm the cause No.
Failure code
Failure mode
1
Alarm buzzer does not stop
2
Steering does not turn to left
3
Steering does not turn to right
4
Steering can be turned fully to left
5
Steering can be turned fully to right
6
Both steering and transmission do not work at all Troubleshooting code when error code is displayed
WA700-3L
56 57 58 59 60 61 62 63 --- --a
b
c
d
e
f
g
h
i
j
●
k T-17
● ● ● ●
●
●
●
H-6, H-8, H-9, H-11, J-9, J-11
●
●
●
H-6, H-8, H-9, H-11, J-9, J-12
●
●
●
● ●
●
J-9, J-10
J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 --- ---
20-603 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
CONTROLLER ACTIONS DURING ABNOMALITY Joystick control system Failure code
56
Abnormal system
Nature of abnormality 1. 2.
Joystick caution relay system
3. 4.
Defective caution relay Short circuit with ground, defective contact, or disconnection in wiring harness between joystick steering controller C2 (female) (9) and L66 (1) (female) Short circuit with ground, defective contact, or disconnection in wiring harness between joystick steering controller C2 (female) (19) and L66 (2) (female) Defective joystick steering controller
1. 2. 3.
57
Defective R SOL Defective steering solenoid cut relay Short circuit in wiring harness between joystick steering controller C2 (female) (2) and (13) Steering (R) (right) Sol. system Short circuit with ground, defective contact, or disconnection in the following wiring harnesses: (short circuit, disconnection) 4. Wiring harness between joystick steering controller C2 (female) (2) and L84 (2) 5. Wiring harness between joystick steering controller C2 (female) (13) and L67 (3) 6. Wiring harness between steering solenoid cut relay L67 (5) and L84 (1) 7. Defective joystick steering controller
1. 2. 3. 58
59
60
20-604 1
Steering (L) (left) Sol. system (short circuit, disconnection)
Defective L SOL Defective steering solenoid cut relay Short circuit in wiring harness between joystick steering controller C2 (female) (3) and (14) Short circuit with ground, defective contact, or disconnection in the following wiring harnesses 4. Wiring harness between joystick steering controller C2 (female) (3) and L83 (2) 5. Wiring harness between joystick steering controller C2 (female) (14) and L67 (3) 6. Wiring harness between steering solenoid cut relay L67 (5) and L83 (1) 7. Defective joystick steering controller
1. Steering R (right) Sol. system 2. short circuit with power source) 3.
Defective R SOL Short circuit with power source in wiring harness between joystick steering controller C2 (female) (2) and L84 (2) Defective joystick steering controller
1. 2.
Defective L SOL Short circuit with power source in wiring harness between joystick steering controller C2 (female) (3) and L83 (2) Defective joystick steering controller
Steering L (left) Sol. system (short circuit with power source)
3.
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
Condition when normal (voltage, current, resistance) 1. 2. 3.
4.
Joystick caution relay: (voltage between C2 (9) and C2 (19): 20 - 30 V) Resistance of relay coil between joystick steering controller C2 (female) (9) and C2 (female) (19): 200 - 400 Ω Resistance between joystick steering controller C2 (female) (9) and chassis ground: Min. 1 MΩ Resistance between joystick steering controller C2 (female) (19) and chassis ground: Min. 1 MΩ
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
Troubleshooting
Caution output: OFF
Joystick caution actuated
J-1
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-2
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-3
Joystick lever at neutral Voltage between joystick steering controller C2 (female) (2) and chassis ground: Less than 1 V
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-4
Joystick lever at neutral Voltage between joystick steering controller C2 (female) (3) and chassis ground: Less than 1 V
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-5
1.
Steering solenoid cut relay: ON (voltage between L67 (1) and (2): 20 - 30 V) 2. Resistance of steering R solenoid: 10 - 20 Ω 3. Resistance between joystick steering controller C2 (female) (2), (13) and chassis ground: Min. 1 MΩ Resistance of the following wiring harnesses: Less than 1Ω 4. Wiring harness between joystick steering controller C2 (female) (2) and L84 (female) (2) 5. Wiring harness between joystick steering controller C2 (female) (2) and L67 (female) (3) 6. Wiring harness between steering solenoid cut relay L67 (female) (5) and L84 (female) (1) 1.
Steering solenoid cut relay: ON (voltage between L67 (1) and (2): 20 - 30 V) 2. Resistance of steering L solenoid: 10 - 20 Ω 3. Resistance between joystick steering controller C2 (female) (3), (14) and chassis ground: Min. 1 MΩ Resistance of the following wiring harnesses: Less than 1 Ω 4. Wiring harness between joystick steering controller C2 (female) (3) and L83 (female) (2) 5. Wiring harness between joystick steering controller C2 (female) (14) and L67 (female) (3) 6. Wiring harness between steering solenoid cut relay L67 (female) (5) and L83 (female) (1) 1.
1.
WA700-3L
20-605 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
Failure code 61
Abnormal system Steering Sol. cut relay system
1. 2. 3. 1. 2.
62
Joystick neutral switch system
3. 4. 1. 2.
63
Joystick potentiometer system
3. 4. 5.
20-606 1
Nature of abnormality Defective steering SOL cut relay Short circuit with ground, defective contact, or disconnection in wiring harness between joystick steering controller C1 (female) (1) and L67 (1) Defective joystick steering controller Defective joystick neutral switch Short circuit with ground, defective contact, or disconnection in wiring harness between joystick steering controller C5 (female) (11) and JL1 (6) Defective contact or disconnection in wiring harness between JL1 (7) and chassis ground Defective joystick steering controller Defective joystick potentiometer Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between joystick steering controller C3A (female) (3) and JL1 (3) Short circuit with power source, defective contact, or disconnection in wiring harness between joystick steering controller C3A (female) (7) and JL1 (4) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between joystick steering controller C3A (female) (17) and JL1 (5) Defective joystick steering controller
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNOMALITY
12
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
Resistance between joystick steering controller C1 (female) (1) and chassis ground: 200 - 400 Ω
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-6
Resistance between joystick steering controller C5 (female) (11) and chassis ground: Min. 1 MΩ (when joystick is at neutral) Less than 1 Ω (joystick at angle of ± 5 - 15° from neutral)
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-7
Voltage between joystick steering controller C3A (female) (3) and C3A (17): 0.5 - 4.5 V (voltage when joystick is at neutral: Approximately 2.5 V)
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF
Impossible to use joystick and joystick caution actuated
J-8
Condition when normal (voltage, current, resistance) 1.
1.
1.
WA700-3L
Troubleshooting
20-607 1
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
12
ELECTRICAL CIRCUIT DIAGRAM See FOLDOUT 20-608 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING Remark FOLDOUTS are located in Section 90 of this manual.
20-608 1
WA700-3L
TROUBLESHOOTING
J-1
12 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. ★ Always turn the starting switch OFF before disconnecting any connector. Cause 4
Yes
Yes Is resistance between C2 (female) (19) and chassis normal? 3 Yes Is resistance between C2 (female) (9) and chassis normal? 2
1. Disconnect C2 2. Min. 1 MΩ 3. Turn starting switch OFF.
Yes Is resistance between C2 (male) (9) and C2 (female) (19) normal? 1 Is failure code displayed when L66 is replaced with other relay of same type?
1. Disconnect C2 2. 200 - 400 Ω 3. Turn starting switch OFF.
1. Turn starting switch OFF. 2. Interchange L66 with other relay of same type. 3. Turn starting switch ON.
No
No
Defective transmission & Replace joystick steering controller Short circuit with chassis ground in wiring harness Repair or between C2 (female) (19) replace and L66 (female) (2) Short circuit with chassis ground in wiring harness between C2 (female) (9) and L66 (female) (1)
Repair or replace
Disconnection in wiring harness between C2 (female) (19) and L66 (female) (2)
Repair or replace
Disconnection in wiring harness between C2 (female) (9) and L66 (female) (1)
Repair or replace
Yes 5
No
Is resistance between C2 (female) (9) and L66 (female1 (1) normal? 1. Disconnect C2 and L66 2. Max. 1 Ω 3. Turn starting switch OFF.
No
1. Disconnect C2 2. Min. 1 MΩ 3. Turn starting switch OFF.
Remedy
No
Defective joystick caution Replace relay
J-l Related electrical circuit diagram
WA700-3L
20-609 1
TROUBLESHOOTING
J-2
12
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause 4
Yes
Yes Is resistance between C2 (female) (2) and (13) normal? 3 Yes Is resistance between C2 (female) (13) and chassis normal? 2 Yes Is resistance between C2 (female) (2) and 1 chassis normal? Is failure code displayed when L67 is replaced with other relay of same type? 1. Turn starting switch OFF 2. Interchange with other relay of same type 3. Turn starting switch ON
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C2 and L84
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C2 and L67
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C2 No
No
Remedy
Defective joystick controller
Replace
Short circuit in wiring harness between C2 (female) (2) and L84 Repair or (female) (2) and between replace C2 (female) (13) and L67 (female) (3) Short circuit with chassis ground in wiring harness Repair or between C2 (female) (13) replace and L67 (female) (3) Short circuit with chassis ground in wiring harness between C2 (female) (2) and L84 (female) (2)
Repair or replace
Defective steering solenoid cut relay
Replace
J-2 Related electrical circuit diagram
20-610 1
WA700-3L
TROUBLESHOOTING
J-3
12 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause 4
Yes
Yes Is resistance between C2 (female)(3) and (14) normal? 3 Yes Is resistance between C2 (female)(13) and chassis normal? 2 Yes Is resistance between C2 (female)(3) and chassis normal? 1 Is failure code displayed when L67 is replaced with other relay of same type? 1. Turn starting switch OFF 2. Interchange with other relay of same type 3. Turn starting switch ON
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C2 and L83
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C2 and L67
No
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C2
No
No
Remedy
Defective joystick controller
Replace
Short circuit in wiring harness between C2 (female) (3) and L83 Repair or (female) (2) and between replace C2 (female) (14) and L67 (female) (3) Short circuit with chassis ground in wiring harness Repair or between C2 (female) (14) replace and L67 (female) (3)
Short circuit with chassis ground in wiring harness between C2 (female) (3) and L83 (female) (2)
Repair or replace
Defective steering solenoid cut relay
Replace
J-3 Related electrical circuit diagram
WA700-3L
20-611 1
TROUBLESHOOTING
J-4
12
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)) IS DISPLAYED ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Yes
Is voltage between C2 (female) (2) and chassis normal? 1. Max. 1 V 2. Turn starting switch ON.
No
Remedy
Defective joystick steering Replace controller Short circuit with power source in wiring harness between C2 (female)(2) and L84 (female)(2)
Repair or replace
J-4 Related electrical circuit diagram
20-612 1
WA700-3L
TROUBLESHOOTING
J-5
12 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. ★ Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter). Cause 1
Yes
Is voltage between C2 (female) (3) and chassis normal? 1. Max. 1 V 2. Turn starting switch ON.
WA700-3L
No
Remedy
Defective joystick steering Replace controller Short circuit with power source in wiring harness between C2 (female)(3) and L83 (female)(2)
Repair or replace
20-613 1
TROUBLESHOOTING
J-6
12
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause 4
Yes
Yes Is resistance between L67 (female)(2) and chassis normal? 3 Yes Is resistance between C1 (female)(1) and chassis normal? 2 Yes Is resistance between C1 (female)(1) and L67 (female)(1) normal? 1 Is failure code displayed when L67 is replaced with other relay of same type? 1. Turn starting switch OFF 2. Interchange with other relay of same type 3. Turn starting switch ON
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and L67
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and L67
No
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L67
No
No
Remedy
Defective joystick controller
Replace
Defective contact or disconnection in wiring harness between L67 (female) (2) - LR5 (2) chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between C1 (female) (1) and L67 (female) (1)
Repair or replace
Defective contact or disconnection in wiring har- Repair or ness between C1 (female) replace (1) and L67 (female) (1)
Defective steering solenoid cut relay
Replace
J-6 Related electrical circuit diagram
20-614 1
WA700-3L
TROUBLESHOOTING
J-7
12 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. Cause Yes
Defective joystick controller or defective joystick potentiometer mount
2 Yes Is resistance between C5 (female)(11) and chassis normal?
Yes 4
1. Disconnect C5 2. Operate joystick lever fully to left or right 3. Max. 1 Ω
1 Is resistance between C5 (female)(11) and chassis normal?
Yes Is resistance between JL1 (male)(7) and 3 chassis normal?
No
1. Disconnect C5 2. Min. 1 MΩ
Is resistance between JL1 (female)(6) and (7) normal? 1. Disconnect JL1 2. Operate joystick lever fully to left or right 3. Max. 1 Ω
5
No
1. Disconnect JL1 2. Max. 1 Ω
No
No
Replace
Defective contact or disconnection in wiring Repair or harness between JLl (male) (6) and C5 (female) replace (11) Defective contact or disconnection in wiring harness between JLl (male) (7) - LR5 (3) chassis ground
Repair or replace
Defective neutral switch
Replace
Yes Short circuit with chassis ground in wiring harness Repair or between JLl (male) (6) and replace C5 (female) (11)
Is resistance between JL1 (male)(6) and chassis ground normal? 1. Disconnect JL1 and C5 2. Max. 1 Ω
Remedy
No
Defective neutral switch
Replace
J-7 Related electrical circuit diagram
WA700-3L
20-615 1
TROUBLESHOOTING
J-8
12
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DISPLAYED ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. ★ After connecting the T-adapter, turn the starting switch ON. Cause Yes Defective joystick potentiometer, neutral position misaligned
2 Yes Does voltage between C3A (3) and (17) change? 1 Is voltage between C3A (7) and (17) normal?
1. Operate joystick lever to left or right (0.5 - 4.5 V).
1. 4.9 - 5.1 V
No
Does resistance between JL1 (female) (3) and (5) change? 1. Operate joystick lever to left or right (0.2 - 5 kΩ)
No
Remedy Replace, adjust, neutral position again
3 Yes Short circuit with power source, short circuit with ground, Repair or defective contact, or disconnection in wiring harness replace between C3A (female) (3) and JLl (male) (3) Defective joystick potentiometer
Replace
Defective joystick steering controller
Replace
No
J-8 Related electrical circuit diagram
20-616 1
WA700-3L
TROUBLESHOOTING
J-9
12 J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Check that fuse is normal. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Yes
Is voltage between C2 (female) (l), (12) and chassis normal? 1. 20 - 30 V 2. Turn starting switch ON
No
Remedy
Defective joystick steering Replace controller Defective contact or disconnection in wiring harness between C2 (female) (1). (12) - FS11 (10) - fuse
Repair or replace
J-9 Related electrical circuit diagram
WA700-3L
20-617 1
TROUBLESHOOTING
J-10
12
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Check that fuse is normal. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. ★ Always connect any disconnected connectors before going on to the next step. Cause Yes
Defective joystick steering Replace controller
1
Yes
Is voltage between C3B (female) (14) and chassis normal?
3 Yes Is voltage between JL1 (male)(1) and chassis normal? 2
1. 20 - 30 V 2. Turn starting switch ON No
Is resistance between C3B (female)(14) and chassis normal when JL1 (male)(2) is grounded to chassis/ 1. Turn starting switch OFF 2. Disconnect JLl and C3B 3. Max. 1 Ω
Remedy
1. 20 - 30 V 2. Turn starting switch ON
No
No
Defective system cut-off switch
Replace
Defective contact or disconnection in wiring harness between fuse FS2 (10) - JLl (male) (1)
Repair or replace
Defective contact or disconnection in wiring harness between C3B (female) (14) - L82 (1), (2) - JLl (male) (2) or defective joystick ON OFF switch
Replace switch or repair or replace
J-10 Related electrical circuit diagram
20-618 1
WA700-3L
TROUBLESHOOTING
J-11
12 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause 4 Yes Is resistance between C67 (female)(5) and 3 chassis normal when L84 (female)(1) is Yes Is resistance between grounded to chassis? C2 (female)(13) and 2 1. Max. 1 Ω chassis normal when 2. Turn starting L67 (female)(3) is switch OFF Yes Is resistance between grounded to chassis? 3. Disconnect L67 C2 (female)(2) and chassis normal when 1 1. Max. 1 Ω No L84 (female)(2) is 2. Turn starting grounded to chassis? switch OFF Is resistance 3. Disconnect C2 between L84 (1) and L67 and (2) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 1. 10 - 20 Ω No 3. Disconnect C2 2. Turn starting switch OFF 3. Disconnect L84 No
Yes
No
Remedy
Defective joystick steering Replace controller Defective contact or disconnection in wiring harness between L67 (female) (5) and L84 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between C2 (female) (13) and L67 (female) (3)
Repair or replace
Defective contact or disconnection in wiring harness between C2 (female) (2) and L84 (female) (2)
Repair or replace
Defective joystick steering Replace right solenoid valve
J-l 1 Related electrical circuit diagram
WA700-3L
20-619 1
TROUBLESHOOTING
J-12
12
J-12 DISCONNECTION IN STEERING LEFT SOLENOID ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause 4 Yes Is resistance between C67 (female)(5) and 3 chassis normal when L83 (female)(1) is Yes Is resistance between grounded to chassis? C2 (female)(14) and 2 1. Max. 1 Ω chassis normal when 2. Turn starting L67 (female)(3) is switch OFF Yes Is resistance between grounded to chassis? 3. Disconnect L67 C2 (female)(3) and chassis normal when 1 1. Max. 1 Ω No L83 (female)(2) is 2. Turn starting grounded to chassis? switch OFF Is resistance 3. Disconnect C2 between L83 (1) and L67 and (2) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 1. 10 - 20 Ω No 3. Disconnect C2 2. Turn starting switch OFF 3. Disconnect L83 No
Yes
No
Remedy
Defective joystick steering Replace controller Defective contact or disconnection in wiring harness between L67 (female) (5) and L83 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between C2 (female) (14) and L67 (female) (3)
Repair or replace
Defective contact or disconnection in wiring harness between C2 (female) (3) and L83 (female) (2)
Repair or replace
Defective joystick steering Replace right solenoid valve
J-12 Related electrical circuit diagram
20-620 1
WA700-3L
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 12 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 . . . . . . . . 20-703 A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-703 B. SOME LAMPS DO NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-703 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT . . . . . . . . . . . . . . . . 20-705 K- 4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH . . . . 20-706 A. ENGINE OIL LEVEL DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706 B. ENGINE WATER LEVEL DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-707 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH . . 20-708 A. ENGINE OIL PRESSURE DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708 B. BATTERY CHARGE LEVEL DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-709 C. BRAKE OIL PRESSURE DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-710 D. AIR CLEANER (L.H.) DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711 E. AIR CLEANER (R.H.) DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712 K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND . . . . . . . . . . . . . 20-713 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS . . . . 20-714 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715 A. CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715 B. CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716 A. CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716 B. CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) . . . . . . . . . . . . . . . . . . . . . . . . . 20-717 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718 K-12 SERVICE METER DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED . . . . . . . . . . . . . . . . . . . . . . . 20-719 K-14 ABNORMALITY IN GAUGE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721 A. ABNORMALITY IN FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721 B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722 C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . 20-723
WA700-3L
20-701â&#x17E;&#x20AC;
TROUBLESHOOTING 12
MEMORANDUM
20-702 1
WA700-3L
TROUBLESHOOTING
K-1
12 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 ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP Cause Yes
Defective monitor module Replace of maintenance monitor
1
Yes 3
Is voltage between L18(1), (2) - (3) normal?
Is voltage between Yes FS1 (female)(2) and chassis ground 2 normal?
1. 20 - 30 V 2. Turn starting switch ON No
Is resistance between L18 (female)(3), L19 (8) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch ON 3. Disconnect L18, L19
Remedy
1. 20 - 30 V 2. Disconnect FS1 3. Turn starting switch ON.
No
No
Defective contact or disconnection in wiring harness between L18 (female) (1), (2) - FS2 (9) - fuse - FSl (male) (2). or blown fuse
Repair or replace or replace fuse
Defective contact or disconnection in wiring harness between FS1 (female) (2) - LR6 (1) slow blow fuse - battery relay or blown slow blow fuse (80A)
Repair or replace or replace fuse
Defective contact or disconnection in wiring harness between L18 (3). L19 (female) (8) - LR4 (12) - chassis ground
Repair or replace
B. SOME LAMPS DO NOT LIGHT UP Cause
Remedy
Defective monitor module Replace of maintenance monitor
WA700-3L
20-703 1
TROUBLESHOOTING
K-2
12
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause
Remedy
Defective monitor module Replace of maintenance monitor
K-1, 2 Related electrical circuit diagram
20-704 1
WA700-3L
TROUBLESHOOTING
K-3
12 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Yes
When starting engine, is voltage between L19 (female) (1) and chassis ground normal? 1. 20 - 30 V 2. Disconnect L19 3. Start engine 4. Measure when starting motor is turning (starting switch at START)
No
Remedy
Defective monitor module Replace of maintenance monitor
Defective contact or disconnection in wiring harness between L19 (female) (1) and neutral relay
Repair or replace
K-3 Related electrical circuit diagram
WA700-3L
20-705 1
TROUBLESHOOTING
K-4
12
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. ENGINE OIL LEVEL DISPLAY FLASHES ★ Before starting troubleshooting, check the engine oil level again. (Check that the engine oil level is correct.) Cause Yes 2 Yes Is resistance between L18 (female)(13) and chassis ground 1 normal? Is resistance between E19 (male)(1) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect E19
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect E18
No
No
Remedy
Defective monitor module Replace of maintenance monitor
Defective contact or disconnection in wiring harness between L18 (female) (13) - LR4 (4) ERl (3) - El9 (female) (1)
Repair or replace
Defective engine oil level Replace sensor
K-4 A. Related electrical circuit diagram
20-706 1
WA700-3L
TROUBLESHOOTING
K-4
12 ENGINE WATER LEVEL DISPLAY FLASHES B. ★ Before starting troubleshooting, check the engine water level again. (Check that the engine water level is correct.) Cause 3
Yes
Yes Is resistance between L18 (female)(8) and chassis ground normal? 2 1 Is resistance between G03 (male)(2) and (1) normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect G03
Is resistance between G03 (female) (1) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect G03
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L18 No
No
Remedy
Defective monitor module Replace of maintenance monitor Defective contact or disconnection in wiring Repair or harness between L18 replace (female) (8) - LR3 (1) GRl (8) - G03 (female) (1) Defective contact or disconnection in wiring harness between G03 (female) (2) - GRI (11) chassis ground
Repair or replace
Defective radiator water level sensor
Replace
K-4 B. Related electrical circuit diagram
WA700-3L
20-707 1
TROUBLESHOOTING
K-5
12
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. ENGINE OIL PRESSURE DISPLAY FLASHES (Check that the engine oil pressure is correct.) Cause Yes 1 Does display go out when E18 is disconnected? 1. Start engine No 2. Disconnect E18
2
Yes
Does condition become normal when engine oil pressure relay L64 is interchanged?
4
Yes
Yes Is resistance between L18 (female)(10) and chassis ground normal? 3
1. Interchange engine oil pressure relay L64 with a normal relay No
Is voltage between E18 and chassis ground normal? 1. 20 - 30 V 2. Disconnect E18 3. Start engine
1. Max. 1 Ω 2. Disconnect L18 3. Turn starting switch Off No
No
Remedy
Defective engine oil pressure switch
Replace
Defective engine oil pressure relay
Replace
Defective monitor module Replace of maintenance monitor Defective contact or disconnection in wiring Repair or harness between L18 (female) (10) - L64 (3), (6) replace - LR5 (2) - chassis ground Contact of ground with wiring harness between Repair or ring terminal - ERl (2) replace LR4 (3) - L64 (female) (2)
K-5 A. Related electrical circuit diagram
20-708 1
WA700-3L
TROUBLESHOOTING
K-5
12 BATTERY CHARGE LEVEL DISPLAY FLASHES B.
Cause 2
Yes
Yes Is voltage between L18 (female) (12) and chassis ground 1 normal? Is voltage between alternator terminal R and chassis ground normal?
1. 20 - 30 V 2. Start engine
1. 20 - 30 V 2. Start engine No
No
Remedy
Defective monitor module Replace of maintenance monitor Defective contact or disconnection in wiring harness between L18 (female) (12) - LR4 (6) ERl (9) - alternator terminal R
Repair or replace
Defective alternator
Replace
K-5 B. Related electrical circuit diagram
WA700-3L
20-709 1
TROUBLESHOOTING 12 C.
K-5
BRAKE OIL PRESSURE DISPLAY FLASHES
(Check that the brake oil pressure is correct.) Cause 4
Yes
Yes Is voltage between L18 (11) and chassis ground normal? 3
2 Yes Is resistance between C04 (male) (1) and (2) normal? 1 Is resistance between C03 (male) (1) and (2) normal?
1. Max. 1 Ω 2. Start engine 3. Disconnect C04
Yes Is resistance between C03 (female) (2) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect C03
No
1. Max. 1 Ω 2. Start engine 3. Disconnect C03 No
1. Start engine 2. Max. 3 V
No
No
Remedy
Defective monitor module Replace of maintenance monitor Defective contact or disconnection in wiring Repair or harness between L18 (female) (11) - LR4(11)- replace BC0l (3)-C03 (female) (1) Defective contact or disconnection in wiring harness between C03 (female) (2) - C04 (female) (1) or between C04 (female) (2) - BC0l (1) - chassis ground
Repair or replace
Defective brake accumulator charge oil Replace pressure switch (C04 end)
Defective brake accumulator charge oil Replace pressure switch (C03 end)
K-5 C. Related electrical circuit diagram
20-710 1
WA700-3L
TROUBLESHOOTING
K-5
12 AIR CLEANER (L.H.) DISPLAY FLASHES D. (Check that there is no clogging of the air cleaner.) Cause Yes 1 Does display go out when B07 is disconnected?
Yes 2
1. Start engine 2. Disconnect B07 No
Does display go out when dust indicator relay L31 is interchanged?
4
No
1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L31
1. Turn starting switch ON 2. Disconnect B07 3. 20 - 30 V No
5
From
A
Yes
Is resistance between L18 (female) (15) and chassis ground normal? 1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L18
No
Defective dust indicator sensor
Replace
Defective dust indicator relay
Replace
Yes To A
Yes Is resistance between L31 (female) (6) and chassis ground 3 normal? Is voltage between B07 (female)(1) and chassis ground normal?
Remedy
No
---
Defective contact or disconnection in wiring harness between L31 (female) (6) - LR5 (2) chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between B07 (female) (1) Repair or - BR1 (6) - LR2 (8) - L31 replace (female) (2) (short circuit or contact with chassis ground) Defective monitor module Repair of maintenance monitor Defective contact or disconnection in wiring harness between L18 (female) (15) and L31 (female) (3)
Repair or replace
K-5 D. Related electrical circuit diagram
WA700-3L
20-711 1
TROUBLESHOOTING 12 E.
K-5
AIR CLEANER (R.H.) DISPLAY FLASHES
(Check that there is no clogging of the air cleaner.) Cause Yes 1 Does display go out when B09 is disconnected?
Yes 2
1. Start engine 2. Disconnect B09 No
Does display go out when dust indicator relay L32 is interchanged?
4
No
1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L32
1. Turn starting switch ON 2. Disconnect B09 3. 20 - 30 V No
5
From
A
Yes
Is resistance between L18 (female) (15) and chassis ground normal? 1. Max. 1 â&#x201E;Ś 2. Turn starting switch OFF 3. Disconnect L18
No
Defective dust indicator sensor
Replace
Defective dust indicator relay
Replace
Yes To A
Yes Is resistance between L32 (female) (6) and chassis ground 3 normal? Is voltage between B09 (female)(1) and chassis ground normal?
Remedy
No
---
Defective contact or disconnection in wiring harness between L32 (female) (6) - LR5 (2) chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between B09 (female) (1) Repair or - BR1 (7) - LR2 (9) - L32 replace (female) (2) (short circuit or contact with chassis ground) Defective monitor module Repair of maintenance monitor Defective contact or disconnection in wiring harness between L18 (female) (14) and L32 (female) (3)
Repair or replace
K-5 E. Related electrical circuit diagram
20-712 1
WA700-3L
TROUBLESHOOTING
K-6
12 K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND ★ ★ ★ ★
The buzzer does not sound for CHARGE or ENGINE OIL LEVEL. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuse 1 - 10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between fuse - FS2 (9) - L42 (1). Cause 2
Yes
Yes Does buzzer sound when L19 (female) (4) is connected to chassis ground? 1 Is voltage between L42 (female) (1) and chassis ground normal?
No
1. 20 - 30 V 2. Disconnect L42 3. Turn starting switch ON
Yes
Does buzzer sound when L43 (female) (1) is connected to chassis ground? 1. Turn starting switch ON
No
Defective monitor module Replace of maintenance monitor 3
1. Turn starting switch ON
Remedy
Defective contact or disconnection in wiring harness between L19 (female) (4) and L43 (male) (1)
Replace
Defective buzzer
Replace
No Defective contact or disconnection in wiring Repair or harness between fuse replace FS2 (9) - L42 (female) (1)
K-6 Related electrical circuit diagram
WA700-3L
20-713 1
TROUBLESHOOTING
K-7
12
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS ★ Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. (Note: When joystick steering is not installed) Cause 2
Yes
Yes Is resistance between L19 (female) (4) and chassis ground 1 normal? Is resistance between L43 (female) (1) and chassis ground normal? 1. Min. 1 MΩ 2.Turn starting switch OFF 3. Disconnect L42 and L43
1. Min. 1 MΩ 2.Turn starting switch OFF 3. Disconnect L06, L19 and L43.
No
No
Remedy
Defective monitor module Replace of maintenance monitor
Short circuit with chassis ground in wiring harness between L19 (female) (4) - Repair or L43 (male) (1) - L06 replace (female) (8) (contact with chassis ground
Defective buzzer
Replace
K-7 Related electrical circuit diagram
20-714 1
WA700-3L
TROUBLESHOOTING
K-8
12 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH ★ Before carrying out troubleshooting, check that there are no blown lamp bulbs. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. CHECK LAMP Cause Yes
Defective monitor module Replace of maintenance monitor
1 Does CHECK lamp light up when L19 (female) (2) is connected to chassis ground?
2
No
1. Disconnect L19 2. Turn starting switch ON.
Remedy
Yes
Does CHECK lamp light up when L06 (male) (10) is connected to chassis ground? 1. Disconnect L06 2. Turn starting switch ON.
No
Defective contact or disconnection in wiring harness between L19 (female) (2) and L06 (female) (10)
Repair or replace
Defective main monitor
Replace
B. CAUTION LAMP Cause Yes
Defective monitor module Replace of maintenance monitor
1 Does CAUTION lamp light up when L19 (female) (3) is connected to chassis ground? 1. Disconnect L19 2. Turn starting switch ON.
2
No
Remedy
Yes
Does CAUTION lamp light up when L06 (male) (9) is connected to chassis ground? 1. Disconnect L06 2. Turn starting switch ON.
No
Defective contact or disconnection in wiring harness between L19 (female) (3) and L06 (female) (10)
Repair or replace
Defective main monitor
Replace
K-8 A, B. Related electrical circuit diagram
WA700-3L
20-715 1
TROUBLESHOOTING
K-9
12
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP ★ Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. CHECK LAMP Cause 1
Yes
Is resistance between L19 (female) (2) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L06 and L19
No
Remedy
Defective monitor module Replace of maintenance monitor
Short circuit with chassis ground in wiring harness between L19 (female) (2) and L06 (female) (10) (contact with chassis ground)
Repair or replace
Cause
Remedy
B. CAUTION LAMP 1
Yes
Is resistance between L19 (female) (3) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L06 and L19
No
Defective monitor module Replace of maintenance monitor
Short circuit with chassis ground in wiring harness between L19 (female) (3) and L06 (female) (9) (contact with chassis ground)
Repair or replace
K-9 Related electrical circuit diagram
20-716 1
WA700-3L
TROUBLESHOOTING
K-10
12 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) ★ Before carrying out troubleshooting, check that there are no blown lamp bulbs. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Yes
Is voltage between L21 (female) (1) and (2) normal? 1. 20 - 30 V 2. Disconnect L21 3. Turn starting switch ON 4. Turn lamp switch ON.
No
Remedy
Disconnection in wiring harness of lamp holder
Replace
Defective contact or disconnection in wiring harness between L21 (female) (1) and FS2 (5)
Repair or replace
K-10 Related electrical circuit diagram
WA700-3L
20-717 1
TROUBLESHOOTING
K-11
12
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 2
Contact of +24 V with wiring harness between Repair or FS2 (male) (4) - fuse box - replace FS2 (5) - L21 (female) (1)
Yes Is voltage between FS2 (female) (4) and chassis ground 1 normal? Is lamp switch normal? 1. Turn starting switch OFF 2. Disconnect L02 3. Check that continuity between L02 (male) (1) and (5) is as shown in table below when lamp switch is turned ON - OFF.
1. Max. 1 V 2. Disconnect FS2 3. Turn lamp switch OFF 4. Turn starting switch ON No
Remedy
Yes
No
Contact of +24 V with wiring harness between L02 (female) (5) and FS2 (female) (4)
Repair or replace
Defective lamp switch
Replace
K-l 1 Related electrical circuit diagram
20-718 1
WA700-3L
TROUBLESHOOTING
K-12
12 K-12 SERVICE METER DOES NOT WORK ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause
Remedy
Yes 1 Is voltage between L22 (female) (2) and (1) normal?
3
1. 20 - 30 V 2. Start engine 3. Disconnect L22
Yes
Yes Is resistance between L22 9female) (1) and chassis ground normal? 2 No
Is voltage between alternator terminal R and chassis ground normal?
1. Turn starting switch OFF 2. Disconnect L22
1. 20 - 30 V 2. Start engine No
No
Defective service meter
Replace
Defective contact or disconnection in wiring harness between L22 (female) (2) - LR4 (6) ERl (9) - alternator terminal R
Repair or replace
Defective contact or disconnection in wiring harness between L22 (female) (1) - LR5 (2) chassis ground
Repair or replace
Defective alternator
Replace
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1
Remedy
Yes Defective service meter
Is voltage between l22 (female) (2) and (1) normal? 1. Max. 3 V 2. Turn starting switch ON No 3. Disconnect L22
2
1. Max. 3 V 2. Turn starting switch ON
WA700-3L
Yes
Is voltage between alternator terminal R and chassis ground normal? No
Replace
Contact of +24 V with wiring harness between or L22 (female) (2) - LR4 (6) Repair replace - ER1 (9) -alternator terminal R Defective alternator
Replace
20-719 1
TROUBLESHOOTING
K-13
12 K-12, 13 Related electrical circuit diagram
20-720 1
WA700-3L
TROUBLESHOOTING
K-14
12 K-14 ABNORMALITY IN GAUGE ITEMS ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. ABNORMALITY IN FUEL GAUGE ★ Before carrying out troubleshooting, check the fuel level again. (Check that the fuel level is correct.) 1.
Little or nothing is displayed in display area Cause
Remedy
Yes Defective fuel sensor 1
3 Yes Is resistance between L18 (female) (6) and chassis ground normal when short connector is connected to R05? 2
Does fuel gauge show FULL when short connector is connected to R05 (female)? 1. Disconnect R05 2. Connect short connector to R05 No (female) 3. Turn starting switch ON
Is resistance between R05 (female) (2) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect R05
1. Max. 1 Ω 2. Turn starting switch OFF 3. Connect short connector to R05 (female) 4. Disconnect L18
No
2.
Yes
No
Replace
Defective monitor module Replace of maintenance monitor Defective contact or disconnection in wiring harness between R05 (female) (1) - LR4 (10) L18 (female) (6)
Repair or replace
Defective contact or disconnection in wiring harness between R05 (female) (2) and chassis ground
Repair or replace
Display always shows FULL and does not move Cause 1
Remedy
Yes Defective fuel sensor
Do all display areas on fuel gauge go out when R05 is disconnected? 1. Disconnect R05 2. Turn starting switch ON No
2
Replace
Yes Defective monitor module Replace of maintenance monitor
Is resistance between R05 (female) (1) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L18 and R05
No
Short circuit with chassis ground in wiring harness Repair or between R05 (female) (1) replace - LR4 (10) - L18 (female) (6)
K-14 A. Related electrical circuit diagram
WA700-3L
20-721 1
TROUBLESHOOTING
K-14
12 B.
ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
1.
Nothing is displayed in display area Cause 1
Yes
Does engine water temperature gauge show minimum level when E09 is disconnected?
Defective engine water temperature 2
Replace
Yes Defective monitor module Replace of maintenance monitor
1. Disconnect E09 2. Turn starting switch ON No
Is resistance between E09 (female) (1) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L18 and E09
2.
Remedy
Short circuit with chassis ground in wiring harness between E09 (female) (1) - Repair or ER1 (6) - LR4 (1) - L18 replace (female) (4) (contact with chassis ground)
No
Display shows lowest level and does not move Cause Yes
Defective engine water temperature sensor
1 When short connector is connected to E09 (female), does engine water temperature gauge display area rise one stage at a time and finally do all lamps go out? 1. Disconnect E09 2. Connect short connector to E09 No (female) 3. Turn starting switch ON
3
Yes
Is resistance between L18 (female) (4) and chassis ground normal when short connector is connected to E09 (female)?
No
Yes
2
Is resistance between E09 (female) (2) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect E09
Remedy
1. Max. 1 Ω 2. Turn starting switch OFF 3. Connect short connector to E09 (female) 4. Disconnect L18
No
Replace
Defective monitor module Replace of maintenance monitor
Defective contact or disconnection in wiring Repair or harness between E09 replace (female) (1) - ER1 (6) LR4 (1) - L18 (female) (4)
Defective contact or disconnection in wiring harness between E09 (female) (2) - ER1 (7) and chassis ground
Repair or replace
K-14 B. Related electrical circuit diagram
20-722 1
WA700-3L
TROUBLESHOOTING
K-14
12 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE C. 1.
Nothing is displayed in display area Cause 1
Yes
Does torque converter oil temperature gauge show minimum level when T06 is disconnected?
Defective Torque converter oil temperature sensor 2
Replace
Yes Defective monitor module Replace of maintenance monitor
1. Disconnect T06 2. Turn starting switch ON No
Is resistance between T06 (female) (1) and chassis ground normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect L18 and T06
2.
Remedy
Short circuit with chassis ground in wiring harness between T06 (female) (1) - Repair or TL1 (9) - L18 (female) (5) replace (contact with chassis ground)
No
Display shows lowest level and does not move Cause Yes
Defective torque converter Replace oil temperature sensor
1
1. Disconnect T06 2. Connect short connector to T06 No (female) 3. Turn starting switch ON
3
Yes
Is resistance between L18 (female) (5) and chassis ground normal when short connector is connected to T06 (female)?
No
Yes
When short connector is connected to T06, does torque converter oil temperature gauge display area rise one stage at a time and finally do all lamps go out?
2
Is resistance between T06 (female) (2) and chassis ground normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T06
Remedy
1. Max. 1 Ω 2. Turn starting switch OFF 3. Connect short connector to T06 (female) 4. Disconnect L18
No
Defective monitor module Replace of maintenance monitor
Defective contact or disconnection in wiring harness between T06 (female) (1) - TL1 (9) L18 (female) (5)
Repair or replace
Defective contact or disconnection in wiring harness between T06 (female) (2) - TL1 (10) LR5 (3) - chassis ground
Repair or replace
K-14 C. Related electrical circuit diagram
WA700-3L
20-723 1
TROUBLESHOOTING
K-14
12
MEMORANDUM
20-724 1
WA700-3L
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 12 M-1 MAIN MONITOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-803 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-804 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-805 M-4 ABNORMALITY IN SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806 A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806 B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806 C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806 D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807 E. DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807 F. DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807 G. DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808 H. DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808 M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810 A. L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810 B. R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810 M-6 ABNORMALITY IN PARKING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811 A. PARKING LAMP DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811 B. PARKING LAMP DISPLAY STAYS LIGHTED UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811 M-7 NIGHT LIGHTING DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812 M-8 ABNORMALITY IN FRONT WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813 A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP . . . . . . . . . . . . . . . . 20-813 B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . 20-813 C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP . . . . . . . . . . . . 20-813 M-9 ABNORMALITY IN REAR WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815 A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP . . . . . . . . . . . . . . . . . 20-815 B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . 20-815 C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP . . . . . . . . . . . . 20-815 M-10 ABNORMALITY IN TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817 STANDARD SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817 A. WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817 B. WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817 C. TRANSMISSION CUT-OFF SWITCH TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818 AUTO-SHIFT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-819 A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE 5 . . . . . 20-819 B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN
WA700-3L
20-801â&#x17E;&#x20AC;
TROUBLESHOOTING PEDAL IS DEPRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-819 C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED . . . . . . . . . . . . . . . . . . . . . 20-819 D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF) . . . . . . . . . . . . . . . . . . . . . . .20-819 E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820 M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821 A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-821 M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED . . . . . . . . . . . . . . . . 20-823 A. ACTUATED CONTINUOUSLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-823 B. NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823 M-13 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824 A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824 B. BUZZER ALWAYS SOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824 M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY . . . . . . . . . . . . . . . . . . . .20-825 M-15 ABNORMALITY IN FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-826 A. DOES NOT ENTER FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-826 B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-826 M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY . . . . . . 20-827 A. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED . . . . . 20-827 B. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED . . . . . 20-827 C. PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED . . . . . . . . . . . 20-827 D. PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED . . . . . . . . . . 20-828 M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY . . . . . . . . . . . . . . . . . . . . . 20-829 A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . 20-829 B. EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP . . . . . . . . . . . . . . . . . . 20-829 M-18 ABNORMALITY IN AUTO-GREASING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-830 A. FORCED GREASING CANNOT BE CARRIED OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-830 B. MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-830 C. WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-830 D. MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-831 E. MONITOR DISPLAY GOES OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-831 M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-832 A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-832 B. MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK 20-832
20-802 1
WA700-3L
TROUBLESHOOTING
M-1
12 M-1 MAIN MONITOR DOES NOT WORK ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1 Is voltage between L05 (1), (2) - (3) normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
Yes
2
No
Yes
Is resistance between L05 (female) (3) and chassis ground normal? 1. Turn starting switch OFF 2. Disconnect L05 3. Max. 1 Ω
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female1 (1). (2) and FS2 (female) (9)
Repair or replace
Defective contact or disconnection in wiring harness between L05 (female) (3) and LR5 (male) (3)
Repair or replace
M-l Related electrical circuit diagram
WA700-3L
20-803 1
TROUBLESHOOTING
M-2
12
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1 Is voltage between L05 (4) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch to START
Remedy
Yes
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female) (4) and L57 (female) (3)
Repair or replace
M-2 Related electrical circuit diagram
20-804 1
WA700-3L
TROUBLESHOOTING
M-3
12 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Check that the gap between the speed sensor and gear is normal. Cause 2
Defective main monitor
Yes Is resistance between L07 (female) (1) and (2) normal? 1 Is resistance between T05 (male) (1) and (2) normal?
1. 500 Ω - 1 kΩ 2. Starting switch OFF 3. Disconnect L07
1. 500 Ω - 1 kΩ 2. Starting switch OFF 3. Disconnect L05 No
Remedy
Yes
No
Replace
Defective contact or disconnection in wiring Repair or harness between L07 (female) (l), (2) - TLl (11), replace (12) - T05 (female) (1), (2)
Defective speed sensor
Replace
M-3 Related electrical circuit diagram
WA700-3L
20-805 1
TROUBLESHOOTING
M-4
12
M-4 ABNORMALITY IN SHIFT INDICATOR ★ ★ ★ ★ ★
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Check that the transmission shifts. Check that the output of the directional lever and speed lever is normal before starting troubleshooting. Check that the steering is in the steering wheel mode.
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F Cause 1 Is voltage between L08 (7) and chassis ground normal?
Remedy
Yes
No
1. 20 - 30 V 2. Turn starting switch ON 3. Directional lever: F
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L08 (female) (7) and L04 (female) (2)
Repair or replace
B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R Cause 1 Is voltage between L08 (8) and chassis ground normal?
Remedy
Yes
No
1. 20 - 30 V 2. Turn starting switch ON 3. Directional lever: R
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L08 (female) (8) and L04 (female) (4)
Repair or replace
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F Cause 1 Is voltage between L08 (7) and chassis ground normal? 1. 0 - 5 V 2. Turn starting switch ON 3. Directional lever: N
20-806 1
Remedy
Yes
No
Defective main monitor
Replace
Short circuit with power source in wiring harness between L08 (female) (7) and L04 (female) (2)
Repair or replace
WA700-3L
TROUBLESHOOTING
M-4
12 DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND D. DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R
Cause 1 Is voltage between L08 (8) and chassis ground normal?
Remedy
Yes
No
1. 0 - 5 V 2. Turn starting switch ON 3. Directional lever: N
Defective main monitor
Replace
Contact of power source with wiring harness between L08 (female) (8) and L04 (female) (4)
Repair or replace
E. DOES NOT DISPLAY 1ST EVEN WHEN SPEED LEVER IS AT 1 (DIRECTIONAL LEVER AT F OR R) Cause 1 Is voltage between L05 female (12) and chassis ground normal?
Remedy
Yes
No
1. 20 - 30 V 2. Turn starting switch ON
Defective main monitor
Replace
<Standard specification> Defective contact or disconnection in wiring harness between L05 (female) (12) and L04 (female) (5)
Repair or replace
<Auto-shift specification> Defective contact or disconnection in wiring Repair or harness between L05 replace (female) (12) and TLl (1) (female)
F. DOES NOT DISPLAY 2ND EVEN WHEN SPEED LEVER IS AT 2 (DIRECTIONAL LEVER AT F OR R) Cause 1 Is voltage between L05 female (13) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
WA700-3L
Remedy
Yes
No
Defective main monitor
Replace
<Standard specification> Defective contact or disconnection in wiring harness between L05 (female) (13) and L04 (female) (6)
Repair or replace
<Auto-shift specification> Defective contact or disconnection in wiring Repair or harness between L05 replace (female) (13) and TLl (2) (female)
20-807 1
TROUBLESHOOTING
M-4
12 G.
DOES NOT DISPLAY 3RD EVEN WHEN SPEED LEVER IS AT 3 (DIRECTIONAL LEVER AT F OR R) Cause 1 Is voltage between L05 female (14) and chassis ground normal?
Remedy
Yes
No
1. 20 - 30 V 2. Turn starting switch ON
Defective main monitor
Replace
<Standard specification> Defective contact or disconnection in wiring harness between L05 (female) (14) and L04 (female) (7)
Repair or replace
<Auto-shift specification> Defective contact or disconnection in wiring Repair or harness between L05 replace (female) (14) and TLl (3) (female)
H. DOES NOT DISPLAY 4TH EVEN WHEN SPEED LEVER IS AT 4 (DIRECTIONAL LEVER AT F OR R) Cause 1 Is voltage between L05 female (15) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
20-808 1
Remedy
Yes
No
Defective main monitor
Replace
<Standard specification> Defective contact or disconnection in wiring harness between L05 (female) (15) and L04 (female) (8)
Repair or replace
<Auto-shift specification> Defective contact or disconnection in wiring Repair or harness between L05 replace (female) (15) and TLl (4) (female)
WA700-3L
TROUBLESHOOTING
M-4
12 M-4 Related electrical circuit diagram Standard specification
Auto-shift specification
WA700-3L
20-809 1
TROUBLESHOOTING
M-5
12
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown
A. L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP Cause 1 Is voltage between L06 (14) and chassis ground normal?
Remedy
Yes
No
1. Repeats 0 V and 20 - 30 V 2. Turn starting switch ON 3. Turn L.H. turn signal ON
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L06 (female) (14) and L03 (female) (4)
Repair or replace
B. R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP Cause 1 Is voltage between L06 (15) and chassis ground normal?
Remedy
Yes
No
1. Repeats 0 V and 20 - 30 V 2. Turn starting switch ON 3. Turn R.H. turn signal ON
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L06 (female) (15) and L03 (female) (3)
Repair or replace
M-5 Related electrical circuit diagram
20-810 1
WA700-3L
TROUBLESHOOTING
M-6
12 M-6 ABNORMALITY IN PARKING DISPLAY ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP Cause 3 Yes Is resistance between F12 (female) (2) and chassis ground 2 normal? Yes Is voltage between L06 (11) and chassis ground normal? 1 Is resistance between F12 (male) (1) and (2) normal? 1. Max. 1 Ω 2. Disconnect F12 3. Turn starting switch ON 4. Turn parking switch ON.
1. 20 - 30 V 2. Turn starting switch ON 3. Turn parking switch ON
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect F12
Remedy
Yes
No
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between F12 (female) (1) and chassis ground
Repair or replace
Defective contact or disconnection in wiring Repair or harness between L06 (female) (11) - LR2 (14) - replace FR2 (6) - F12 (female) (1) Defective parking brake indicator switch
No
Replace
B. PARKING LAMP DISPLAY STAYS LIGHTED UP Cause 2
Yes Defective main monitor
Yes Is voltage between F12 (1) and chassis ground normal? 1 Is resistance between F12 (male) (1) and (2) normal? 1. Max. 1 Ω 2. Disconnect F12 3. Turn starting switch ON 4. Turn starting switch OFF
1. 0 - 2 V 2. Turn starting switch ON 3. Turn parking switch OFF No
Remedy
No
Replace
Short circuit with power source in harness between Repair or L06 (female) (11) - LR2 replace (14) FR2 (6) - CNl9 (female) (1) Defective parking brake indicator switch
Replace
M-6 Related electrical circuit diagram
WA700-3L
20-811 1
TROUBLESHOOTING
M-7
12
M-7 NIGHT LIGHTING DOES NOT LIGHT UP ★ ★ ★ ★
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the lamp bulbs are not blown. Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between FS2 (female) (5) and L05 (female) (16). Cause 1 Is voltage between L05 (16) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON 3. Turn small lamp switch ON
Remedy
Yes
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female) (16) and FS2 (5)
Repair or replace
M-7 Related electrical circuit diagram
20-812 1
WA700-3L
TROUBLESHOOTING
M-8
12 M-8 ABNORMALITY IN FRONT WORKING LAMP ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP Cause Yes
1 Is voltage between L60 (1) and chassis ground normal?
3
Yes
Yes Is voltage between L60 (6) and chassis ground normal?
1. 0 - 3 V 2. Turn starting switch ON
2
No
Is voltage between L60 (2), (5) and chassis ground normal?
1. 0 - 3 V 2. Turn starting switch ON
4
No
1. 20 - 30 V 2. Turn starting switch ON
1. 20 - 30 V 2. Turn starting switch ON No
Yes
Is voltage between L06 (1) and chassis ground normal?
Remedy
Defective contact or disconnection in wiring harness between L60 (female) (1) - L05 (17), CL1 (female) (7)
Repair or replace
Defective front working lamp relay
Replace
Defective contact or disconnection in wiring harness between L06 (female) (1) and L60 (female) (6)
Repair or replace
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L60 (female) (2), (5) and FS5 (female) (1)
Repair or replace
No
B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP Cause 1 Is voltage between L05 (17) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
Yes
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female) (17) and L60 (female) (1)
Repair or replace
C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP Cause
Remedy
Defective contact or disconnection in wiring harness between L60 (female) (1) - CL1 (7) CO3 (female) (1). C04 (female) (1). or between L60 (female) (3) - LR1 (12) - FR1 (7) - F0l (1). F04 (1) - front working lamp, or blown bulb in front working lamp
WA700-3L
Repair or replace
20-813 1
TROUBLESHOOTING
M-8
12 M-8 Related electrical circuit diagram
20-814 1
WA700-3L
TROUBLESHOOTING
M-9
12 M-9 ABNORMALITY IN REAR WORKING LAMP ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP Cause Yes
1 Is voltage between L61 (1) and chassis ground normal?
3
Yes
Yes Is voltage between L61 (6) and chassis ground normal?
1. 20 - 30 V 2. Turn starting switch ON
2
No
Is voltage between L61 (2), (5) and chassis ground normal?
1. 0 - 3 V 2. Turn starting switch ON
4
No
1. 0 - 3 V 2. Turn starting switch ON
1. 20 - 30 V 2. Turn starting switch ON No
Yes
Is voltage between L06 (2) and chassis ground normal?
Remedy
Defective contact or disconnection in wiring harness between L61 (female) (1) - L05 (18), LR1 (female) (8)
Repair or replace
Defective front working lamp relay
Replace
Defective contact or disconnection in wiring harness between L06 (female) (2) and L61 (female) (6)
Repair or replace
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L61 (female) (2), (5) and FS5 (female) (2)
Repair or replace
No
B. WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP Cause 1 Is voltage between L05 (17) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
Yes
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female) (18) and L61 (female) (1)
Repair or replace
C. MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP Cause
Remedy
Defective contact or disconnection in wiring harness between L61 (female) (1) - LR1 (8) GRl (7) - G06 (female) (l), Repair or G07 (female) (I), or replace between L61 (female) (3) LR1 (9) - GR1 (9) - G02 (I), G08 (1) or blown bulb in working lamp
WA700-3L
20-815 1
TROUBLESHOOTING
M-9
12 M-9 Related electrical circuit diagram
20-816 1
WA700-3L
TROUBLESHOOTING
M-10
12 M-10 ABNORMALITY IN TRANSMISSION CUT-OFF
STANDARD SPECIFICATION ★ Before disconnecting or connecting connectors, always turn starting switch OFF. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE Cause
Remedy
Defective main monitor
Replace
B. WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED. Cause
Remedy
Yes 1 Is voltage between L06 (3) and chassis ground normal?
4
1. 20 - 30 V 2. Turn cut-off switch ON
Yes Is voltage between L65 (1) and chassis 2 ground normal?
No
Is resistance between L06 (female) (3) and L65 (female) (2) normal? 1. Max. 1 Ω 2. Turn starting switch Off 3. Disconnect L05 and L65
WA700-3L
Yes
Yes Is voltage between L65 (5) and chassis ground normal? 3
1. 20 - 30 V 2. Turn starting switch ON 3. Disconnect L65
No
1. 20 - 30 V 2. Turn starting switch ON 3. Turn parking switch OFF No
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L65 (female) (5) and L66 (female) (1)
Repair or replace
Defective transmission cut-off relay
Replace
Defective contact or disconnection in wiring Repair or harness between L65 (female) (1), FS2 (female) replace (8) and fuse Defective contact or disconnection in wiring harness between L06 (female) (3) and L65 (female) (2)
Repair or replace
20-817 1
TROUBLESHOOTING
M-10
12 C.
TRANSMISSION CUT-OFF SWITCH TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED Cause 3 Yes 2 Yes Is voltage between L65 (5) and chassis ground normal? 1 Does cut-off function work? 1. Turn starting switch ON 2. Remove cut-off relay 3. Turn parking switch OFF
1. 0 - 3 V 2. Turn starting switch ON 3. Turn parking switch OFF No
Remedy
Yes Defective monitor panel
Replace
Does cut-off function work? 1. Disconnect L06 2. Turn starting switch ON 3. Turn parking switch OFF
No
No
Short circuit with chassis ground in harness between Repair or L06 (female) (3) and L65 replace (female) (2) Defective cut-off relay
Replace
Short circuit between L65 Repair or (female) (3) and (5) or replace defective cut-off switch
M-10 Related electrical circuit diagram
20-818 1
WA700-3L
TROUBLESHOOTING
M-10
AUTO-SHIFT SPECIFICATION ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE Cause
Remedy
Defective main monitor
Replace
B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED Cause 1
Yes
Is voltage between L06 (3) and chassis ground normal? 1. 0 - 3 V 2. Turn starting switch ON 3.Disconnect L12
No
Remedy
Defective contact or disconnection in wiring harness between L06 (female) (3) and C5 (female) (6)
Replace
Defective main monitor
Repair or replace
C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED Cause 2
Yes
Yes Is resistance between L12 (female) (2) and chassis ground 1 normal? Is resistance between L12 (male) (1) and (2) normal?
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L12
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L12 No
No
Remedy
Defective contact or disconnection in wiring harness between L12 (female) (1) and C5 (female) (6)
Repair or replace
Defective contact or disconnection in wiring harness between L12 (female) (2) and chassis ground
Repair or replace
Defective transmission cut-off switch
Replace
D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF) Cause 1 Is voltage between C5 (6) and chassis ground normal? 1. Max. 3 V
WA700-3L
Yes
No
Remedy
Defective transmission controller
Replace
Defective contact or disconnection in wiring harness between C5 Repair or (female) (6) and L06 replace (female) (3), L12 (female) (1)
20-819 1
TROUBLESHOOTING
M-10
12 E.
MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED Cause 1
Yes
Does cut-off function work when L12 is disconnected 1. Disconnect L12 2. Turn starting switch ON No
2
Defective transmission cut-off switch
Replace
Defective main monitor
Replace
Defective transmission controller
Replace
Yes
Does cut-off function work when L06 is disconnected? 1. Disconnect L06 2. Turn starting switch ON
Remedy
3
No
Yes
Is voltage between C5 (6) and chassis ground normal? 1. Disconnect L12 2. Turn starting switch ON 3. 20 - 30 V
No
Short circuit with power source in harness between Repair or L06 (female) (3) - C5 replace (female) (6) - L12 (female) (1)
M-10 Related electrical circuit diagram
20-820 1
WA700-3L
TROUBLESHOOTING
M-11
12 M-11 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ With or without auto-shift, use the flowchart below when in the steering wheel mode.
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N Cause 1
Remedy
Yes
Is voltage between L05 (8) and chassis ground normal? No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female) (8) - L04 (female) (3)
Repair or replace
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 ★ Check that the synchronous flash signal is normal. Cause 1
Defective main monitor
Is voltage between L05 (8) and chassis ground normal? 1. 0 - 5 V 2. Turn starting switch ON 3. Directional lever: Other than N
WA700-3L
Remedy
Yes
2
No
Yes
Is resistance between L05 (male) (8) and (3) normal? 1. 3 kΩ - 4 kΩ 2. Turn starting switch OFF 3. Disconnect L05
No
Replace
Short circuit with power source in wiring harness or between L05 (female) (8) - Repair replace L04 (female) (3). or defective directional lever Defective main monitor
Replace
20-821 1
TROUBLESHOOTING
M-11
12 M-11 Related electrical circuit diagram
20-822 1
WA700-3L
TROUBLESHOOTING
M-12
12 M-12 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. ACTUATED CONTINUOUSLY Cause 2 Yes 1
1. Turn starting switch ON 2. Connect L07 (6) to chassis ground.
Does buzzer stop and lamp go out? 1. Turn starting switch ON 2. Connect L19 (female) (5) to chassis ground.
Does buzzer stop and lamp go out?
Yes
No
No
Remedy
Defective maintenance monitor
Replace
Defective contact or disconnection in wiring harness between L07 (female1 (6) and L19 (female) (5)
Repair or replace
Defective main monitor
Replace
B. NOT ACTUATED Cause 2 Yes 1 Does buzzer and lamp work? 1. Turn starting switch ON 2. Disconnect L07
Yes
Remedy
Defective maintenance monitor
Replace
Does buzzer and lamp work? 1. Turn starting switch ON 2. Disconnect L19
No
No
Short circuit with power source in harness between Repair or L07 (female) (6) and L19 replace (female) (5) Defective main monitor
Replace
M-12 Related electrical circuit diagram
WA700-3L
20-823 1
TROUBLESHOOTING
M-13
12
M-13 ABNORMALITY IN BUZZER ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK) Cause Yes 1 Does buzzer sound?
2
1. Turn starting switch ON 2. Contact L43 (female) to chassis ground.
No
Defective contact or disconnection in wiring harness between L06 (female) (8) and L43 (male) (1)
Repair or replace
Defective buzzer
Replace
Defective contact or disconnection in wiring harness between L42 (female) (1) and FS2 (female) (9)
Repair or replace
Yes
Is voltage between L42 (female) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
No
B. BUZZER ALWAYS SOUNDS Cause
Remedy
Yes Defective main monitor
1 Yes
Does buzzer stop when L06 is disconnected? 1. Disconnect L06 2. Turn starting switch ON No
Go to Troubleshooting for maintenance monitor
2 3
Does buzzer stop when L19 is disconnected 1. Disconnect L19 2. Turn starting switch ON
No
Yes
Does buzzer stop when L43 is disconnected? 1. Disconnect L43 2. Turn starting switch ON
No
Replace
---
Short circuit with power source in harness between Repair or L06 (female) (8) and L43 replace (male) (1) Defective buzzer
Replace
M-13 Related electrical circuit diagram
20-824 1
WA700-3L
TROUBLESHOOTING
M-14
12 M-14 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 1 Is voltage between L07 (10) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON.
Remedy
Yes
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L07 (female) (10) and L09 (female) (2)
Repair or replace
M-14 Related electrical circuit diagram
WA700-3L
20-825 1
TROUBLESHOOTING
M-15
12
M-15 ABNORMALITY IN FAILURE DISPLAY MODE ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. DOES NOT ENTER FAILURE DISPLAY MODE Cause 1
Defective main monitor
Is voltage between L05 (5) and chassis ground normal? 1. 0 - 5 V 2. Turn starting switch ON
Remedy
Yes
No
Replace
Short circuit with power source in wiring harness between L05 (female) (5) - Repair or LR4 (6) - ER1 (9) replace alternator terminal R, or defective alternator
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE Cause 1
Yes
Is voltage between L05 (5) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L05 (female) (5) - LR4 (6) ER1 (9) - alternator terminal R or defective alternator
Repair or replace
M-15 Related electrical circuit diagram
20-826 1
WA700-3L
TROUBLESHOOTING
M-16
12 M-16 ABNORMALITY IN ELECTRIC ENGINE THROTTLE CONTROLLER ERROR DISPLAY ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step.
A. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [91] IS DISPLAYED Cause 1
Defective main monitor
Is voltage between L07 (9) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
Yes
2
No
Yes
Is voltage between EC1 (female) (15) and chassis ground normal? 1. 20 - 30 V 2. Disconnect EC1 3. Turn starting switch ON
Replace
No
See Troubleshooting (G mode) of electric engine throttle controller
---
Short circuit with chassis ground in wiring harness between L07 (female) (9) and EC1 (female) (15)
Repair or replace
B. THERE IS NO ABNORMALITY ON MACHINE BUT ERROR CODE [92] IS DISPLAYED Cause 1
Defective main monitor
Is voltage between L07 (5) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
Yes
2
No
Yes
Is voltage between EC1 (female) (6) and chassis ground normal? 1. 20 - 30 V 2. Disconnect EC1 (female) 3. Turn starting switch ON
Replace
No
See Troubleshooting (G mode) of electric engine throttle controller
---
Short circuit with chassis ground in wiring harness between L07 (female) (5) and EC1 (female) (6)
Repair or replace
C. PROBLEM IS ERROR CODE [90(94)] BUT ERROR CODE [91(93)] IS DISPLAYED Cause 1 Is voltage between L07 (5) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON
2
No
Yes
Is voltage between EC1 (female) (6) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON
WA700-3L
Remedy
Yes
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L07 (female) (5) and EC1 (female) (6)
Repair or replace
See Troubleshooting (G mode) of electric engine throttle controller
---
20-827 1
TROUBLESHOOTING
M-16
12 D.
PROBLEM IS ERROR CODE [90(96)] BUT ERROR CODE [92(95)] IS DISPLAYED Cause 1 Is voltage between L07 (9) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON
Remedy
Yes
2
No
Yes
Is voltage between EC1 (female) (15) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON
No
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between L07 (female) (9) and EC1 (female) (15)
Repair or replace
See Troubleshooting (G mode) of electric engine throttle controller
---
M-16 Related electrical circuit diagram
20-828 1
WA700-3L
TROUBLESHOOTING
M-17
12 M-17 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step.
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP Cause 1
Yes Defective main monitor
Is voltage between L05 (11) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
No
Replace
Short circuit with chassis ground in wiring harness Repair or between L05 (female) (11) replace - LR4 (13) - R0l (female) (1) or defective emergency steering actuation sensor
Replace
B. EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP Cause 1
Defective main monitor
Is voltage between L05 (11) and chassis ground normal? 1. 0 - 2 V 2. Turn starting switch ON
Remedy
Yes
No
Replace
Defective contact or disconnection in wiring Repair or harness between L05 (female) (11) - LR4 (13) - replace R0l (female) (1) or defective emergency steering actuation sensor
Replace
M-17 Related electrical circuit diagram
WA700-3L
20-829 1
TROUBLESHOOTING
M-18
12
M-18 ABNORMALITY IN AUTO-GREASING SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. FORCED GREASING CANNOT BE CARRIED OUT Cause 2
Yes
Yes Is voltage between GRE (1) and chassis ground normal? 1 Is voltage between LO6 (5) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON 3. Turn autogreasing switch ON.
1. Max. 3 V 2. Turn starting switch ON 3. Turn autogreasing switch ON.
No
No
Remedy
See “Handling autogreasing system” in Operation and Maintenance Manual
---
Defective contact or disconnection in wiring Repair or harness between L06 replace (female1 (5) and GRE (1)
Defective main monitor
Disconnect
B. MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SET) Cause 1
Yes
Is voltage between L08 (5) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Remedy
2
No
Replace
Defective contact or disconnection in wiring harness between L08 (female) (5) and GRE (3)
Repair or replace
Yes
Is voltage between GRE (3) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
Defective main monitor
No
See “Handling autogreasing system” in Operation and Maintenance Manual
---
C. WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) Cause 1
Defective main monitor
Is voltage between L07 (11) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
2
No
Replace
Yes Defective contact or disconnection in wiring Repair or harness between L07 replace (female) (11) and GRE (2)
Is voltage between GRE (2) and chassis ground normal? 1. 20 - 30 V 2. Turn starting switch ON
20-830 1
Remedy
Yes
No
See “Handling autogreasing system” in Operation and Maintenance Manual
---
WA700-3L
TROUBLESHOOTING
M-18
12 MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) D.
Confirm that grease is not empty.
Cause
Remedy
See “Handling autogreasing system” in Operation and Maintenance Manual
---
E. MONITOR DISPLAY GOES OUT Cause 1
Yes Defective main monitor
Is voltage between L78 (11) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON
Remedy
2
No
Yes Short circuit with power source in wiring harness Repair or between L07 (female)(11) replace and GRE (female) (2)
Is voltage between GRE (female) (2) and chassis ground normal? 1. 2 - 3 V 2. Turn starting switch ON 3. Disconnect GRE
Replace
See “Handling autogreasing system” in Operation and Maintenance Manual
No
Table 1
Relationship between input signal and display
L07(11)
L08(5)
L
L
Rapid flashing (2 times/sec)
H
L
Slow flashing (1 time/sec)
H
H
OFF
L
H
ON
---
Display
M-18 Related electrical circuit diagram
WA700-3L
20-831 1
TROUBLESHOOTING
M-19
12
M-19 ABNORMALITY IN LOW IDLING SELECT SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step.
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED Cause
Remedy
Defective main monitor
Replace
B. MONITOR DISPLAY LIGHTS UP BUT LOW IDLING SELECT FUNCTION DOES NOT WORK Cause 2
Yes
Yes Is voltage between EC5A (5) and chassis ground 1 normal? Is voltage between LO6 (7) and chassis ground normal? 1. Max. 3 V 2. Turn starting switch ON
1. Max. 3 V 2. Turn starting switch ON
No
No
Remedy
See Troubleshooting (G mode) of electric engine throttle controller
---
Defective contact or disconnection in wiring Repair or harness between L06 replace (female1 (7) and EC5A (5)
Defective main monitor
Replace
M-19 Related electrical circuit diagram
20-832 1
WA700-3L
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 12G26G S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) . . . . . . . . . . . . . . . . . 20-903 S-2 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-908 A. ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-908 B. EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) . . . . . . . . . . . . . . . . . . . . . . . . . 20-911 S-4 ENGINE STOPS DURING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-914 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-915 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-916 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) . . . . . . . . . . . . . . . . . . . . . . 20-917 S-9 OIL BECOMES CONTAMINATED QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918 S-10 FUEL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-919 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN . 20-920 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) . . . . . . . . . . . . . . . . . . . 20-921 S-13 OIL LEVEL RISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) . . . . . . . . . . . . . . . . . . . . . . . . 20-923 S-15 ABNORMAL NOISE IS MADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-924 S-16 VIBRATION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-926
WA700-3L
20-901â&#x17E;&#x20AC;
TROUBLESHOOTING 12
MEMORANDUM
20-902 1
WA700-3L
TROUBLESHOOTING
S-1
12 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) General causes why exhaust smoke comes out but engine takes time to start • Defective electrical system • Insufficient supply of fuel • Insufficient supply of air • Improper selection of fuel (At ambient temperature of 10°C or below, use ASTM D975 No. 1) ★ Battery charging rate Ambient temperature 100%
• •
Charging rate 90%
80%
75%
70%
20° C
1.28
1.26
1.24
1.23
1.22
0° C
1.29
1.27
1.25
1.24
1.23
-10° C
1.30
1.28
1.26
1.25
1.24
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.
WA700-3L
20-903 1
TROUBLESHOOTING
S-1
12
Defective injection timing
Defective injection nozzle
Defective or deteriorated battery
Defective alternator
O
Defective regulator
Clogged fuel filter, priming pump strainer
O
Defective APS device heater
Clogged air cleaner element
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) â&#x2014;?: Items to confirm the cause
Worn piston ring, cylinder
This chart is part ONE of FOUR parts
Defective contact of valve, valve seat
Causes
Confirm recent repair history Degree of use of machine - Operated for long period
Questions
Ease of starting - Gradually became worse Ease of starting - Starts when warm Starting again takes time after warm-up Preheating indicator lamp is light up Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual
O
Dust indicator is red Non-specified fuel has been used
O
O
Battery charge caution lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinder is low Check items
Engine does not pick up smoothly and combustion is irregular
O
O
Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor; 1. Little fuel comes out even when injection pump sleeve nut is loosened 2. little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular)
20-904 1
O
WA700-3L
TROUBLESHOOTING
S-1 ●
When compression pressure is measured, it is found to be low
● ●
When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged
●
When priming pump strainer is inspected directly, it is found to be clogged
● ●
Glow plug mount does not become warm
●
Troubleshooting
Is voltage 26 - 30 V between alternator terminal B and terminal E with engine at low idling - Yes
●
Is voltage 26 - 30 V between alternator terminal B and terminal E with engine at low idling - No
●
Either specific gravity of electrolyte or voltage of battery is low
●
Speed does not change when operation of certain cylinders is stopped
●
When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed, it does not return (when rack stopper bolt at rear of pump is removed and rack piston is pushed with a screwdriver during cleaning, rack does not Move) When fuel tank cap is inspected directly, it is found to be clogged Inspect governor oil pump directly Inspect governor spool valve directly When governor oil supply pipe is inspected directly, it is found to be clogged When governor oil strainer is inspected directly, it is found to be clogged
Adjust
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Remedy
Replace
When overflow valve is inspected, it is found to be stiff or open
This chart is part TWO of FOUR parts
WA700-3L
20-905 1
TROUBLESHOOTING
S-1
12
Clogged governor oil supply pipe
Clogged governor oil strainer
Defective overflow valve of fuel injection pump
Defective operation of relief valve of governor oil pump
Seized governor oil pump gear, shaft
Stuck governor spool valve
Clogged air breather hole in fuel tank
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) â&#x2014;?: Items to confirm the cause
Defective injection pump (rack,
This chart is part THREE of FOUR parts
Leakage, clogging, air in injection system
Causes
O
O
Confirm recent repair history Degree of use of machine - Operated for long period
Questions
Ease of starting - Gradually became worse
O
Ease of starting - Starts when warm Starting again takes time after warm-up Preheating indicator lamp is lite up Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual
O
Dust indicator is red Non-specified fuel has been used
O
Battery charge caution lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinder is low Check items
Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap
O
When engine is cranked with starting motor; 1. Little fuel comes out even when injection pump sleeve nut is loosened
O
O
O
O
2. little fuel comes out even when fuel filter air bleed plug is loosened
O
O
O
O
Leakage from fuel piping There is hunting from engine (rotation is irregular)
20-906 1
O O
WA700-3L
TROUBLESHOOTING
S-1
When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged ●
When fuel filter, strainer are inspected directly, they are found to be clogged When priming pump strainer is inspected directly, it is found to be clogged Glow plug mount does not become warm Is voltage 26 - 30 V between alternator terminal B and terminal E with engine at low idling - No Either specific gravity of electrolyte or voltage of battery is low When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed, it does not return (when rack stopper bolt at rear of pump is removed and rack piston is pushed with a screwdriver during cleaning, rack does not Move)
● ●
When fuel tank cap is inspected directly, it is found to be clogged
●
Inspect governor oil pump directly
●
●
Inspect governor spool valve directly
●
When governor oil supply pipe is inspected directly, it is found to be clogged
●
When governor oil strainer is inspected directly, it is found to be clogged
Clean
Replace
Adjust
Replace
Clean
Correct
Replace
Remedy
Replace
●
When overflow valve is inspected, it is found to be stiff or open
clean
Troubleshooting
Is voltage 26 - 30 V between alternator terminal B and terminal E with engine at low idling - Yes
This chart is part FOUR of FOUR parts
WA700-3L
20-907 1
TROUBLESHOOTING
S-2
12
S-2 ENGINE DOES NOT START A. ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) General causes why engine turns but no exhaust smoke comes out • Supply of fuel impossible • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) ★ Standards for use of fuel ★ In winter, if No. 1 diesel oil is not available, a 50 - 50 mixture of No. 2 diesel oil and kerosene can be used.
This is chart one of two charts.
Seized governor oil pump gear, shaft
Defective operation of relief valve of governor oil pump
●
●
Replace
Replace
O
Improper fuel used
O
Clogged air breather hole in fuel tank
O
Clogged, leaking fuel piping
Clogged priming pump strainer
O
Lack of fuel
Clogged fuel filter, strainer
Seized, broken feed pump piston (gear, shaft)
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Defective injection pump (rack, plunger seized)
Broken injection pump drive shaft, key
Causes
Confirm recent repair history Questions
Degree of use of machine - Operated for long period Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operational Manual When fuel tank is inspected, it is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank
Check items
When fuel filter is drained, fuel does not come out When engine is cracked with starting motor; 1. Injection pump coupling does not turn 2. No fuel comes out even when fuel filter air bleed plug is loosened Rust and water are found when fuel is drained ●
Inspect fuel pump directly
●
Control rack does not move Troubleshooting
O
3. No fuel spurts out even when injection pipe sleeve nut is loosened
●
Inspect feed pump directly
●
When fuel filter, strainer are inspected directly, they are found to be clogged
● ●
When fuel cap is inspected directly, it is found to be clogged Inspect governor oil pump directly Inspect governor spool valve directly When governor oil supply pipe is inspected directly, it is found to be clogged
20-908 1
Replace
Correct
Correct
Add
Clean
Clean
Replace
Replace
Remedy
Replace
When governor oil strainer is inspected directly, it is found to be clogged
WA700-3L
TROUBLESHOOTING
S-2
12
This is chart two of two charts.
Clogged governor oil strainer
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged governor oil supply pipe
Stuck governor spool valve
Causes
O
O
O
O
Confirm recent repair history Questions
Degree of use of machine - Operated for long period Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operational Manual When fuel tank is inspected, it is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank Check items
When fuel filter is drained, fuel does not come out When engine is cracked with starting motor; 1. Injection pump coupling does not turn 2. No fuel comes out even when fuel filter air bleed plug is loosened 3. No fuel spurts out even when injection pipe sleeve nut is loosened Rust and water are found when fuel is drained Inspect fuel pump directly Inspect feed pump directly When fuel filter, strainer are inspected directly, they are found to be clogged
When fuel cap is inspected directly, it is found to be clogged Inspect governor oil pump directly ●
Inspect governor spool valve directly
●
When governor oil supply pipe is inspected directly, it is found to be clogged
●
WA700-3L
Clean
Remedy
Replace
When governor oil strainer is inspected directly, it is found to be clogged
Clean
Troubleshooting
Control rack does not move
20-909 1
TROUBLESHOOTING
S-2
12 B.
EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air Improper selection of fuel and oil
Engine oil viscosity too high
Improper fuel used
Clogged air breather hole in fuel tank
Clogged injection nozzle, defective spray
Leakage, clogging, air in fuel system
Defective or deteriorated battery
Defective APS device
Clogged air cleaner element
Clogged feed pump strainer
Clogged fuel filter, strainer
Worn piston ring, cylinder liner
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Defective injection pump (rack, plunger stuck)
Defective, broken dynamic valve system (valve, rocker lever, etc.)
Causes
Confirm recent repair history
Questions
Degree of use of machine - Operated for long period Suddenly failed to start When engine is cranked, abnormal noise is heard from around head Engine oil must be added more frequently Non-specified fuel is being used
O
O
Replacement of filters has not been carried out according to Operation Manual Rust is found when fuel is drained Dust indicator is red Preheating pilot does not light up Starting motor cranks engine slowly Check items
Mud is stuck to fuel cap
O
When engine is cranked with starting motor; 1. Little fuel comes out even when injection pump sleeve nut is loosened 2. Little fuel comes out even when fuel filter air bleed plug is loosened
O
There is leakage from fuel piping When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When fuel filter is drained, no fuel comes out ●
Remove head cover and check
●
When control rack is pushed, it is found to be heavy or does not return
● ●
When fuel filter, strainer are inspected, they are found to be clogged
● ●
When feed pump strainer is inspected, it is found to be clogged
●
When air cleaner element is inspected, it is found to be clogged
●
Glow plug mount does not become warm
●
Either specific gravity of electrolyte or voltage of battery is low
●
When feed pump is operated, operation is too light or too heavy
●
Speed does not change when operation of certain cylinders is stopped
20-910 1
Replace
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Replace
Remedy
Replace
●
When fuel cap is inspected, it is found to be clogged
Clean
Troubleshooting
When compression pressure is measured, it is found to be low
WA700-3L
TROUBLESHOOTING
S-3
12 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
Clogged, leaking fuel piping
O
O
Defective contact of valve and valve seat
Clogged air breather hole in fuel tank cap
Improper valve clearance
Seized turbocharger, interference
Worn piston ring, cylinder liner
Seized injection pump plunger
Clogged feed pump strainer
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged fuel filter, strainer
Check that there is no abnormality display for the governor control system on the monitor panel. General causes why engine does not pick up smoothly • Insufficient supply of air • Insufficient supply of fuel • Improper condition of fuel injection • Improper fuel used
Clogged air cleaner element
•
Clogged injection nozzle, defective spray
Causes
Confirm recent repair history
Questions
Degree of use machine - Operated for long period Replacement of filters has not been carried out according to the Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Rust and water are found when fuel tank is drained Dust indicator caution is red Noise of interference is heard from around turbocharger Engine pick-up suddenly became poor
O
Color of exhaust gas - Blue under light load Color of exhaust gas - Black
O
Check items
Clanging sound is heard from around cylinder head Mud is stuck to fuel tank cap There is leakage from fuel piping High idling speed under no load is normal, but speed suddenly drops when load is applied
O
There is hunting from engine (rotation is irregular)
O
O
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
O O
Blow-by gas is excessive ●
When air cleaner element is inspected, it is found to be clogged
●
When fuel filter, strainer is inspected and are found to be clogged
● ●
Speed does not change when operation of certain cylinders is stopped
●
When control rack is pushed and found to be heavy or does not return
●
When compression pressure is measured and found to be low
● ●
When turbocharger is rotated by hand and found to be heavy
●
When valve clearance is checked and found to be outside standard value
●
When valve clearance is checked and found to be outside the standard value
●
When fuel tank cap is inspected and found to be clogged
●
WA700-3L
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
Replace
Troubleshooting
When feed pump strainer is inspected and found to be clogged
20-911 1
TROUBLESHOOTING
S-4
12
S-4 ENGINE STOPS DURING OPERATIONS
Clogged priming pump strainer
Clogged fuel filter, strainer
Lack of fuel
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Broken injection pump drive shaft, key
This is chart one of two charts
Broken pump or auxiliary equipment
If the machine stopped because of a failure on the machine, carry out troubleshooting for the chassis.
Broken, seized gear train
★
Broken dynamic valve system (valve, broken lever, etc.)
If there is overheating and the engine stops, carry out troubleshooting for overheating. Failure on machine
Broken, seized crankshaft bearing
★ •
Broken, seized piston, connection rod
Causes General causes why engine stops during operations • Seized parts inside engine • Insufficient supply of fuel • Overheating
Confirm recent repair history Degree of use of machine - Operated for long period
Questions
Abnormal noise was heard and engine stopped suddenly Condition when engine stopped
Engine over heated and stopped
O
O
Engine stopped slowly
O
O
There was hunting and the engine stopped
O
O
Non-specified fuel is being used
O
O
When feed pump is operated, operation is too light or too heavy
O
O
O
O
Fuel level lamp is lit up When fuel tank is inspected and found to be empty Replacement of filters has not been carried out according to the Operational Manual
Check items
Mud is stuck to fuel tank cap Engine turns but stops when transmission lever is operated Does not turn at all When it is attempted to turn by hand using barring tool
Turns in opposite direction Moves amount of backlash Shaft does not rotate
Rust and water are found when fuel tank is drained Metal particles are found when oil is drained ●
Remove oil pan and inspect
● ●
Remove head cover and inspect
●
Troubleshooting
When gear train is inspected, it does not turn
●
When pump auxiliary equipment is removed, pump turns
●
When fuel filter, strainer are inspected and found to be clogged
●
When priming pump strainer is inspected and found to be clogged Inspect feed pump directly Control rack does not move Inspect governor oil pump When governor oil supply pipe is inspected and found to be clogged
20-912 1
Clean
Clean
Add
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
When governor oil strainer is inspected and found to be clogged
WA700-3L
TROUBLESHOOTING
S-4
12
Clogged governor oil strainer
Clogged governor oil supply pipe
Defective operation of relief valve of governor oil pump
Broken, seized governor oil pump gear, shaft
Failure at chassis end
Clogged air breather hole in fuel tank
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged, leaking fuel piping
Broken, seized gear, shaft
This is chart two of two charts
Defective injection pump (rack, plunger stuck)
Causes
Confirm recent repair history Degree of use of machine - Operated for long period
Questions
Abnormal noise was heard and engine stopped suddenly Condition when engine stopped
O
O
O
O
Engine over heated and stopped Engine stopped slowly There was hunting and the engine stopped
Fuel level lamp is lit up When fuel tank is inspected and found to be empty Replacement of filters has not been carried out according to the Operational Manual Non-specified fuel is being used When feed pump is operated, operation is too light or too heavy
Check items
Mud is stuck to fuel tank cap Engine turns but stops when transmission lever is operated Does not turn at all When it is attempted to turn by hand using barring tool
Turns in opposite direction Moves amount of backlash Shaft does not rotate
Rust and water are found when fuel tank is drained O
When priming pump strainer is inspected and found to be clogged ●
Inspect feed pump directly
●
Control rack does not move Inspect governor oil pump When governor oil supply pipe is inspected and found to be clogged
WA700-3L
Replace
Clean
Correct
Remedy
Replace
When governor oil strainer is inspected and found to be clogged
●
● ● ● Clean
When fuel filter, strainer are inspected and found to be clogged
Clean
When pump auxiliary equipment is removed, pump turns
Replace
Troubleshooting
When gear train is inspected, it does not turn
Replace
Remove head cover and inspect
---
Remove oil pan and inspect
Carry out troubleshooting for the chassis
Metal particles are found when oil is drained
20-913 1
TROUBLESHOOTING
S-5
12
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
Clogged, air in circuit between feed pump and nozzle
O
O
O
O
Clogged governor oil pump inlet port filter, pipe
Clogging, air in circuit between fuel tank and priming pump
O
Clogged governor oil pump screen filter
Clogged fuel filter, strainer
O
Clogged air breather hole in fuel tank
Clogged priming pump strainer
O
Lack of fuel
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Low idling speed is too low
Defective adjustment of governor (solenoid, spool)
O
General causes why engine does not rotate smoothly • Air in fuel system • Defective governor mechanism
Defective operation of control rack
Defective operation of governor
Causes
Confirm recent repair history Degree of use of machine
Operated for long period
Questions
occurs at a certain speed range Condition of hunting
Occurs at low idling
O
Occurs even when speed is raised
O
O
Occurs on slopes When fuel tank is inspected and found to be empty Replacement of filters has not been carried out according to the Operation Manual Rust is found when the fuel is drained
Check items
Leakage from fuel piping When priming pump is operated; 1. No response, light, return is quick 2. No response, light, return is normal Engine speed sometimes rises too far Engine is sometimes difficult to stop ●
●
●
●
Movement of spool valve is stiff
●
When control rack is pushed, it is found to be heavy or does not turn
●
When fuel cap is inspected and found to be clogged
● ●
When priming pump strainer is inspected and found to be clogged
●
When fuel filter, strainer are inspected and found to be clogged
●
When governor oil screen filter is inspected and found to be clogged
●
20-914 1
Replace
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust
When governor oil inlet port filter, supply pipe are inspected and found to be clogged
Clean
Troubleshooting
Movement of governor lever (solenoid plunger) is stiff
WA700-3L
TROUBLESHOOTING
S-6
12 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
Defective variable pre-stroke spool solenoid
Clogged air breather hole in fuel tank
O
Clogged, leaking fuel piping
O
Defective contact of valve and valve seat
Clogged injection nozzle, defective spray
O
Improper valve clearance
Clogged feed pump strainer
O
Sized injection pump plunger
Clogged fuel filter, strainer
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Worn piston ring, cylinder
If there is overheating and lack of output, carry out troubleshooting for OVERHEATING.
Seized turbocharger, interference
★
Clogged air cleaner element
Causes General causes why engine lacks output • Insufficient supply of air • Insufficient supply of fuel • Improper condition of fuel injection • Improper fuel used (if non-specified fuel is used, output drops) • Lack of output due to overtaking
Confirm recent repair history
Questions
Degree of use machine Power was lost
Operated for long period Suddenly Gradually
O
O
Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Dust indicator caution is red
Check items
Color of exhaust gas
Black Blue under light load
Noise of interference is heard from around turbocharger Blow-by gas is excessive Engine pickup is poor and combustion is irregular
O
O
High idling speed under no load is normal, but speed suddenly drops when load is applied
O O
When exhaust manifold is touched immediately after starting engine,
O
temperature of some cylinders is low There is hunting from engine (rotation is irregular)
O
O
O
O
Clanging sound is heard from around cylinder head High idling speed of engine is low
O
Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged
● ●
When turbocharger is rotated by hand, it is found to be heavy
●
● ●
When fuel filter, strainer are inspected directly, they are found to be clogged
●
When feed pump strainer is inspected directly, it is found to be clogged
●
Speed does not change when operation of certain cylinders is stopped
●
When control rack is pushed and found to be heavy or does not return
●
When valve clearance is checked and found to be outside standard value
●
When feed pump is operated, operation is too light or to heavy
●
When fuel cap is inspected and found to be clogged
●
WA700-3L
Clean
Correct
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
Inspect sliding of spool valve solenoid for variable pre-stroke
---
Troubleshooting
When compression pressure is measured, it is found to be low
20-915 1
TROUBLESHOOTING
S-7
12
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
Defective variable pre-stroke spool solenoid
Defective injection pump (rack, plunger seized)
Defective contact of valve and valve seat
Leakage of air between turbocharger and head
Crushed, clogged muffler
Improper valve clearance
Defective injection pump (excessive injection)
Improper injection timing
Worn piston ring, cylinder
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged air cleaner element
Seized turbocharger, interference
General causes why exhaust smoke is black • Insufficient supply of air • Improper condition of fuel injection • Excessive injection of fuel
Clogged injection nozzle, defective spray
Causes
Confirm recent repair history
Questions
Degree of use machine Color of exhaust gas
Operated for long period Suddenly became black
O
Gradually became black
O
O O
Blue under light load Engine oil must be added more frequently Power was lost
Suddenly
O
Gradually
O
O
O
Non-specified fuel is being used
O O
O
O
O
Noise of interference is heard from around turbocharger Dust indicator caution is red Blow-by gas is excessive Check items
Engine pick-up is poor and combustion is irregular
O
O
O
O
O
When exhaust manifold is touched immediately after stating engine, temperature of
O
some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal
O
O
Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated is rotated by hand and found to be heavy
● ●
When air cleaner is inspected and found to be clogged
●
● ●
Speed does not change when operation of certain cylinders is stopped When check is made using piston displacement method, injection timing is found to be correct
● ●
injection pump test shows that injection amount is incorrect
●
When valve clearance is checked directly and found to be outside standard value
●
When muffler is removed, exhaust color returns to normal
●
When control rack is pushed and found to be heavy or does not return
●
20-916 1
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
Inspect sliding of spool valve of solenoid for variable pre-stroke
---
Troubleshooting
When compression pressure is measured and found to be low
WA700-3L
TROUBLESHOOTING
S-8
12 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) Remark Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
Worn valve (stem, guide), broken seal
Dust sucked in from intake system
Worn, broken rear seal, seal surface
Worn seal at blower end
Worn seal at Turbine end
Turbocharger
Broken oil cooler
Leakage from oil pan or cylinder head
leakage from oil drain plug
Leakage from oil piping
Clogged breather or breather hose
Worn piston ring, cylinder liner
Broken piston ring
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Leakage from oil filter or oil cooler
Causes General causes why oil consumption is excessive; • Abnormal combustion of oil • External leakage of oil • Wear of lubrication system
Questions
Confirm recent repair history Degree of use machine
Operated for long period
Oil consumption suddenly increased
O
Engine oil must be added more frequently
O
Engine oil becomes contaminated quickly
O
O
Exhaust smoke is blue under light load
Check items
Amount of blow-by gas
O
O
Excessive None
Area around engine is dirty with oil Oil is in engine cooling water When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil
O
Oil rises in clutch or TORQFLOW transmission damper chamber Clamps for intake system are loose ●
When compression pressure is measured and found to be low
● ● ●
There is external leakage of oil from the engine
●
●
● ●
Pressure-tightness test of oil cooler shows there is leakage
●
Excessive play of turbocharger shaft
● ●
Inspect rear seal directly
●
When intake manifold is removed, dust is found inside
●
WA700-3L
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be dirty with oil
Correct
Troubleshooting
When breather element is inspected and found to be clogged with dirty oil
20-917 1
TROUBLESHOOTING
S-9
12
S-9 OIL BECOMES CONTAMINATED QUICKLY
Degree of use machine
O
Non-specified oil is being used
Amount of blow-by gas
O Blue under light load Black Excessive
O
O
O
None
When oil filter is inspected, metal particles are found
O
O
When exhaust pipe is removed and inside of pipe is dirty with oil Engine oil temperature rises quickly Oil is higher than H line on level gauge ●
When compression pressure is measured and found to be low
● ●
When breather element is inspected and hose is broken or found to be clogged with dirty oil
●
When oil filter is inspected and found to be clogged
●
When oil cooler is inspected and found to be clogged
●
Turbocharger drain tube is clogged
●
Excessive play of turbocharger shaft
●
When safety valve is inspected, spring found to be catching or broken
●
20-918 1
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Remedy
Replace
Oil is higher than H line on level gauge
Correct
Troubleshooting
Exhaust smoke is black
Too much oil added
Defective safety valve
Defective seal at turbocharger turbine end
Clogged turbocharger drain pipe
Clogged oil cooler
Operated for long period
Engine oil must be added more frequently
Color of exhaust gas Check items
Worn valve, valve guide
Confirm recent repair history
Carry out troubleshooting for EXHAUST SMOKE IS BLACK
Questions
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged oil filter
Worn piston ring, cylinder liner
General causes why oil becomes contaminated quickly • Entry of exhaust gas due to internal wear • Clogging of lubrication passage • Improper fuel • Improper oil used • Operation under excessive load
Clogged breather, breather hose
Causes
WA700-3L
TROUBLESHOOTING
S-10
12 S-10 FUEL CONSUMPTION IS EXCESSIVE
O
Defective adjustment of fuel control linkage
O
Defective oil seal inside feed pump (piston)
Leakage of fuel inside head cover
O
External leakage from fuel piping, fuel filter
O
Defective fuel injection timing
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Defective injection pump plunger
Defective injection pump (excessive injection)
General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection • Excessive injection of fuel
Defective nozzle holder spray
Causes
Questions
Confirm recent repair history Degree of use machine
Operated for long period More than for other machines of same model
Condition of fuel consumption
O
Gradually increased Suddenly increased
Check items
Exhaust smoke color
Black
O
O
O
White
O
Seal on injection pump has come off There is irregular combustion When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
O
Match mark on injection pump is misaligned There is external leakage of fuel from engine O
Engine low idling speed is high
O
When injection pump is tested, injection amount is found to be excessive
● ●
Speed does not change when operation of certain cylinders is stopped
●
When control rack is pushed and found to be heavy or does not run
●
When check is made, injection timing is found to be incorrect
●
Remove head cover and inspect
●
Remove feed pump and inspect
●
WA700-3L
Correct
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
When engine speed is measured, low idling speed is found to be high
Adjust
Troubleshooting
Engine oil level rises and smells of diesel fuel
20-919 1
TROUBLESHOOTING
S-11
12
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
O
Damaged water pump seal (breather clogged)
O
Broken oil cooler for power train
Internal cracks in cylinder block
O
Insufficient protrusion of liner
Broken cylinder head, head gasket
O
Confirm recent repair history Degree of use machine Oil level
Operated for long period Suddenly increased Gradually increased
Hard water is being used as cooling water Check items
Broken oil cooler core, O-ring
Questions
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Damaged liner O-ring, holes made by pitting
Causes General causes why oil is in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system
O
O
Engine oil level has risen, oil is cloudy white
O
O
●
●
O
Excessive air bubbles inside radiator, spurts back Power train oil is milky white ●
Pressure-tightness test of oil cooler shows there is leakage
●
Pressure-tightness test of cylinder head shows there is leakage
●
Remove cylinder head and inspect Remove oil pan and inspect
20-920 1
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
●
When water pump is inspected, there is an abnormal noise Replace
Troubleshooting
When power train oil is drained, water comes out
WA700-3L
TROUBLESHOOTING
S-12
12 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) General causes why oil pressure caution lamp lights up • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating Check that the engine oil level is correct before starting troubleshooting. Standards for engine oil selection
Defective oil pressure sensor
O
O
Water, fuel in oil
Defective oil level sensor
Leaking, crushed hydraulic piping
Defective relief valve
Defective regulator valve
Lack of oil pan oil
Defective oil pump
O
Broken suction pipe brazing
O
Clogged oil pipe inside oil pan
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged strainer inside oil pan
Causes
Worn bearing, journal
★
Clogged oil filter
★
Questions
Confirm recent repair history Degree of use machine
Operated for long period
Replacement of filters has not been carried out according to Operation Manual Caution lamp is ON
O
Non-specified oil is being used Lights up at low idling
Check items
Condition when oil pressure lamp lights up
O
Lights up at high idling
O
O
Lights up on slopes Sometimes lights up
There is crushing, leakage from hydraulic piping (external) Oil level sensor lights up When oil level in oil pan is inspected and found to be low Metal particles are found when the oil is drained Metal particles are stuck to oil filter element
O
Oil is cloudy white or smells of diesel oil ●
●
● ●
Oil pump rotation is heavy and there is play There is catching of relief valve or regulator valve, spring or valve guide is broken
●
● ●
When oil level sensor is replaced, oil level sensor lamp goes out
●
WA700-3L
---
Replace
Correct
Adjust
Adjust
Replace
Correct
Clean
Clean
Clean
Remedy
Clean
When oil pressure is measured and found to be within standard value
---
Troubleshooting
●
Remove oil pan and inspect
Carry out troubleshooting for OIL LEVEL RISES
●
When oil filter is inspected and found to be clogged
20-921 1
TROUBLESHOOTING
S-13
12
S-13 OIL LEVEL RISES
Cracks inside cylinder block
Defective thermostat
Defective part inside injection pump
O
O
Confirm recent repair history Degree of use machine
Operated for long period
When engine is first started, drops of water come from muffler Exhaust smoke is white
O
There is oil in radiator cooling water Check items
Leakage of fuel from piping inside head cover
Defective sealing of pump or other starting aids
O
Damaged liner O-ring, holes made by pitting
Questions
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Broken oil cooler core, O-ring
If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”. General causes why oil level rises • Water in oil • Fuel in oil (diluted, and smells of diesel fuel) • Oil leaking in from other component
Worn, damaged rear seal surface
Broken cylinder head, head gasket (including precombustion chamber)
O
★
Defective sealing, clogged weep hole
Defective nozzle holder sleeve
Causes
O
Leave radiator cap open. When engine is idling, an abnormal number of bubbles appear or water spurts
O
Water pump breather is clogged with mud When water pump breather is cleaned and then water comes out Oil level in damper chamber goes down Oil level in hydraulic tank goes down Engine oil smells of diesel fuel Fuel must be added more frequently ●
Pressure-tightness test of oil cooler shows there is a leakage
● ●
When compression pressure is measured and found to be low
●
Remove water pump and check for clogging of weep hole
●
Remove rear seal and inspect
●
When pump is removed, seal is found to be broken
●
Remove head cover and inspect
●
Remove thermostat cover and inspect
20-922 1
Replace
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and check
●
● Replace
●
Defective contact with thermostat seal valve
Replace
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage
WA700-3L
TROUBLESHOOTING
S-14
12 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
Rise in torque converter oil temperature
Holes made by pitting
Broken cylinder head, head gasket
Defective pressure valve
Clogged, broken oil cooler
Fan belt slipping, worn fan pulley
Lack of cooling water
Defective water temperature gauge
Defective thermostat (does not open)
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged radiator core
Carry out troubleshooting for chassis.
Broken water pump
★
Clogged, crushed radiator fins
Causes General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Rise in oil temperature in power train
Confirm recent repair history Questions
Degree of use machine Condition of overheating Water temperature gauge
Operated for long period Suddenly overheated
O
Always tends to overheat
O
O O
Rises quickly
O
Does not go down from red range
Radiator water level caution lamp is lit up Fan belt whines under sudden load Cloudy white oil is floating on cooling water Cooling water flows out from overflow hose Check items
Excessive air bubbles inside radiator, water spurts back Engine oil level has risen, oil is cloudy white
O
There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps When belt tension is inspected and found to be loose Torque converter oil temperature gauge enters red range before engine water temperature gauge ● ● ●
When water filler port is inspected, core is found to be clogged
●
When function test is carried out on thermostat, it does not open, even at cracking temperature
●
When water temperature is measured and found to be normal
●
When oil cooler is inspected and found to be clogged
●
When measurement is made with radiator cap tester, set pressure is found to be low
●
When compression pressure is measured and found to be low
●
WA700-3L
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
Remove oil pan and inspect
Replace
Troubleshooting
Temperature difference between top and bottom radiator tanks is slight
Carry out troubleshooting for the chassis
Temperature difference between top and bottom radiator tanks is excessive
20-923 1
TROUBLESHOOTING
S-15
12
S-15 ABNORMAL NOISE IS MADE
Defective adjustment of valve clearance
Deformed fan, fan belt interference
O
Defective injection pump (excessive injection)
O
Defective injection pump (rack, plunger seized)
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Clogged, seized injection nozzle
Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system
Missing, seized bushing
★
Seized turbocharger, interference
This is chart one of two charts Excessive wear of piston ring, cylinder liner
★
Broken dynamic valve system (valve, rocker lever, etc.)
Causes
Questions
Confirm recent repair history Degree of use machine Condition of abnormal noise
Operated for long period Gradually occurred
O
Suddenly occurred
O
Non-specified oil must be added more frequently
O O
O
Engine oil must be added more frequently Color of exhaust gas
Blue under light load Black
Metal particles are found in oil filter Blow-by gas is excessive Check items
Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is abnormal When exhaust manifold is touched immediately after starting engine, temperature of some cylinders
O
is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine
O
O
O
O
O
Clanging sound is heard from around cylinder head Leakage of air between turbocharger and head, loose clamp Vibrating noise is heard from around muffler ●
When compression pressure is measured and found to be low
●
When turbocharger is rotated by hand and found to be heavy
●
Remove gear cover and inspect
●
Troubleshooting
Speed does not change when operation of certain cylinders is stopped
●
When control rack is pushed and found to be heavy or does not return
●
Injection pump test shows that injection amount is incorrect
●
Fan is deformed, belt is loose
●
When valve clearance is checked and found to be outside standard value
●
Remove cylinder head cover and inspect When muffler is removed, abnormal noise disappears Inspect air compressor piping for leakage
20-924 1
Replace
Adjust
Correct
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and inspect
WA700-3L
TROUBLESHOOTING
S-15
Improper gear train backlash
Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Seized crankshaft bearing
★
Leakage from air compressor piping
This is chart two of two charts Leakage of air between turbocharger and head
★
Defect inside muffler (dividing board out of position)
Causes
Questions
Confirm recent repair history Degree of use machine Condition of abnormal noise
Operated for long period Gradually occurred Suddenly occurred
Non-specified oil must be added more frequently Engine oil must be added more frequently Color of exhaust gas
Blue under light load Black
O
Metal particles are found in oil filter Blow-by gas is excessive Check items
Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is abnormal When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine
O
O
Clanging sound is heard from around cylinder head leakage of air between turbocharger and head, loose clamp Vibrating noise is heard from around muffler When compression pressure is measured and found to be low When turbocharger is rotated by hand and found to be heavy ●
Troubleshooting
Remove gear cover and inspect Speed does not change when operation of certain cylinders is stopped When control rack is pushed and found to be heavy or does not return Injection pump test shows that injection amount is incorrect Fan is deformed, belt is loose When valve clearance is checked and found to be outside standard value Remove cylinder head cover and inspect
●
When muffler is removed, abnormal noise disappears
●
Inspect air compressor piping for leakage
WA700-3L
Replace
Replace
correct
Correct
Remedy
Replace
●
Remove oil pan and inspect
20-925 1
TROUBLESHOOTING
S-16
S-16 VIBRATION IS EXCESSIVE
O
O
Defective vibration damper
O
Clogged injection nozzle
O
Defective injection pump (excessive injection)
O
Improper gear train backlash
O
Center of engine and power train misaligned
Loose engine mount bolts, broken cushion
O
Broken part inside output shaft (damper)
Worn balancer, cam bushing
Legend O: Possible causes (judging from questions and check items) : Most probable causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) ●: Items to confirm the cause
Worn connecting rod, main bearing
General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment • Abnormal combustion
Defective dynamic valve system (valve, rocker lever, etc. stuck)
Causes If there is abnormal noise together with the vibration, carry out troubleshooting also for “Abnormal noise is made”.
Questions
Confirm recent repair history Degree of use machine Condition of vibration
Operated for long period Suddenly increased Gradually increased
Non-specified oil is being used
O
O
O
Metal particles are found in oil filter Check items
Metal particles are found when oil is drained Oil pressure is low at low idling Vibration occurs at mid-range speed
O
O
Vibration follows engine speed
O
O
O
O
O
Exhaust smoke is black
O
O
Seal on injection pump has come off ●
Remove oil pan and inspect
● ●
Inspect for loose engine mount bolts, broken cushion
●
Inspect inside of output shaft (damper) directly
●
When face runout and radial runout are inspected, they are found to be incorrect
●
Remove front cover and inspect Remove head cover and inspect
●
Injection pump test shows that injection amount is incorrect
●
● ●
20-926 1
Replace
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
Remove vibration damper and inspect
Replace
Troubleshooting
Remove side cover and inspect
WA700-3L
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE) 12 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS . . . . . . . . . 20-1002 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1004 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . 20-1010 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1011 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1012 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1013 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1015 T-7 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016 T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1018 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1020 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1022 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1024 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1025 A. TRANSMISSION CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1025 B. ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1025 T-13 HOLD SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1028 T-14 KICK-DOWN SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1028 T-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1029 T-16 NEUTRALIZER RELAY SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1030 T-17 BUZZER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1031 T-18 NETWORK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1032 T-19 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1033 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1034
WA700-3L
20-1001â&#x17E;&#x20AC;
TROUBLESHOOTING
JUDGEMENT TABLE
12
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
Short circuit, disconnection in range switch system
Disconnection in travel sensor system
Short circuit, disconnection in engine speed sensor system
20
21
22
23
h
i
j
k
l
Short circuit, disconnection in directional switch system
19
Short circuit, disconnection in joystick directional switch system
17
Short circuit, disconnection in 4 solenoid
Short circuit, disconnection in 3 solenoid
Short circuit, disconnection in 2 solenoid
Short circuit, disconnection in 1 solenoid
Short circuit, disconnection in R solenoid
Short circuit, disconnection in F solenoid
â&#x2DC;&#x2026; THIS IS CHART ONE OF TWO CHARTS
Short circuit, disconnection in backup lamp relay
Location of failure Self-diagnostic display (abnormality display)
Transmission controller error Legend O: Possible causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) No.
Failure code
Failure mode
10
a
12
13
14
15
16
b
c
d
e
f
g
O
O
O
O
O
O
1
Travel is impossible
2
Auto-shifing is not carried out
3
Directional level and direction of travel are different
4
Machine travels forward when directional lever is not at F
5
Machine travels in reverse when directional lever is not at R
6
Shifts down regardless of travel speed
O
7
Shifts up regardless of travel speed
O
8
Speed range is not same as position of lever
O
9
There is excessive gearshifting shock
O O O
O O
O
O
10 There is shift hunting when traveling 11 There is shift hunting when shifting gear
O
12 Speed range cannot be controlled with speed lever 13 Backup lamp and buzzer do not work
O
O O O
14 Shift cannot be held 15 Kickdown does not work 16 When kick down is actuated, there is no scooping power 17 Transmission is not cut off with left brake 18 It is possible to travel even when parking brake is applied 19 If F-R lever is operated when traveling at high speed, alarm buzzer does not sound 20 Alarm buzzer continues to sound 21 Main monitor does not display transmission controller information (alarm buzzer, failure code, etc.) 22 Gearshifing speed is abnormal (tire compensation) Troubleshooting code when no error code is displayed
20-1002 1
T-1
T-2
T-3 T-4 T-5
T-6
T-7
T-8
T-9
T-10
T-11
T-12
WA700-3L
TROUBLESHOOTING
JUDGEMENT TABLE
12
Abnormality in network signal system or main monitor
Abnormality in network signal system
Abnormality in alarm buzzer signal system
Abnormality in neutralizer signal system
Abnormality in transmission cut-off signal system
Abnormality in kick down switch signal system
â&#x2DC;&#x2026; THIS IS CHART TWO OF TWO CHARTS
Abnormality in hold switch signal system
Location of failure Self-diagnostic display (abnormality display)
Troubleshooting code when no abnormality display is given
Transmission controller error
Legend O: Possible causes (judging from questions and check items) : Possible causes do to length of use (used for a long period) No.
Failure code
Failure mode
1
Travel is impossible
2
Auto-shifing is not carried out
3
Directional level and direction of travel are different
4
Machine travels forward when directional lever is not at F
5
Machine travels in reverse when directional lever is not at R
6
Shifts down regardless of travel speed
7
Shifts up regardless of travel speed
8
Speed range is not same as position of lever
9
There is excessive gearshifting shock
-
-
-
-
-
-
-
m
n
o
p
q
r
s
t H-1
10 There is shift hunting when traveling 11 There is shift hunting when shifting gear 12 Speed range cannot be controlled with speed lever 13 Backup lamp and buzzer do not work 14 Shift cannot be held
O
T-13
15 Kickdown does not work
O
16 When kick down is actuated, there is no scooping power
O
17 Transmission is not cut off with left brake
T-14, E-8 O
18 It is possible to travel even when parking brake is applied
T-15 O
T-16, H-15, E-3
19 If F-R lever is operated when traveling at high speed, alarm buzzer does not sound
O
T-17
20 Alarm buzzer continues to sound
O
T-17, J-1
21 Main monitor does not display transmission controller information (alarm buzzer, failure code, etc.)
O
22 Gearshifing speed is abnormal (tire compensation) Troubleshooting code when no error code is displayed
WA700-3L
T-18 O
-
-
-
-
-
-
-
20-1003 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNORMALITY
12
CONTROLLER ACTIONS DURING ABNORMALITY 1.
Transmission controller system
Failure code
Abnormal system 1. 2.
10
Backup lamp relay 3. 4. 1. 2.
12
Abnormality in F solenoid system
3. 4. 1. 2.
13
Abnormality in R solenoid system
3. 4. 1. 2.
14
Abnormality in 1st solenoid system
3. 4. 1. 2.
15
Abnormality in 2nd solenoid system
3. 4. 1. 2.
16
Abnormality in 3rd solenoid system
3. 4.
20-1004 1
Nature of abnormality Defective backup lamp relay Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (8) and L76 (1) Defective contact or disconnection in wiring harness between backup lamp relay L76 (female) (2) - CL1 (12) - chassis ground Defective transmission controller Defective F solenoid Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (2) - TL1 (5) - T01 (D) Short circuit with ground, defective contact, disconnection in wiring harness between T01 (A) - TL1 (7) - CL1 (12) - chassis ground Defective transmission controller Defective R solenoid Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (9) - TL1 (6) - T01 (C) Short circuit with ground, defective contact, disconnection in wiring harness between T01 (A) - TL1 (7) - CL1 (12) - chassis ground Defective transmission controller Defective 1st solenoid Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (3) - TL1 (1) - T01 (H) Short circuit with ground, defective contact, disconnection in wiring harness between T01 (B) - TL1 (7) - CL1 (12) - chassis ground Defective transmission controller Defective 2nd solenoid Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (10) TL1 (2) - T01 (G) Short circuit with ground, defective contact, disconnection in wiring harness between T01 (B) - TL1 (7) - CL1 (12) - chassis ground Defective transmission controller Defective 3rd solenoid Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (5) - TL1 (3) - T01 (F) Short circuit with ground, defective contact, disconnection in wiring harness between T01 (B) - TL1 (7) - CL1 (12) - chassis ground Defective transmission controller
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNORMALITY
12
Condition when normal (voltage, current, resistance) 1. 2. 3. 4.
1. 2. 1. 2. 1. 2. 1. 2. 1. 2.
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
Resistance of relay coil: 200 - 400 Ω Voltage between transmission controller C1 (8) and chassis ground at neutral: Less than 1V Resistance in wiring harness between transmission controller C1 (female) (8) and L76 (female) (I): Max. 1 Ω Resistance in wiring harness between backup lamp relay L76 (female) (2) - CL1 (12) - chassis ground: Max. 1 Ω
Neutral (All solenoid outputs: OFF).
Resistance between transmission controller C1 (female) (2) and chassis ground: 5 - 15 Ω Voltage between transmission controller C1 (2) and chassis ground at neutral: Less than 1 V
Neutral (All solenoid outputs: OFF).
Travel impossible
Resistance between transmission controller C1 (female) (9) and chassis ground: 5 - 15 Ω Voltage between transmission controller C1 (9) and chassis ground at neutral: Less than 1 V
Neutral (All solenoid outputs: OFF).
Travel impossible
Resistance between transmission controller C1 (female) (3) and chassis ground: 5 - 15 Ω Voltage between transmission controller C1 (3) and chassis ground at neutral: Less than 1 V
Neutral (All solenoid outputs: OFF).
Travel impossible
Resistance between transmission controller C1 (female) (10) and chassis ground: 5 - 15 Ω Voltage between transmission controller C1 (10) and chassis ground at neutral: Less than 1 V
Neutral (All solenoid outputs: OFF).
Travel impossible
Resistance between transmission controller C1 (female) (5) and chassis ground: 5 - 15 Ω Voltage between transmission controller C1 (5) and chassis ground at neutral: Less than 1 V
Neutral (All solenoid outputs: OFF).
Travel impossible
WA700-3L
Troubleshooting
Backup lamp is not actuated when driving in reverse T-1
T-2
T-3
T-4
T-5
T-6
20-1005 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNORMALITY
12 Failure code
Abnormal system
Nature of abnormality 1. 2.
17
Abnormality in 4th solenoid system
3. 4. 1. 2. 3.
19
Abnormality in joystick directional switch system
4.
5.
1. 2. 20
Abnormality in directional switch signal system
21
Abnormality in speed switch signal system
22
Disconnection in travelspeed sensor
3. 4. 5. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5.
20-1006 1
Defective 4th solenoid Short circuit with power source, short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C1 (female) (11) TL1 (4) - T01 (E) Defective contact, disconnection in wiring harness between T01 (B) - TL1 (7) - CL1 (12) - chassis ground Defective transmission controller Defective joystick directional lever F, N, R switch Disconnection between joystick directional lever connector (8) and chassis ground When chassis wiring harness is in any of the following conditions with the switch not pressed Defective contact or disconnection in wiring harness between transmission controller C5 (female) (8) - JL2 (2) - joystick lever connector (2) or short circuit with ground in wiring harness between C5 (female) (16) - JL2 (3) - joystick lever connector (3) Defective contact or disconnection in wiring harness between transmission controller C5 (female) (7) - JL2 (4) - joystick lever connector (4) or short circuit with ground in wiring harness between C5 (female) (15) - JL2 (5) - joystick lever connector (5) Defective contact or disconnection in wiring harness between transmission controller C5 (female) (9) - JL2 (6) - joystick lever connector (6) or short circuit with ground in wiring harness between C5 (female) (17) - JL2 (7) - joystick lever connector (7) Defective directional lever Defective combination switch power source Short circuit with power source, short circuit with ground, defective contact, disconnection in the following wiring harnesses Wiring harness between transmission controller C3B (female) (5) and L04 (2) Wiring harness between transmission controller C3B (female) (13) and L04 (3) Wiring harness between transmission controller C3B (female) (6) and L04 (4) Defective speed lever Defective combination switch power source Short circuit with power source, short circuit with ground, defective contact, disconnection in the following wiring harnesses Wiring harness between transmission controller C3B (female) (7) and L04 (5) Wiring harness between transmission controller C3B (female) (15) and L4 (6) Wiring harness between transmission controller C3B (female) (8) and L04 (7) Wiring harness between transmission controller C3B (female) (16) and L04 (8) Defective travel speed sensor Defective adjustment of travel speed sensor mount Defective contact or disconnection in wiring harness between transmission controller C5 (female) (2) - TL1 (11) - T05 (1) Defective contact or disconnection in wiring harness between transmission controller C5 (female) (10) - TL1 (12) - T05 (2) Defective transmission controller
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNORMALITY
12
Condition when normal (voltage, current, resistance) 1.
Problem that appears on machine when there is abnormality
Action by controller when abnormality is detected
Troubleshooting
Resistance between transmission controller C1 (female) (11) and chassis ground: 5 - 15 Ω Voltage between transmission controller C1 (11) and chassis ground at neutral: Less than 1 V
Neutral (All solenoid outputs: OFF)
Travel impossible
Resistance between joystick directional lever connector (8) and chassis ground: Less than 1 Ω The following conditions are when the switch is not pressed: 2. Resistance between transmission controller C5 (female) (8) and chassis ground: Less than 1 Ω and resistance between C5 (female) (16) and chassis ground: Min. 1 MΩ 3. Resistance between transmission controller C5 (female) (7) and chassis ground: Less than 1 Ω and resistance between C5 (female) (15) and chassis ground: Min. 1 MΩ 4. Resistance between transmission controller C5 (female) (9) and chassis ground: Less than 1 Ω and resistance between C5 (female) (17) and chassis ground: Min. 1 MΩ
Neutral (All solenoid outputs: OFF)
Cannot travel in joystick mode (possible in steering wheel mode)
1.
Voltage between combination switch L04 (1) and chassis ground: 20 - 30 V 2) Voltage for only 1 system in accordance with position of directional lever: 20 - 30 V (Others: Less than 1 V) F: Between transmission controller C3B (5) chassis ground N: Between transmission controller C3B (13) chassis ground R: Between transmission controller C3B (6) chassis ground
•
Voltage between combination switch L04 (1) and chassis ground: 20 - 30 V Voltage for only 1 system in accordance with position of speed lever: 20 - 30 V (Others: Less than 1 V) 1st: Between transmission controller C3B (7) chassis ground 2nd: Between transmission controller C3B (15) chassis ground 3rd: Between transmission controller C3B (8) chassis ground 4th: Between transmission controller C3B (16) chassis ground
•
Resistance between speed sensor T05 (1) and (2): 500 - 1000 Ω Voltage between transmission controller C5 (female) (2) and (10): Min. 0.5 V (AC range)
1. 2.
2. 1.
2.
1. 2.
1. 2.
WA700-3L
T-7
T-8
•
•
Shifts to neutral immediately when short circuit with power source is detected When there is no signal (disconnection), holds previous signal condition for 2 seconds
Travel impossible
If 2 signals are input, it judges speed range position in order of priority 4 ← 3← 2 ← 1 When there is no signal (disconnection), holds previous signal condition (speed range position
1.
Switches to manual mode Shifts gear according to operation of speed lever
1.
T-9
2.
Auto-shift limit is different from range position selected by operator Impossible to shift gear in manual mode T-10
2.
Does not carry out auto-shift Switches to manual shift
T11
20-1007 1
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNORMALITY
12 Failure code
23
Abnormal system
Abnormality in engine speed sensor system
1. 2. 3. 4. 5.
20-1008 1
Nature of abnormality Defective engine speed sensor Defective adjustment of engine speed sensor mount Short circuit with ground, defective contact, disconnection in wiring harness between transmission controller C4 (female) (2) and EC3A (5) Defective contact or disconnection in wiring harness between transmission controller C4 (female) (9) - LR5 (3) - chassis ground Defective transmission controller
WA700-3L
TROUBLESHOOTING
CONTROLLER ACTIONS DURING ABNORMALITY
12
Condition when normal (voltage, current, resistance) 1. 2.
Resistance between engine speed sensor E10, E13 (1) and (2): 100 - 500 â&#x201E;Ś Voltage between transmission controller C4 (female) (2) and (9): Min. 0.5 V
WA700-3L
Action by controller when abnormality is detected It is possible to travel with engine speed taken as 2100 rpm
Problem that appears on machine when there is abnormality
Troubleshooting
There is gearshifting shock T-12
20-1009 1
TROUBLESHOOTING
T-1
12
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 4
Go to A
Yes Is resistance between L76 (female) (1) and chassis ground normal? 3 Yes Is resistance between C1 (female) (8) and chassis normal when L76 (female1 (1) is grounded to chassis? 2 Yes Is resistance between L76 (female) (2) and chassis ground normal? 1 Is troubleshooting code 10 displayed when the relay is interchanged with other relay of same type? 1. Turn starting switch OFF 2. Interchange with other relay of same type 3. Turn starting switch ON 4. Directional lever: R 5
From
A
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect L76
No
No Yes
Is voltage between C1 (female) (8) and chassis normal? 1. Turn starting switch OFF 2. Disconnect C1 and L76 3. Less than 0.l V
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect C1 and L76
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and L76 No
Remedy
Yes
No
---
Short circuit with chassis ground in wiring harness between C1 (female) (8) and L76 (female) (1)
Repair or replace
Disconnection in wiring harness between C1 (female) (8) and L76 (female) (1)
Repair or replace
Disconnection in wiring harness between L76 (female) (2) - LR5 (2) chassis ground
Repair or replace
Defective backup lamp relay
Replace
Defective transmission controller
Replace
Short circuit with power source in wiring harness between C1 (female) (8) and L76 (female) (1)
Replace
T-1 Related electrical circuit diagram
20-1010 1
WA700-3L
TROUBLESHOOTING
T-2
12 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 Yes
Is voltage between C1 (2) - (6), (12) normal?
2
1. Directional lever: N 2. Turn starting switch ON 3. Max. 1 V
Yes Is resistance between C1 (female) (2) and chassis normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect C1
Yes
Yes Is resistance between T01 (female) (A) and chassis ground normal? 4 No
Is resistance between C1 (female) (2) T01 (female) (D) chassis ground normal? 1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and T01
No
No
5
Is resistance between T01 (male) (D) and (A) normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect T01
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
No
No
Remedy
Defective transmission & Replace joystick steering controller Short circuit with power source in wiring harness Repair or between C1 (female) (2) - replace TL1 (5) - T01 (female) (D) Defective contact or disconnection in wiring harness between C1 (female) (2) - TL1 (5) T01 (female) (D)
Repair or replace
Defective contact or disconnection in wiring harness between T01 (female) (A) -TL1 (7) LR5 (2) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C1 (female) (2) - replace TL1 (5) - T01 (female) (D) Defective F solenoid
Replace
T-2 Related electrical circuit diagram
WA700-3L
20-1011 1
TROUBLESHOOTING
T-3
12
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 Yes
Is voltage between C1 (9) - (6), (12) normal?
2
1. Directional lever: N 2. Turn starting switch ON 3. Max. 1 V
Yes Is resistance between C1 (female) (9) and chassis normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect C1
Yes
Yes Is resistance between T01 (female) (A) and chassis ground normal? 4 No
Is resistance between C1 (female) (2) T01 (female) (D) chassis ground normal? 1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and T01
No
No
5
Is resistance between T01 (male) (C) and (A) normal? 1. 5 - 15 Ω 2.Turn starting switch OFF 3. Disconnect T01
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
No
No
Remedy
Defective transmission & Replace joystick steering controller Short circuit with power source in wiring harness Repair or between C1 (female) (9) - replace TL1 (6) - T01 (female) (C) Defective contact or disconnection in wiring harness between C1 (female) (9) - TL1 (6) T01 (female) (C)
Repair or replace
Defective contact or disconnection in wiring harness between T01 (female) (A) -TL1 (7) LR5 (2) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C1 (female) (9) - replace TL1 (6) - T01 (female) (C) Defective R solenoid
Replace
T-3 Related electrical circuit diagram
20-1012 1
WA700-3L
TROUBLESHOOTING
T-4
12 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 Yes
Is voltage between C1 (3) - (6), (12) normal?
2
1. Directional lever: N 2. Turn starting switch ON 3. Max. 1 V
Yes Is resistance between C1 (female) (3) and chassis normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect C1
Yes
Yes Is resistance between T01 (female) (B) and chassis ground normal? 4 No
Is resistance between C1 (female) (3) T01 (female) (H) chassis ground normal? 1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and T01
No
No
5
Is resistance between T01 (male) (H) and (B) normal? 1. 5 - 15 Ω 2.Turn starting switch OFF 3. Disconnect T01
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
No
No
Remedy
Defective transmission & Replace joystick steering controller Short circuit with power source in wiring harness Repair or between C1 (female) (3) - replace TL1 (1) - T01 (female) (H) Defective contact or disconnection in wiring harness between C1 (female) (3) - TL1 (1) T01 (female) (H)
Repair or replace
Defective contact or disconnection in wiring harness between T01 (female) (B) -TL1 (7) LR5 (2) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C1 (female) (3) - replace TL1 (1) - T01 (female) (H) Defective 1st solenoid
Replace
T-4 Related electrical circuit diagram
WA700-3L
20-1013 1
TROUBLESHOOTING
T-5
12
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 Yes
Is voltage between C1 (10) - (6), (12) normal?
2
1. Directional lever: N 2. Turn starting switch ON 3. Max. 1 V
Yes Is resistance between C1 (female) (10) and chassis normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect C1
Yes
Yes Is resistance between T01 (female) (B) and chassis ground normal? 4 No
Is resistance between C1 (female) (10) T01 (female) (G) chassis ground normal? 1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and T01
No
No
5
Is resistance between T01 (male) (G) and (B) normal? 1. 5 - 15 Ω 2.Turn starting switch OFF 3. Disconnect T01
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
No
No
Remedy
Defective transmission & Replace joystick steering controller Short circuit with power source in wiring harness or between C1 (female) (10) Repair - TL1 (2) - T01 (female) replace (G) Defective contact or disconnection in wiring harness between C1 (female) (10) - TL1 (2) T01 (female) (G)
Repair or replace
Defective contact or disconnection in wiring harness between T01 (female) (B) -TL1 (7) LR5 (2) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C1 (female) (10) replace - TL1 (2) - T01 (female) (G) Defective 2nd solenoid
Replace
T-5 Related electrical circuit diagram
20-1014 1
WA700-3L
TROUBLESHOOTING
T-6
12 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 Yes
Is voltage between C1 (5) - (6), (12) normal?
2
1. Directional lever: N 2. Turn starting switch ON 3. Max. 1 V
Yes Is resistance between C1 (female) (5) and chassis normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect C1
Yes
Yes Is resistance between T01 (female) (B) and chassis ground normal? 4 No
Is resistance between C1 (female) (5) T01 (female) (F) chassis ground normal? 1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and T01
No
No
5
Is resistance between T01 (male) (F) and (B) normal? 1. 5 - 15 Ω 2.Turn starting switch OFF 3. Disconnect T01
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
No
No
Remedy
Defective transmission & Replace joystick steering controller Short circuit with power source in wiring harness Repair or between C1 (female) (5) - replace TL1 (3) - T01 (female) (F) Defective contact or disconnection in wiring harness between C1 (female) (5) - TL1 (3) T01 (female) (F)
Repair or replace
Defective contact or disconnection in wiring harness between T01 (female) (B) -TL1 (7) LR5 (2) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C1 (female) (5) - replace TL1 (3) - T01 (female) (F) Defective 3rd solenoid
Replace
T-6 Related electrical circuit diagram
WA700-3L
20-1015 1
TROUBLESHOOTING
T-7
12
T-7 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 Yes
Is voltage between C1 (11) - (6), (12) normal?
2
1. Directional lever: N 2. Turn starting switch ON 3. Max. 1 V
Yes Is resistance between C1 (female) (11) and chassis normal? 1. 5 - 15 Ω 2. Turn starting switch OFF 3. Disconnect C1
Yes
Yes Is resistance between T01 (female) (B) and chassis ground normal? 4 No
Is resistance between C1 (female) (11) T01 (female) (E) chassis ground normal? 1. Max. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C1 and T01
No
No
5
Is resistance between T01 (male) (E) and (B) normal? 1. 5 - 15 Ω 2.Turn starting switch OFF 3. Disconnect T01
Yes
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect T01
No
No
Remedy
Defective transmission & Replace joystick steering controller Short circuit with power source in wiring harness Repair or between C1 (female) (11) - replace TL1 (4) - T01 (female) (E) Defective contact or disconnection in wiring harness between C1 (female) (11) - TL1 (4) T01 (female) (E)
Repair or replace
Defective contact or disconnection in wiring harness between T01 (female) (B) -TL1 (7) LR5 (2) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C1 (female) (11) - replace TL1 (4) - T01 (female) (E) Defective 4th solenoid
Replace
T-7 Related electrical circuit diagram
20-1016 1
WA700-3L
TROUBLESHOOTING
T-7
12
MEMORANDUM
WA700-3L
20-1017 1
TROUBLESHOOTING
T-8
12
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 4
Yes
Yes Is voltage between C5 (female) (7), (8). (9), (15), (16), (17) 3 and chassis as shown in Table 1? Yes Is resistance between JL2 (female) (8) and chassis normal? 2 Yes Is voltage between JL2 (1) and chassis normal?
1
No
20-1018 1
No
No
1. Turn starting switch ON
No
1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect JL2
1. 20 - 30 V 2. Turn starting switch ON
Is voltage between JL2 (8) and terminals (2), (3), (4), (5), (6), and (7) as shown in Table 1?
1. Turn starting switch ON
Remedy
Defective transmission controller
Replace
Short circuit with chassis ground, defective contact, or disconnection in wiring Repair or harness between JL2 (female) (2), (3), (4), (5), replace (6), (7) - C5 (female) (7), (8), (9), (15), (16), (17)
Defective contact or disconnection in wiring harness between JL2 (female) (8)- LR5 (3) chassis
Repair or replace
Short circuit with chassis ground. defective contact, or disconnection in wiring Repair or harness between C3A replace (male) (6) - JL2 (1) - LR5 (3) -chassis
Defective joystick lever
Replace
WA700-3L
TROUBLESHOOTING
T-8
12 T-8 Related electrical circuit diagram
WA700-3L
20-1019 1
TROUBLESHOOTING
T-9
12
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Yes
a 5 Yes b
2 Yes Is voltage between C3B (female) (5), (6), (13) - chassis ground as shown in Table 1
1
Is voltage between No C3B (female) (5), (6), (13) - chassis ground normal?
Is voltage between L04 (female) (1) and (10) normal? 1. Turn starting switch OFF 2. Disconnect L04 3. Turn starting switch ON 4. 20 - 30 V
Yes Is resistance between C3B 3 (female) (5), (6), (13) and chassis ground normal?
1. Turn starting switch OFF 2. Disconnect C3B and L04 3. Turn starting switch ON 4. Max. 1 Ω
Is there continuity L04 Yes between (female) (2) - C3B (female) (5), L04 4 (female) (4) - C3B (female) (6), L04 (female) (3) - C3B (female)(13)?
1. Turn starting switch OFF 2. Disconnect C3B and L04 3. Max. 1 Ω
1. Turn starting switch OFF 2. Disconnect C3B and L04 3. Max. 1 Ω
c No
d
No e
No
f No
20-1020 1
WA700-3L
TROUBLESHOOTING
T-9
12 Cause a
Remedy
Defective transmission & Replace joystick steering controller
b Defective directional lever Replace
c
d
e
f
Defective contact or disconnection in wiring harness between L04 (female) (2) - C3B Repair or (female) (5), L04 (female) replace (4) - C3B (female) (6), L04 (female) 13) - C3B (female) (13) Short circuit with chassis ground in wiring harness between L04 (female) (2) - Repair or C3B (female) (5), L04 replace (female) (4) - C3B (female) (6). L04 (female) (3) - C38 (female) (13) Short circuit with power source in wiring harness between L04 (female) (2) - Repair or C3B (female) (5). L04 replace (female) 14) - C3B (female) 6). L04 (female) (3) - C38 (female) (13) Defective contact, disconnection, or short circuit with chassis ground Repair or in wiring harness between replace L04 (female) (1) and FS2 (8). blown fuse
T-9 Related electrical circuit diagram
WA700-3L
20-1021 1
TROUBLESHOOTING
T-10
12
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Yes
a 5 Is there continuity between L04 Yes (female) (5) - C3B (female) (7), L04 (female) (6) - C3B (female) (15), L04 (female) (7) - C3B 4 (female) (8), L04 (female) (8) - C3B (female) (16)?
2 voltage between Yes Is C3B (female) (7), (15), (8), (16) chassis ground as shown in Table 1? 1 Is voltage between L04 (female) (1) and (10) normal?
resistance Yes Is between C3B (female) (7), (15), (8), (16) and chassis ground normal? 3
1. Turn starting Is voltage between switch OFF C3B (female) (7), 2. Disconnect C3B No (15), (8), (16) 3. Turn starting chassis ground switch ON normal?
1. Turn starting switch OFF 2. Disconnect L04 3. Turn starting switch ON 4. 20 - 30 V
1. Turn starting switch OFF 2. Disconnect C3B and L04 3. Turn starting switch ON 4. Max. 1 Ω
1. Turn starting switch OFF 2. Disconnect C3B and L04 3. Max. 1 Ω
Yes
b
c No
1. Turn starting switch OFF 2. Disconnect C3B and L04 3. Max. 1 Ω d No e
No
f No
20-1022 1
WA700-3L
TROUBLESHOOTING
T-10
12 Cause a
Remedy
Defective transmission & Replace joystick steering controller
b Defective directional lever Replace
c
d
e
f
Defective contact or disconnection in wiring harness between L04 (female) (5) - C3B or (female) (7), L04 (female) Repair replace (6) - C3B (female) (15), L04 (female) (7) - C3B (female) (8), L04 (female) (8) - C3B (female) (16) Short circuit with chassis gound in wiring harness between L04 (female) (5) C3B (female) (7), L04 (female) (6) - C3B Repair or (female) (15), L04 replace (female) (7) - C3B (female) (8), L04 (female1 (8) - C3B (female) (16) Short circuit with power source in wiring harness between L04 (female) (5) C3B (female) (7), L04 Repair or (female) (6) - C3B replace (female1 (15), L04 (female) (7) - C3B (female1 (8), L04 (female) (8) - C3B (female) (16) Defective contact. disconnection, or short circuit with chassis ground Repair or in wiring harness between replace L04 (female) (1) and FS2 (8). blown fuse
T-10 Related electrical circuit diagram
WA700-3L
20-1023 1
TROUBLESHOOTING
T-11
12
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause 3 2 Yes Is resistance between C5 (female) (10) and 1 Yes Is resistance between chassis normal when T05 (female) (2) is C5 (female) (2) and Is resistance grounded to chassis? chassis normal when between T05 T05 (female) (1) is (male) (1) and (2). 1. Max. 1 Ω grounded to chassis? and between (1). 2. Disconnect C5, (2) and chassis T05, and L07 1. Max. 1 Ω normal? 3. Turn starting 2. Disconnect T05, switch OFF C5, and L07 1. Between (1) and 3.Turn starting (2): 500 - 1000 Ω switch OFF. 2. Between (1), (2) No and chassis: Min. 1 MΩ 3. Disconnect T05 4. Turn starting No switch OFF.
Yes
No
Remedy
Defective transmission controller
Replace
Defective contact or disconnection in wiring Repair or harness between C5 (female) (10) - TL1 (12) - replace T05 (female) (2) Defective contact or disconnection in wiring harness between C5 (female) (2) - TL1 (11) T05 (female) (1)
Repair or replace
Defective speed sensor
Replace
T-11 Related electrical circuit diagram
20-1024 1
WA700-3L
TROUBLESHOOTING
T-12
12 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED ★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step.
A. TRANSMISSION CONTROLLER SYSTEM 2
Is resistance between C4 (male) (2) and chassis normal?
Yes
a
1 Yes Is resistance between C4 (female) (9) and chassis normal?
1. Min. 1 MΩ 2. Disconnect C4, EC3A, and L07 3. Turn starting switch OFF
1. Max. 1 Ω 2. Disconnect C4 3. Turn starting switch OFF
b No c
No
B. ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM 6 Yes d
Is resistance between EC3A Yes (female) (2), (3) normal when E10, E13 (female) (1) 1 are grounded to chassis? Is resistance between E10, El3 (male) (1) and (2) 1. Min. 1 MΩ normal? 2. Disconnect EC3A, E10, and 1. 100 - 500 Ω E13 2. Disconnect 3. Turn starting E10 and E13 switch OFF 3. Turn starting switch OFF
Is resistance between EC3A 3 Yes (female) (14) and chassis normal when E10, E13 Is resistance (female1 (2) are 2 Yes between EC3A grounded to (female) (2). (3) chassis? chassis normal? 1. Min. 1 MΩ 2. Disconnect EC3A, E10, and E13 3. Turn starting switch OFF
1. Min. 1 MΩ 2. Disconnect EC3A, E10, and E13 3. Turn starting switch OFF
Is resistance 4 Yes between EC3A (female) (14) and chassis normal? 1. Min. 1 MΩ 2. Disconnect EC3A, E10, and E13 3. Turn starting switch OFF
5 Yes Is resistance between EC3A (female) (2), (3) (14)? 1. Min. 1 MΩ 2. Disconnect EC3A, E10. and E13 3. Turn starting switch OFF
e No
f
No g
No
h No i No j
No
★ Normally, the engine speed is detected from E13 Engine speed sensor A. When an abnormality occurs in sensor A, it switches to E10 Engine speed sensor B.
WA700-3L
20-1025 1
TROUBLESHOOTING
T-12
12
Cause a
b
Remedy
Defective transmission controller
Replace
Defective contact or disconnection in wiring harness between C4 (female) (9) - LR5 (3) chassis ground
Repair or replace
c
Short circuit with chassis ground in wiring harness Repair or between C4 (female) (2) - replace EC3A (female) (5) or L07 (female) (3)
d
Defective electric engine throttle controller
e
f
g
h
i
j
20-1026 1
Replace
Short circuit in wiring harness between EC3A (female) (2). (3) - LR8 (5), (3) - ER3 (5), (3) or E10,.E13 (female) (1) and Repair replace wiring harness between EC3A (female) (14) - LR8 (4), (6) - ER3 (4), (6) E10, E13 (female) (2) Short circuit with chassis ground in wiring harness between EC3A (female) (14) - LR8 (4), (6) - ER3 (4), (6) - E10, E13 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between EC3A Repair or (female) (14) and LR8 (4), replace (6) - ER3 (4). (6) - E10, E13 (female) (2) Short circuit with chassis ground in wiring harness between EC3A (female) (2), (3) - LR8 (5), (3) ER3 (5), (3) - E10, E13 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between EC3A Repair or (female) (2), (3) - LR8 (5), replace (3) - ER3 (5), (3) - E10, E13 (female) (1) Defective engine speed sensor A, B
Replace
WA700-3L
TROUBLESHOOTING
T-12
12 T-12 Related electrical circuit diagram
WA700-3L
20-1027 1
TROUBLESHOOTING
T-13
12
T-13 HOLD SWITCH SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket). Cause Yes
Defective transmission controller
1 Is resistance between C5 (female) (13) and chassis normal?
2
1. Disconnect C5 2. Hold switch ON: Max. 1 Ω OFF: Min. 1 MΩ
No
Remedy
Yes
Is resistance between L15 (male) (3) and (4) normal? 1. Disconnect L15 2. Hold switch ON: Max. 1 Ω OFF: Min. 1 MΩ
No
Replace
Short circuit with chassis ground, defective contact, or disconnection in wiring Repair or harness between C5 replace (female) (13) and L15 (female) (3)
Defective hold switch
Replace
T-14 KICK-DOWN SWITCH SYSTEM Cause Yes
Defective transmission controller
1 Is resistance between C5 (female) (5) and chassis normal? 1. Disconnect C5 2. Kick-down switch ON: Max. 1 Ω OFF: Min. 1 MΩ
2 No
Remedy
Yes
Is resistance between L15 (male) (1) and (2) normal? 1. Disconnect L15 2. Kick-down switch ON: Max. 1 Ω OFF: Min. 1 MΩ
No
Replace
Short circuit with chassis ground, defective contact, or disconnection in wiring Repair or harness between C5 replace (female) (5) and L15 (female) (1) Defective kick-down switch
Replace
T-13, T-14 Related electrical circuit diagram
20-1028 1
WA700-3L
TROUBLESHOOTING
T-15
12 T-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket). Cause Yes
Defective transmission controller
1 Is resistance between C5 (female) (6) and chassis normal? 1. Disconnect C5 2. Transmission cut-off switch ON: Max. 1 Ω OFF: Min. 1 MΩ
2 No
Remedy
Yes
Is resistance between L12 (male) (1) and (2) normal? 1. Disconnect L12 2. Transmission cutoff switch ON: Max. 1 Ω OFF: Min. 1 MΩ
No
Replace
1. Short circuit with chassis ground, defective contact, or disconnection in wiring harness between C5 (female) (6) and L12 (female) (1) Repair or replace 2. Short circuit with chassis ground in wiring harness between C5 (female) (6) and L06 (female) (3) Defective transmission cut-off switch
Replace
T-15 Related electrical circuit diagram
WA700-3L
20-1029 1
TROUBLESHOOTING
T-16
12
T-16 NEUTRALIZER RELAY SIGNAL SYSTEM ★ Check that the parking brake works normally. ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket). Cause Yes
Defective transmission controller
1
4
Yes Is voltage between L58 (female) (1) and chassis normal? 2 No
Is resistance between L58 (female) (2) and chassis normal? 1. Disconnect L58 2. Max. 1 Ω
1. Disconnect L58 2. Turn starting switch ON 3. Parking brake switch: ON ? OFF 4. 20 - 30 V
No
1. Disconnect C3A and L58 2. Short circuit L58 (female) (13) and (5) 3. Max. 1 Ω
No
Replace
Yes Defective neutralizer relay Replace
Yes Is resistance between C3A (female) (6) and 3 C3A (female) (19) normal?
Is voltage between C3A (19) and (6) normal? 1. Insert T-adapter 2. Turn starting switch ON 3. Parking brake switch: ON ? OFF 4. 20 - 30 V
Remedy
No
Defective contact or disconnection in wiring harness between C3A Repair or (female) (6) - L58 replace (female) (5), L58 (female) (3) - C3A (female) (19) Short circuit with chassis ground, defective contact, or disconnection in wiring Repair or harness between L58 replace (female) (1) and L01 (female) (2) Defective contact or disconnection in wiring harness between L58 (female) (2) and chassis
Repair or replace
T-16 Related electrical circuit diagram
20-1030 1
WA700-3L
TROUBLESHOOTING
T-17
12 T-17 BUZZER SIGNAL SYSTEM ★ ★ ★ ★
Check that the main monitor and alarm buzzer work normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket). Cause 2
Yes
Yes Is resistance between C2 (female) (10) and 1 chassis normal? Is resistance between C2 (female) (10) and chassis normal? 1. Disconnect C2 and L08 2. Min. 1 MΩ
1. Disconnect C2 and L08 2. Short circuit between L08 (female) (6) and chassis 3. Max. 1 Ω No
No
Remedy
Defective transmission controller
Replace
Defective contact or disconnection in wiring harness between C2 (female) (10) and L08 (female) (6)
Repair or replace
Short circuit with chassis ground in wiring harness Repair or between C2 (female) (10) replace and L08 (female) (6)
T-17 Related electrical circuit diagram
WA700-3L
20-1031 1
TROUBLESHOOTING
T-18
12
T-18 NETWORK SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. ★ Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket). Cause 2
Yes
Yes Is resistance between C3B (female) (4), (12) and chassis 1 normal? Is resistance between C2 (female) (10) and chassis normal? 1. Min. 1 MΩ 2. Turn starting switch OFF 3. Disconnect C3B, and L08
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect C3B and L08 4. Make short circuit between L08 (female) (1), (3) and chassis No
No
Remedy
Defective transmission controller
Replace
Defective contact or disconnection in wiring Repair or harness between C3B (female) (4), (12) and L08 replace (female) (1), (3)
Short circuit with chassis ground in wiring harness Repair or between C3B (female) (4), replace (12) and L08 (female) (1), (3)
T-18 Related electrical circuit diagram
20-1032 1
WA700-3L
TROUBLESHOOTING
T-19
12 T-19 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM ★ ★ ★ ★
Check that fuse II ➅ is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket). Cause Yes
Defective transmission controller
1 Is voltage between C1 (7). (13), C2 (1), (12) - C1 (6), (12), C2 (11), (21) normal? 1. 20 - 30 V 2. Turn starting switch ON
2 No
Yes
Is resistance between C1 (female) (6), (12) and C2 (female) (11), (21) - chassis normal? 1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect C1 and C2
Remedy
No
Replace
Short circuit with ground, defective contact or disconnection in wiring Repair or harness between C1 (female) (7), (13) and C2 replace (female) (1), (12) - FS11 (female) (1) Defective contact or disconnection in wiring harness between C1 (female) (6), (12) and C2 (female) (11), (21) - LR5 (female) (3) - chassis
Repair or replace
T-19 Related electrical circuit diagram
WA700-3L
20-1033 1
TROUBLESHOOTING
T-20
12
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on to the next step. Cause Yes
Defective transmission controller
1
Replace
Is resistance between C5 (female) (2) and (10) normal?
Short circuit in wiring harness between C5 (female) (2) - L07 (female) (1) -TL1 (11) or T05 (male) (1) and wiring Repair replace harness between C5 (female) (10) - L07 (female) (2) -TLl (12) T05 (female) (2)
1. Max. 1 Ω 2. Turn starting switch OFF 3. Disconnect C5, T05, and L07
Short circuit with chassis ground in wiring harness between C5 (female) (2) - Repair or TLl (11) T05 (male) (1), replace and between C5 (female) (2) and L07 (female) (1)
Is resistance between C5 (female) (2) and chassis normal? 1. Min. 1 MΩ No 2. Turn starting switch OFF 3. Disconnect C5, T05, and L07
Remedy
2
Yes
No
T-20 Related electrical circuit diagram
20-1034 1
WA700-3L
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 20-1103 GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1103 STRUCTURE AND HANDLING OF GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1104 CHARGING HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1106 GAS LEAK DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1107 HALIDE TORCH LEAK DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1107 ELECTRIC LEAK TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1109 VALVE FOR SERVICE CANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1111 MAINTENANCE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1112 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1112 PROHIBITED WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1112 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1112 BLEEDING AIR FROM REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1114 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1114 CONNECTING GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1114 EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1115 AIR-TIGHTNESS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1115 GAS-LEAK CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1116 EVACUATION (REPEATING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1116 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 20-1117 CHARGING FROM THE HIGH-PRESSURE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1117 CHARGING FROM THE LOW PRESSURE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1118 WHEN THE AMBIENT TEMPERATURE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1119 WHEN THE AMBIENT TEMPERATURE IS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1119 REPLACING SERVICE CANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1120 CHECKING THE AMOUNT OF REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1120 REMOVAL OF GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1122 DISCHARGING THE REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1122 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1123 CHECK REFRIGERANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1123 CLEANING THE CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1123 CHECKING THE V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1123 CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1124 PROCEDURE FOR CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1124 PROCEDURE FOR CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1124 ADDING AND REMOVING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1125 ADDING OIL BY EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1125 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1126 VISUAL AND ACOUSTICAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1126 DEFECTIVE COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1127 TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1129 DEFECTIVE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1131 TROUBLESHOOTING USING GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1132 PREPARATIONS BEFORE MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1132 INSUFFICIENT REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1132 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER . . . . . . . . . . . 20-1133 AIR INSIDE REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1134
WA700-3L
20-1101 1
TROUBLESHOOTING MOISTURE IN REFRIGERATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1135 REFRIGERANT DOES NOT CIRCULATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1136 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1137 DEFECTIVE COMPRESSION BY COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1138
20-1102 1
WA700-3L
TROUBLESHOOTING
SERVICE TOOLS
12 SERVICE TOOLS
GAUGE MANIFOLD The gauge manifold is used not only for evacuation and charging refrigerant, but also for troubleshooting. The dials on the front of the gauge manifold are used to open and close the valves. LO indicates “Low pressure valve”, and HI indicates “High pressure valve”. Each valve can be opened and closed by turning the respective dial.
1. Low pressure valve 2. Low pressure gauge 3. High pressure gauge 4. High pressure valve 5. Red hose 6. Green hose 7. Blue hose
Fig. 1
WA700-3L
20-1103 1
TROUBLESHOOTING
SERVICE TOOLS
STRUCTURE AND HANDLING OF GAUGE MANIFOLD The following four circuits (A to D) can be structured by opening or closing the high and low pressure valves.
1. Low pressure gauge 2. High pressure gauge 3. High pressure valve (HI) 4. Low pressure valve (LO) 5. Built-in valve (Also called schrader valve)
1. Valve operation knob 2. Valve plate 3. Spring 4. Seat
A. When both low pressure valve (LO) and high pressure valve (HI) are closed.
20-1104 1
WA700-3L
TROUBLESHOOTING
SERVICE TOOLS
12 B. When low pressure valve (LO) is open, and high pressure valve (HI) is closed.
C. When low pressure valve (LO) is closed, and high pressure valve (HI) is open.
D. When both low pressure (LO) and high pressure valve (HI) are open.
WA700-3L
20-1105 1
TROUBLESHOOTING 12 CHARGING
SERVICE TOOLS
HOSES
The three charging hoses are blue, green, and red. The blue one is connected to the low pressure side, the green one to the adapter at the center, and the red one to the high pressure side. When storing the gauge manifold, connect each charging hose to an empty adapter as shown in Fig. 1 (on page 20-1003) to prevent dust and water from entering the manifold. Since the pin which opens the core type valve is built into the nut on the bent adapter (45°) at the end of the hose, it is not necessary to install an adapter (joint to open the core type valve) when connecting with another core type valve. 1. Pin 2. Packing 3. 45° swivel 4. Nut WARNING! For the above reason, be sure to connect the straight end to the gauge manifold, and the bent end to the mate side (service valve or charge valve of the compressor).
Since there is a packing in the nut at the end of the hose, it can be connected to the mate side by tightening it lightly by han d. (It is not necessary to tighten it with pliers.) Although the core type valve can be opened and closed with the pin, the valve cannot be adjusted with a valve plunger as in service valves (a stem type valve opened and closed with a ratchet wrench). â&#x2DC;&#x2026; If the needle of the gauge fluctuates, tighten nut (4) a little more
20-1106 1
WA700-3L
TROUBLESHOOTING
SERVICE TOOLS
12 GAS LEAK DETECTOR A tester that can detect the leak of refrigerant gas is called a gas leak detector. To find the place from which gas is leaking, look for it patiently. Even if a highly accurate detector is used, a gas leak may be missed if you do not look carefully. Especially, 10 days or so after the gas has been charged, if the operator feels that the cooling capacity might have decreased because of a gas leak, check all connections, rotating parts, welded zones (including fusible plug of liquid tank) carefully. There are two types of gas leak detectors:
1.
Halide torch leak detector - it can detect any gas leak which causes a significant drop in cooling capacity any time during one season.
2.
Electric leak tester - can detect l/15 of the amount of gas that a halide torch type can detect.
HALIDE TORCH LEAK DETECTOR The main components of the halide torch leak detector are a bin (l), valve (2), intake pipe (3) nozzle (6), torch (7), and combustion cylinder (11). 1. Bin 2. Valve 3. Intake pipe and hose 4. Strainer 5. Holder (set screw for combustion cylinder) 6. Nozzle 7. Torch 8. Ignition window 9. Set screw for copper plate 10. Copper plate 11. Combustion cylinder 12. Cap 13. Wrench for nozzle 14. Handle 15. Adjustment line for flame length (upper limit) 16. Adjustment line for flame length (lower limit) 17. Core type valve (for bin) 18. Nozzle cleaner 19. Wrench for bin valve
WA700-3L
20-1107 1
TROUBLESHOOTING
SERVICE TOOLS
12 When air containing the refrigerant gas is inhaled from the intake pipe, it will contact the heated copper plate (10). Copper halide will be produced to change the color of the flame. A gas leak can be detected with this change in color of the flame. WARNING! In the halide torch gas leak detector, an open flame is used. Since it can ignite a combustible gas, make sure that there are no flammable substances before using the detector.
WARNING! Do not breathe the vapor coming out of the detector. Although freon gas is not poisonous by itself, it can form poisonous phosgene gas, hydrochloric acid, or fluoride when it contacts the flame. Therefore, never breathe the vapor coming out of the gas leak detector.
How to detect gas leak 1.
Confirm that propane gas is charged in the bin. Connect the bin to the valve, and turn the valve fully clockwise. The core type valve (inside valve) of the bin will open, and the gas will be ready to flow out. If the valve handle is turned counterclockwise, the gas will flow out.
2.
To ignite the gas, insert a match or lighter through the ignition window of the combustion cylinder, and turn the handle counterclockwise.
3.
Use the valve to adjust the flame length between the upper limit line (15) and the lower limit line (16). If the flame is too long, it can only overheat the combustion cylinder. It cannot detect slight leaks of the refrigerant. The shorter the flame, the more sensitive the detector.
4.
After adjusting the flame length, slowly bring the end of the intake pipe to possible leaking places (connections of the piping) and observe the color of the flame. Always keep the detector in the upright position.
5.
When the leak detector is not in use, remove the bin. Replace the bin when empty.
20-1108 1
WA700-3L
TROUBLESHOOTING
SERVICE TOOLS
12
ELECTRIC LEAK TESTER The electric tester utilizes the cations discharged from metals at high temperature. This tester uses a platinum wire as the heating electrode. It is based on the principle that many cations are discharged when halide gas or air containing halides comes into contact with the heated platinum. The detector electrodes are made of double cylinders; the inside positive electrode heated to approximately 800° C (1472° F) and the outside negative electrode. A voltage of 200 V is applied between these two electrodes. If air containing halide gas flows between the electrodes, the cation current flows from the positive to the negative electrode. This current is amplified to turn on the lamp and buzzer to indicate a gas leak. The electric leak tester can detect a gas leak as low as 10-4mmHg.L/sec.
WARNING! The detectors electrode is heated to 800° C (1472° F), which can ignite a combustible gas. Therefore, confirm that there are no combustible substances around the work area.
How to detect gas leak 1.
Connect the detector cable to the metal plug socket at the rear of the amplifier.
2.
Connect the power cables. A. For HGT-112 model, connect the power cable to an automobile battery (12 V), the red clip to the positive (+) terminal, and the black clip to the negative (-) terminal. ★ If the cables are connected in reverse, the tester will break down. B. For HGT-200 model, connect the power cable to the AC power source (AC l00V, 50/60 Hz).
3.
Set the “SELECTOR” knob to “STANDBY” and turn the power switch “ON”. Wait for about ten minutes until the electrode heater is warmed up.
4.
Set the “SELECTOR” knob to “CHECK”. Using the check leak liquid, check the operation of the buzzer and alarm lamp in a place where there is no halide gas. Unscrew the leak valve of the check leak liquid one turn with a screw driver, and bring the intake pipe of the tester near the leak valve. If the buzzer and alarm lamp operate, the tester is normal. If they do not operate, or readjustment is necessary, set the “ALARM SET” knob to the point where the buzzer and the alarm lamp start to operate. ★ If the “ALARM SET” knob is turned by a large angle at one time, its sensitivity is not stable, and will cause misoperation. Wait for about 20 seconds after turning the knob one scale.
5.
Set the “SELECTOR” knob to “LEAK TEST-l” (buzzer and alarm lamp operate) or “LEAK TEST-2” (alarm lamp only operate).
6.
Slowly bring the end of the intake pipe of the tester to possible leaking places (connections of the piping). When the buzzer or alarm lamp operate at a certain place, gas is leaking from there.
7.
When stopping use of the tester for a short time, set the “SELECTOR” knob to “STANDBY”.
8.
Although the sensitivity of the electrodes gradually decrease, they have long lives. Adjust the sensitivity with the “ALARM SET” knob until adjustment is no longer possible. When adjustment is no longer possible, replace the electrodes with new ones.
WA700-3L
20-1109 1
TROUBLESHOOTING
SERVICE TOOLS
12 WARNING! The electrode of the tester is heated to 800° C (1472° F) while the tester is in use. Never use it in a place where there are combustible gases (city gas, propane gas, thinner, gasoline, etc.).
WARNING! If the tester is used for a long time, the end of the detector (intake pipe and electrode housing) will be heated to approximately 60 ° C (140° F). Never touch it.
WARNING! A highly dense halide gas (gas from a freon gas bin) can damage the electrode of the tester, or deteriorate the performance. Never let it flow into the tester.
WARNING! Note that the tester will not operate correctly if there are halide gases in the ambient air (gasoline, thinner, cigarette smoke, etc.).
WARNING! Be sure to close the leak valve of the check leak liquid after using.
WARNING! When the humidity of the ambient air is very high or water vapor is inhaled, the buzzer may continue to operate even if the “ALARM SET” knob is set to “0”. This is not a failure. After the vapor has cleared, the tester will operate correctly.
WARNING! Always keep the intake pipe and filter clean. A clogged filter can cause insufficient sensitivity, instability, incorrect responses, etc.
WARNING! If the intake pipe is blocked or bent, or the opening of a vent for the fan is blocked, the fan motor will overheat and damage may occur.
WARNING! When the tester is not in use for short periods, set the “SELECTOR” knob to “STANDBY”. When the tester is not in use for long periods of time set the power switch to “OFF”. Note that the detector is heated to 70 to 80° C (158 to 176° F) while in “STANDBY”.
WARNING! Never apply a strong shock to the detector and amplifier.
20-1110 1
WA700-3L
TROUBLESHOOTING
SERVICE TOOLS
12
VALVE FOR SERVICE CANS The valve for the service cans is used when charging refrigerating system. Handle it as follows: 1.
Before using the service can, confirm that a packing can be used on it. Then, turn the handle fully counterclockwise to lift the needle. Lift the disc (circular nut) at this time.
2.
Screw the valve into the service can, and tighten the disc. Take care not to tighten it so much that the service can is damaged.
3.
Connect the green charging hose of the gauge manifold to the valve.
4.
Turn the handle of the valve clockwise to lower the needle and make a hole on the blind cap of the service can.
5.
Turn the handle counterclockwise to lift the needle. Then, the refrigerant will flow into the refrigerating system through the valve. To stop the gas, turn the handle fully clockwise to lower the needle. WARNING! Never reuse an empty can.
1. Adapter for charging hose 2. Handle 3. Needle 4. Packing 5. Service can 6. Disc
WA700-3L
20-1111 1
TROUBLESHOOTING
MAINTENANCE PROCEDURE
12
MAINTENANCE PROCEDURE PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING PROHIBITED WORK The following operations are prohibited: 1.
Never allow moisture, dirt, or air to get into the air conditioner parts. If moisture, dirt, or air does enter into the air conditioner parts, it will become completely impossible for the air conditioner to work properly, so be particularly careful when carrying out operations. For this reason, never work outside, and avoid working on rainy days.
2.
Never leave the air conditioner parts with the blind plug removed. To prevent rust and the entry of dust, dirt, or moisture, the air conditioner parts are all carefully dried, and parts such as the compressor are filled with gas and completely sealed with blind plugs. Therefore, do not remove the blind plugs until immediately before connecting the piping, and after removing the plugs, complete the work quickly.
In particular, if the receiver is left open, the desiccant (drying agent) inside will completely lose its effect. WARNING! Never let moisture or dirt get into the parts of the cooler.
WARNING! Never leave the parts of the cooler with the blind plugs removes. 3.
Never run the compressor in the refrigeration cycle without any refrigerant. If the compressor is run without any refrigerant, the oil will not lubricate properly and this may lead to seizure.
OTHER PRECAUTIONS 1.
When trying to bend a stiff pipe, never heat it with a burner. If a burner is used on the pipe, an oxidized film will be formed inside, and this will cause the same kind of problem as dirt. If it is necessary to clean the inside of the pipe, use Freon, never use compressed air because it contains moisture.
20-1112 1
WA700-3L
TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 2.
Be careful not to connect the receiver in reverse. There is an “IN” mark at the refrigerant inlet side of the receiver sight glass, so be careful not to connect the inlet and outlet sides in reverse when connecting the piping. If the ports are connected in reverse, it will lead to such troubles as overcharging with refrigerant and defective cooling. ★ When removing the piping, replace the receiver.
3.
When connecting the piping, coat with oil. When connecting the piping, coat the O-ring with compressor oil before tightening. Always use two spanner wrenches when tightening. When tightening, turn only the spanner on the flared nut, keep the other nut in position and do not let it turn.
4.
Tighten the piping connections to the specified tightening torque. When connecting the piping, if the pipe connection nut is tightened too much, damage to the flared part and cause the nut to fall off. With Oring type nuts the seal may be deformed, leading to gas leakage. On the other hand, if the connections are not tight enough, the gas will leak, so always tighten to the standard torques given in the table below.
Standard torques for piping connection nuts
WA700-3L
Type of tightening nut
Tightening torque
3/8 in (9.5 mm)
104.2 - 130.1 lbf in (11.7 - 14.6 Nm)
1/2 in (12.7 mm)
173.6 - 216.9 lbf in (19.6 - 24.5 Nm)
5/8 in (15.8 mm)
260.4 - 303.7 lbf in (29.4 - 34.3 Nm)
20-1113 1
TROUBLESHOOTING 12 BLEEDING
MAINTENANCE PROCEDURE
AIR FROM REFRIGERATION CIRCUIT
PURPOSE Extreme care should be taken during handling, to prevent moisture from entering the air conditioner. Since the refrigerant does not dissolve easily in water, small amounts of water remaining inside the circuit may become frozen in the small orifice of the expansion valve, and cause rusting of the compressor valves. This can impair the operation of the air conditioner in various ways. Thus, it is necessary to remove all moisture from the air conditioner before charging it with refrigerant. To remove the moisture from the air conditioner, the water is evaporated by evacuation. To obtain a good vacuum, a high performance vacuum pump must be used. Otherwise, a long time is required for evacuation. Moisture in the air conditioner can be removed by a “repeating vacuum method” in a relatively short period of time.
CONNECTING GAUGE MANIFOLD 1.
Close high-pressure (HI) and low-pressure (LO) valves at the gauge manifold.
2.
Connect charging hoses (red and blue) to the compressor service valves. Red hose.. . . . . . . .to high pressure side (D side) Blue hose. . . . . . . . . to low pressure side (S side) WARNING! The “L” shaped ends of the charging hoses should be connected to the compressor service valves. Otherwise, the valve core will not open. Each charging hose should be connected to the correct (high or low pressure) side.
3.
With the engine stopped, open the high pressure valve of the gauge manifold and the valve for the service can. Charge approximately 4/5 of the amount of refrigerant.
20-1114 1
WA700-3L
TROUBLESHOOTING
MAINTENANCE PROCEDURE
EVACUATION 1.
Open both the high-pressure valve (HI) and the low pressure valve (LO) at the gauge manifold.
2.
Switch on the vacuum pump and allow it to run for approximately 15 minutes.
3.
When the negative pressure (degree of vacuum) reading of the low pressure gauge is 750 mmhg or more, turn off the vacuum pump switch and close the high and low pressure valves.
AIR-TIGHTNESS CHECK 1.
Maintain this vacuum (keep the high and low pressure valves closed) for 5 minutes or more. Then, make sure that the needle of the gauges does not move back to zero.
2.
If the needle moves toward the zero mark, it indicates a leak. If this happens, retighten or repair the piping connections and perform the evacuation again until it is confirmed that no air is leaking.
WA700-3L
20-1115 1
TROUBLESHOOTING
MAINTENANCE PROCEDURE
12
GAS-LEAK CHECK 1.
Reconnect the charging hose (green), which has been connected to the vacuum pump, to a service can. ★ For method of installing the service can. See VALVE FOR SERVICE CANS on page 20-1011.
2.
Open the service can valve, keeping the nut on the gauge manifold side of the charging hose (green) in the open position. Thus, the air in the charging hose is bled out under pressure of the refrigerant. (when a “Whoosh” sound is heard, retighten the hose.)
3.
Open the high pressure valve at the gauge manifold and charge with refrigerant until the low pressure gauge reads 1 kg/cm 2. After charging, close the high pressure valve.
4.
Carefully check the refrigeration circuit for gas leaks, using a gas leak detector.
5.
If a leak is detected, retighten or repair it. WARNING! Before checking for gas leaks, make sure there are no flammable substances (such as fuel) in the vicinity. If the refrigerant comes into contact with a naked flame, a poisonous gas (phosgene) will be given off.
EVACUATION (REPEATING) 1.
Close the service can valve and disconnect the green charging hose from the service can, then connect it to the vacuum pump. ★ Both the high and low pressure valves at the gauge manifold should be kept closed.
2.
Repeat the evacuation procedure described on page 20-1015 (EVACUATION) until the low- pressure gauge reads 750 mmHg or higher, for 15 minutes or more.
3.
After evacuation, close the high and low pressure valves at the gauge manifold. WARNING! Evacuation should be repeated at least two times. Particularly in rainy or humid weather.
20-1116 1
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TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT After evacuation, charge the refrigeration circuit with refrigerant in the following manner:
CHARGING FROM THE HIGH-PRESSURE SIDE 1.
Disconnect green charging hose from the vacuum pump, then connect it to the service can
2.
Open the service can valve, keeping the nut on the gauge manifold side of the charging hose open, to bleed the air out of the charging hose under the pressure of the refrigerant. ★ When a ‘whoosh” sound is heard, retighten the nut.
WA700-3L
20-1117 1
TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 3. Open the high-pressure valve at the gauge manifold and the service can valve, with the engine stopped. Charge specified amount of refrigerant. WARNING! While charging with refrigerant, do not operate the compressor. If the compressor is operated, the refrigerant will flow back into the service can and hoses, causing them to burst. WARNING! If the compressor is operated without refrigerant in the refrigeration cycle, it will burst or seize up. WARNING! The low pressure valve at the gauge manifold must not be opened (to prevent compression of the liquid refrigerant).
4.
Close both the high pressure valve at the gauge manifold and the service can valve.
CHARGING FROM THE LOW PRESSURE SIDE (REPLENISHING THE REFRIGERATION CIRCUIT) 1.
Make sure that the high pressure valve at the gauge manifold is closed.
2.
Start the engine and open all the doors of the cab.
3.
Turn on the air conditioner switch. Thermal control lever. . . . . . set to “COLDEST” Blower switch . . . . . . . . . . . . . . . . . . set to “HI”
4.
Set the engine speed to 1300 - 1500 rpm. WARNING! If valve is opened the service can will be broken off, causing serious injury.
20-1118 1
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TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 5. Open the low pressure valve at the gauge manifold and the service can valve. Then, charge the circuit with refrigerant until air bubbles in the sight glass at the liquid tank disappear. Gauge manifold indications: High pressure side . . . . . 12 to 17 kg/cm2 (ambient temperature 30째 C) Low pressure side . . . . . 1.5 to 2 kg/cm 2 (ambient temperature 30째 C) 6.
After charging the refrigeration circuit with refrigerant, close the low pressure valve at the gauge manifold and the service can valve. Then, stop the engine.
7.
Using a gas leak detector, make sure there are no gas leaks. WARNING! Do not open the high pressure valve (HI) at the gauge manifold. If the high pressure valve is open, the gas will flow into the service can and charging hoses, causing them to burst.
WARNING! Keep the service can right side up while charging the air conditioner with refrigerant. (When charging with the engine running). If the service can is turned upside down, the liquid refrigerant will be drawn into the compressor, causing damage to the compressor valves and packing. Set or hold the service can upright and charge the circuit with gaseous refrigerant.
WHEN THE AMBIENT TEMPERATURE IS LOW Where the refrigerant is not flowing into the refrigeration circuit easily, warm the service can in warm (40째C or below) water to raise the pressure in the service can.
If the service can is heated in hot water or by direct flame, it will burst. When warming a service can in warm water, make sure the water temperature is not higher than 40째 C.
WHEN THE AMBIENT TEMPERATURE IS HIGH If the ambient temperature is high, to speed the flow of the refrigerant into the circuit, cool the condenser by using a fan.
WA700-3L
20-1119 1
TROUBLESHOOTING 12 REPLACING
MAINTENANCE PROCEDURE
SERVICE CANS
If the service can is emptied before the circuit is completely charged, replace it with a new can in the following manner: 1.
Close the high and low pressure valves at the gauge manifold.
2.
Raise the needle and disc of the service can valve.
3.
Install the service can valve into a new service can.
4.
Bleed the air from the charging hose as follows: A. Tighten the service can valve, then loosen it slightly. B. Slightly open the low pressure valve at the gauge manifold. C. When the refrigerant flows out between the service can valve, making a “whoosh” sound, immediately close the service can valve and the low pressure valve at the gauge manifold. WARNING! Be careful not to let the refrigerant contact your skin.
5.
Screw the service can valve handle into the can to provide a hole and continue charging with refrigerant.
CHECKING THE AMOUNT OF REFRIGERANT After charging the refrigeration circuit with refrigerant, check the amount as follows: 1.
Disconnect the lead wire to the magnetic clutch and reconnect it so the power is directly from the battery.
2.
Open all doors and start the engine. Run the engine speed at 1300 to 1500 rpm.
3.
Connect the magnetic clutch lead wire directly to the battery. Turn the blower switch to the “HI” position. (Set the thermal control lever coldest position.)
4.
Maintain a pressure of 13 to 15 kg/cm2 on the high pressure side for approximately 5 minutes, or until the refrigeration circuit is stabilized.
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TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 5. After the refrigeration circuit is stabilized, turn off the blower switch, so that only the compressor is running. The pressure on the low pressure side will gradually decrease. If the pressure on the high pressure side is kept between 13 to 15 kg/cm2, the amount of refrigerant charged can be measured in the following manner: A. Too little refrigerant charged At a pressure of 1.01 kg/cm2 or above on the low pressure side, bubbles pass continuously through the sight glass. B. Proper amount of refrigerant charged. At a pressure of 1.0 to 0.6 kg/cm2 on the low pressure side, bubbles pass continuously through the sight glass. C. Too much refrigerant charged. At a pressure of 0.6 kg/cm2 or less on the low pressure side, bubbles may or may not be observed in the sight glass at all. 6.
If there is too little refrigerant, add some from the low pressure side as described on page 20-1018 (see CHARGING FROM THE LOW PRESSURE SIDE.)
7.
If there too much refrigerant, discharge some gradually from the low pressure side until the amount is decreased to the proper level.
8.
After making sure the refrigeration circuit contains the proper amount of refrigerant, turn on the blower switch and confirm that, at a pressure of 1.01 kg/cm2 or more on the low pressure side, no air bubbles appear in the sight glass. Turn off the blower switch and confirm that, at a pressure of 1.0 to 0.6 kg/cm2, air bubbles pass through the sight glass. Repeat these checks two or three more times.
9.
Stop the engine, and reconnect the magnetic clutch lead wire as it was before.
10. Disconnect the charging hoses and remove the gauge manifold (SEE REMOVAL OF GAUGE MANIFOLD - page 20-1022).
WA700-3L
20-1121 1
TROUBLESHOOTING
MAINTENANCE PROCEDURE
REMOVAL OF GAUGE MANIFOLD 1.
After charging the refrigeration circuit with refrigerant remove the charging hoses from the compressor as follows:
2.
Push the â&#x20AC;&#x153;Lâ&#x20AC;? shaped fitting on the low pressure charging hose (blue) against the compressor service valve to prevent leakage. Then, loosen the flared nut.
3.
As soon as the flared nut is removed, disconnect the charging hose from the service valve.
4.
Leave the charging unit connected to the refrigeration circuit until the high pressure gauge shows the lowest possible reading (10 kg/cm2).
5.
Disconnect the high pressure hose (red) in the same manner as the low pressure charging hose.
WARNING! Disconnect charging hoses from compressor as quickly as possible to minimize loss of refrigerant. Particularly on the high pressure side, compressor oil may sometimes gush out together with refrigerant. Therefore, wait for the gauge to drop to its lowest reading and remove the hose quickly.
WARNING! Be careful not to get any refrigerant on your skin. Use safety goggles to protect your eyes from the refrigerant.
DISCHARGING THE REFRIGERANT If the coolant is discharged during the refrigerating cycle, always use the charging valve and discharge the refrigerant gradually from the high pressure side. WARNING! If the piping connection is removed immediately, the refrigerant will get in your eyes.
WARNING! If all the refrigerant is discharged at one time, the compressor oil will leak out, so be sure to discharge the refrigeration circuit gradually.
20-1122 1
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TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 DAILY CHECKS When carrying out the daily maintenance checks before operating the machine, also check the following items:
CHECK REFRIGERANT LEVEL Start the engine and check the following: 1.
Turn the air conditioner switch ON, and run the engine at the standard speed (generally at 2000 rpm).
2.
Run the blower motor at maximum speed.
3.
Set the temperature control lever at maximum cooling.
4.
Check the sight glass. Look at the sight glass at the top of the receiver and dryer, and check the flow of the refrigerant in the refrigerating cycle. If there are bubbles in the flow as shown in the figure, the refrigerant is low. If there are no bubbles, the refrigerant is at the correct level. However, even if the refrigerant level is too high, there are no bubbles, so in this case, check the temperature of the suction hose (low pressure piping) connected to the compressor. If it is warm, the refrigerant level is too high.
CLEANING THE CONDENSER Direct tap water on the condenser installed at the front of the machine to wash off any dirt or mud stuck to the condenser. If the is excessive dirt, use a soft haired brush while applying the water. A hard haired brush may damage or bend the fins, so do not use a hard haired brush. Repair any crushed fins with a screwdriver blade or electrical pliers.
CHECKING THE V-BELT If the V-belt is loose, it will slip and cause the compressor speed to drop. As a result, it will be impossible to obtain the specified cooling capacity, and cooling will be defective, so check the V-belt in the following manner. Push the V-belt with a finger midway between the pulleys. The V-belt should deflect about 10 mm, but this varies according to the machine model. For details of the V-belt tension, see the operating manual for that machine. Do not use any deteriorated V-belt. Replace it with the same size and type of V-belt.
WA700-3L
20-1123 1
TROUBLESHOOTING 12 CHECKING
MAINTENANCE PROCEDURE
OIL LEVEL
PROCEDURE FOR CHECKING (Unnecessary if oil is normal) Before checking the oil level, run the refrigerating cycle at low speed (approximately 1000 rpm) for 5 to 6 minutes. This circulates the refrigerant. In addition, the compressor oil which circulates in the refrigeration cycle and remains at each functional part is collected as far as possible in the compressor. Next, discharge the refrigerant inside the refrigerating system. Depending on the type of compressor, it may be impossible to check the oil level. However, for those models where the oil level can be checked, check per PROCEDURE FOR CHECKING OIL LEVEL. (Only check if there is any abnormality, such as defective cooling or leakage of oil from the refrigeration system.)
PROCEDURE FOR CHECKING OIL LEVEL Use a dipstick to check the oil level. There are various types of compressors. In some, the end of the oil plug acts as the gauge, and in others, there is only an oil plug. For compressors with only the oil plug, insert a dipstick (95456-02020). When doing this, measure with the handle end of the dipstick in close contact with the crankshaft case. Pull out the dipstick and check that the oil level is between the top and bottom lines on the gauge. This range indicates that the oil is at the correct level. If the oil is not between the top and bottom lines, correct the oil level.
For compressors with a dipstick built into the oil plug, the procedure for measuring is the same. However, there is already oil on the dipstick, so wipe off that oil before measuring. When doing this, bring the threaded part of the oil plug into contact with the crankcase. Do not screw it in.
20-1124 1
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TROUBLESHOOTING
MAINTENANCE PROCEDURE
12 ADDING AND REMOVING OIL If there is any failure in the functional parts during the operation of the refrigeration system, some compressor oil will remain in the refrigerating system. If trouble had occurred in the evaporator or condenser, and these are replaced with new parts, it is necessary to add an amount of oil equal to the oil which would have remained in those parts. On the other hand, when replacing the compressor, the oil level inside the new compressor must be the same as the oil level remaining in the failed compressor. (Remove any excess oil.)
Amount of compressor oil to add (when replacing functional parts). Replaced part Condenser replaced as individual part Adding Evaporator replace as individual part Receiver replaced as individual part Removing
Compressor replaced as an individual part
Amount of oil to add or remove 2M110 Series, 2M126 Series 30 cc 60 cc 10 cc Remove enough oil to give the same volume of oil as in the removed compressor
NOTE: The values in the above table show the oil remaining after running for 5 to 6 minutes at an engine speed of 1000 rpm.
ADDING OIL BY EVACUATION If the structure of the refrigerating system is kept intact, oil must be added by evacuation. First, use a measuring cylinder to prepare slightly more compressor oil than is needed for adding to the refrigerating system. As shown in the figure, connect the service valve at the high pressure side of the compressor with the valve at the high pressure side of the gauge manifold. Connect a vacuum pump to the connection port at the center of the gauge manifold. Connect a charging hose to the service valve at the low pressure side of the compressor, and put the other end into the compressor oil prepared in the measuring cylinder. When the vacuum pump is started, the oil will be sucked from the low pressure side of the compressor and will go into the compressor. When the specified amount of oil has been sucked into the compressor, stop the vacuum pump.
WA700-3L
20-1125 1
TROUBLESHOOTING
TROUBLESHOOTING
12
TROUBLESHOOTING Before the hot season sets in, make a systematic check on each functional part in the refrigeration system. This will make it possible to find those problems which customers are seldom aware of. The early discovery and prompt repair will contribute to a longer service life of the air conditioner system.
VISUAL AND ACOUSTICAL CHECKS 1.
V-belt If the V-belt is too loose, it will be torn off because of slippage. To prevent such problems, keep the belt tight. Replace a torn belt with a new one.
2.
Noise around the compressor Check the compressor mounting bolts and the bracket mounting bolts for looseness and tighten as necessary.
3.
Noise from inside the compressor This may indicate that either a delivery or suction valve has been damaged, or that the connecting rod has come loose. Dismount the compressor and repair or replace it.
4.
Mud and dirt on the condenser fins If the condenser and fins are fouled with mud or dust, the cooling effect of the condenser will decline, and the cooling capacity of the air conditioner will also be reduced. Be sure to wash the mud and dust off the condenser. Use a soft haired brush, if the condenser fins are washed with a hard hair brush, they will be scratched or bent. Therefore, clean them very carefully.
5.
Clogged air filter If an air filter is clogged, the air flow will be significantly reduced, deteriorating the cooling capacity. Remove and clean all air filters.
6.
Dirty connections and portions with oil The presence of oil indicates that the refrigerant is leaking. The compressor oil contained in the refrigerating gas escapes from the system together with the leaking refrigerant. Consequently, the gas leaking portions get fouled with oil. If any place has gotten dirty with oil, retighten the connections or replace the related parts to prevent gas leakage. Oil stains are frequently found in the compressor gaskets and piping connections, so check these areas carefully.
7.
Noise around the blower Run the blower motor at low (Lo), medium (Med), and high (Hi) speeds. If you notice any abnormal operating noise or unsatisfactory rotation, replace the blower motor. But before replacing the blower motor, check to see if the noise is caused by foreign matter stuck in the motor, or if the motor is running unsatisfactorily because of loose parts.
8.
Checking the quantity of refrigerant through the sight glass When many air bubbles are seen through the sight glass, it indicated a lack of refrigerant. Therefore, add refrigerant to its proper level. In this case, see if there are any oil stains (step 6) and confirm that the refrigerant is not leaking from any point. If no air bubbles are seen through the sight glass even when the condenser is cooled with water, it indicates that too much refrigerant has been charged into the condenser. In this case, carefully drain the refrigerant through a low pressure service valve a little at a time, until the proper level is obtained. Otherwise, too much refrigerant will drain out or the compressor oil will spurt out.
20-1126 1
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TROUBLESHOOTING
TROUBLESHOOTING
12 DEFECTIVE COOLING YES
Possible Cause Pressure normal Air in system Pressure at high pressure end too high
YES YES
Is compressor rotation normal?
Too much refrigerant Condenser covered with dirt or dust
Is pressure normal?
Refrigerant low
NO
Pressure at high pressure end and too low
Compressor delivery valve broken Gasket broken (compressor) Low pressure in piping (crushed/clogged Expansion valve open too far
Is air flow normal?
Pressure at low pressure end to high
Defective contact of heat sensing tube Refrigerant too much
Refrigerant not enough Gas leaking from heat sensing tube Pressure at low pressure end too low
Frost on evaporator Low pressure piping abnormal Expansion valve clogged
Pressure at high pressure and low pressure ends too high Pressure at high pressure and low pressure ends too low
B
Refrigerant too much
Refrigerant not enough
See "B", next page NO Other
A NO
See "Other", next page
See "A", next page
WA700-3L
20-1127 1
TROUBLESHOOTING
TROUBLESHOOTING
Possible Cause Drop in battery voltage Abnormality of internal parts of compressor B
Broken, disconnected wiring
NO See "B", previous page
Interference between rotor and stator
Magnetic clutch Failure or defective adjustment in relay Belt slipping
Layer short in coil
Defective grounding
Disconnection in coil
Other
Outside air entering through ventilator to window
See "Other", previous page
Temperature control function defective Heater is on
Obstruction near suction port Frost on evaporator
YES
Filter clogged A
Air duct clogged or disconnected See "A", previous Are blower & motor page NO normal? Defective switch
Defective resistor NO
Blower & motor related parts Battery voltage low
Blown fuse
20-1128 1
C NO
Defective or disconnected wiring
See "C", next page
Defective contact of brush
WA700-3L
TROUBLESHOOTING
TROUBLESHOOTING
Possible Cause Defective tightening of blower
C See "C", previous page
NO
Blower system
Contact between blower and heater case Deformation of blower
TROUBLESHOOTING TABLE Problem
Location
Condition When compressor is stopped, high and low Compressor related parts pressure immediately becomes the same Area around low Suction pressure (pressure at low pressure side) abnormally Expansion valve related pressure hose, low parts pressure service valve high (more than abnormally cold 2 approximately 3 kg/cm ) Pressure at high pressure side also high; suction Refrigerating system pressure drops after related parts forced cooling of condenser Poor suction of air by Condenser related parts condenser cooling fan (insufficient cooling air)
Engine related parts Delivery pressure (pressure at high pressure side) Others abnormally high (more than approximately 20 kg/cm2)
Refrigerating system related parts
Refrigerating system related parts Suction pressure (pressure at low pressure) abnormally low (less than approximately 0.5 kg/cm2)
WA700-3L
Possible cause 1. Gasket, O-ring broken 2. High, low pressure valve reed broken 3. Dirt or dust stuck in reed valve
Replace compressor
1. Valve open to far 2. Defective contact (disconnection) of heat sensing tube
1. Replace valve 2. Securely fix heat sensing tube
Too much refrigerant in refrigeration system
Bleed from compressor schrader valve (high pressure side) to adjust to correct amount.
1. Defective motor 2. Condenser fins clogged with dirt
1. Replace motor 2. Clean fins (wash with water)
1. Insufficient cooling water, oil 2. Ignition timing incorrect Engine tends to overheat 3. Defective water pump, insufficient capacity 4. Radiator fins clogged with dirt 1. Outside temperature extremely high Heat load too high 2. Source of heat inside machine (heater, etc.) Even when condenser is cooled by water no Too much refrigerant bubbles are seen in sight glass Immediately after compressor is stopped, pressure drops suddenly Air in refrigeration system about 2 kg/cm2 Cooling is poor, many bubbles can be seen in sight glass Receiver and dryer abnormally cold (condensation, etc.)
Remedy
1. Add to correct level 2. Adjust timing 3. Replace or repair 4. Clean fins (wash with water) 1. Improve cooling of condenser 2. Turn off heater, etc. Bleed from compressor schrader valve (high pressure side) to adjust to correct amount
Discharge all refrigerant and evacuate, then refill to correct level
Insufficient refrigerant
Add to correct level
Receiver and dryer clogged
Replace (evacuate completely
1. Valve clogged (defective adjustment, entry of dirt or dust) No condensation at 2. Gas lost from heat sensing tube valve, piping at low pres3. Temporary clogging caused by Expansion valve related sure end not cold freezing of valve (trouble caused by parts entry of water) Valve tends to clog (defective Frost on valve adjustment or dirt in valve)
1. Replace valve 2. Replace valve 3. After replacing valve and receiver, evacuate completely Replace valve
20-1129 1
TROUBLESHOOTING
TROUBLESHOOTING
Problem Location Suction pressure (pressure at low pressure) abnormally low Others (less than approximately 0.5
Condition Wind discharge temperature low, no wind Heat load is too low kg/cm2) When compressor is stopped, high and low Compressor related parts pressure immediately becomes the same Cooling is poor, many Delivery pressure (pressure at Refrigerating system bubbles can be seen in high pressure side) related parts sight glass abnormally low (less than approximately 10 kg/cm2)
Gas leakage, oil leakage
No attraction for magnetic clutch
Magnetic clutch slips
20-1130 1
No condensation at valve, piping at low Expansion valve related pressure end not cold parts (may become negative pressure) Area around shaft seal Compressor related parts dirty with oil, gas level reduced Area around piping Refrigerating system connections dirty with related parts oil, gas level reduced Cooler switch ON
Clutch
Clutch
Possible cause Frost on evaporator Outside temperature extremely low 1. Gasket, O-ring broken 2. High, low pressure valve reed broken 3. Dirt or dust stuck in reed valve
Remedy Check, adjust thermostat --Replace compressor
Insufficient refrigerant
Add to correct level
1. Valve clogged (defective adjustment, entry of dirt or dust) 2. Gas lost from heat sensing tube 3. Temporary clogging caused by freezing of valve (trouble caused by entry of water)
1. Replace valve 2. Replace valve 3. After replacing valve and receiver, evacuate completely
Gas leaking from shaft seal
Replace shaft seal
Gas leaking from piping connection
1. tighten connection 2. Replace piping
Disconnection in coil Defective wiring or connections (ground, fuse) No attraction even when Defective contact or switch related cooling switch is ON parts (thermostat, stabilizer relay, cooler switch) When switch is turned ON, rotor shows Excessive clearance between rotor movement and is and stator attracted when pushed Battery voltage low Clutch slips during Oil on clutch face rotation Layer short in coil
Replace Reconnect or replace parts Repair or service
Repair or replace Charge battery Remove oil Replace
WA700-3L
TROUBLESHOOTING
TROUBLESHOOTING
12 DEFECTIVE HEATING
Cause Water valve clogged YES Piping clogged or bent YES
Is cooling water temperature normal?
Air in hot water circuit
Insufficient level of cooling water NO
Defective engine radiator thermostat
Obstruction near suction port
YES
Frost on evaporator
Is air flow normal? Filter clogged Air duct clogged or disconnected
Are blower and NO motor normal?
Defective switch
Defective resistor
Battery low voltage
Blown fuse
1. Blower & motor related parts NO 2. blower system
Defective or disconnected wiring Defective contact of brush Defective tightening of blower Contact between blower and heater case Deformation of blower
WA700-3L
20-1131 1
TROUBLESHOOTING 12 TROUBLESHOOTING
TROUBLESHOOTING
USING GAUGE MANIFOLD
In this method, the gauge manifold is used to indicate on its gauges the pressure at the high pressure and the low pressure sides of the refrigerating system, to locate problems and to repair them.
PREPARATIONS BEFORE MEASURING Precautions 1.
Close the valves firmly on the high pressure and low pressure sides of the gauge manifold, then connect the charging hoses (red high side, blue low side) to the service valves of the compressor. When doing this, always set the valve plunger type service valve at the intermediate seat position (if the indicator moves, this means the back seat) so that measurement can be carried out with the gauge. ★ When measuring, remove the air inside the charging hoses from the connection port at the gauge manifold end using the pressure of the refrigerant in the air conditioning system.
2.
Generally speaking, when the refrigerating system is working normally, (and under the following conditions: Air temperature at cooler suction port: 30 to 35° C; Engine speed: 2000 rpm; Maximum cooling, blower running at maximum speed) the gauge manifold readings are as follows: • Low pressure side: approximately 1.5 - 2.0 kg/cm 2. • High pressure side: approximately 14.5 - l 5 kg/cm 2.
3.
If the outside temperature is low for machines mounting the EPR, at around 1.8 kg/cm 2, the pressure at the low pressure side continuously alternates between high pressure and low pressure.
★ The gauge manifold readings given in the diagrams are all for the same conditions (Air temperature at cooler suction port: 30 to 35° C; Engine speed: 2000 rpm; Maximum cooling: Blower running at maximum speed), but the actual gauge reading will vary slightly according to the surrounding air conditions.
INSUFFICIENT REFRIGERANT Conditions 1.
Cooling effect is poor.
Symptoms in refrigerating system 1.
Pressure low at both low and high pressure ends.
2.
Bubbles seen in sight glass.
3.
Air coming from cooler vents only slightly cold.
Cause 1.
Gas leakage somewhere in the refrigerating system.
20-1132 1
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TROUBLESHOOTING
TROUBLESHOOTING
12 Judgement 1.
Insufficient refrigerant in system - refrigerant leaking.
Remedy 1.
Check for leakage with leak tester, repair.
2.
Add refrigerant to correct level.
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER Conditions 1.
Very little cooling effect
Symptoms in refrigerating system 1.
Pressure high at both low and high pressure ends.
Cause 1.
There is excessive refrigerant in the system, so the capacity is not being fully displayed.
Judgement 1.
Excessive refrigerant in system - too much refrigerant.
2.
Defective cooling of condenser - clogged condenser fins or loose fan belt.
Remedy 1.
Clean condenser (with water).
2.
Correct tension of fan belt.
3.
Replace condenser fan motor.
4.
If items l, 2 and 3 are normal, check the amount of refrigerant.
For details, see page 20-1023, â&#x20AC;&#x153;Check refrigerant levelâ&#x20AC;?. When discharging the refrigerant, push the schrader valve on the low pressure side of the gauge manifold and discharge the refrigerant gradually.
WA700-3L
20-1133 1
TROUBLESHOOTING 12 AIR
TROUBLESHOOTING
INSIDE REFRIGERATION SYSTEM
Condition 1.
Cooling effect is insufficient.
Symptoms in refrigerating system 1.
Pressure high at both low and high pressure ends.
2.
Piping at low pressure end does not feel cold.
Cause 1.
Air in refrigerating system.
Judgement 1.
Air in refrigerating system - incomplete evacuation.
Remedy 1.
Replace receiver and dryer.
2.
Check compressor oil level, check for dirt in compressor oil.
3.
Evacuate, then charge with new refrigerant
20-1134 1
WA700-3L
TROUBLESHOOTING
TROUBLESHOOTING
12 MOISTURE IN REFRIGERATING SYSTEM Conditions 1.
The cooler repeats a cycle of cooling and non-cooling.
Symptoms in refrigerating system 2.
During operation, the pressure at the low pressure end sometimes changes between negative pressure and normal pressure.
Cause 1.
The moisture in the refrigerant of the refrigerating system is freezing at the orifice in the expansion valve, so the system is temporarily shut-off. After a short time, the ice melts and the system returns to the normal condition.
Judgement 1.
The dryer is oversaturated the moisture in the refrigerating system is freezing at the orifice in the expansion valve and preventing the refrigerant from circulating.
Remedy 1.
Replace receiver and dryer.
2.
To remove the moisture in the system, carry out repeated evacuation of the system.
3.
Add new refrigerant to the correct level.
WA700-3L
20-1135 1
TROUBLESHOOTING 12 REFRIGERANT
TROUBLESHOOTING
DOES NOT CIRCULATE
Conditions 1.
No cooling effect (there may be cooling occasionally).
Symptoms in refrigerating system 1.
The pressure on the low pressure side indicates negative pressure and the pressure on the high pressure side is extremely low.
2.
There is frost or condensation on the piping on both sides of the expansion valve or the receiver and dryer.
Cause 1.
Water or dirt in the refrigerating system is freezing or sticking at the orifice of the expansion valve and preventing the flow of refrigerant.
2.
Gas leakage from the heat sensing tube of the expansion valve is preventing the flow of refrigerant.
Judgement 1.
Orifice of the expansion valve is closed - refrigerant does not circulate.
Remedy Leave for a short time, then start operation again to judge if the problem is caused by water or by dirt. 1.
If the problem is caused by water, carry out the action given in "MOISTURE IN REGRIGERATING SYSTEM".
2.
If the problem is caused by dirt: • Remove the expansion valve and blow out the dirt with compressed air. If the dirt can not be removed, replace the expansion valve. • Replace the receiver and dryer. • Evacuate the refrigeration system, then add new refrigerant to the correct level.
3.
If the problem is gas leakage from the heat sensing tube, replace the expansion valve.
20-1136 1
WA700-3L
TROUBLESHOOTING
TROUBLESHOOTING
12 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE Conditions 1.
Cooling effect is poor.
Symptoms in refrigerating system 1.
Pressure high at both low and high pressure end.
2.
Frost or excessive condensation on piping at low pressure end.
Cause 1.
Failure of expansion valve or defective mounting of heat sensing tube.
2.
Flow control is not being carried out properly.
Judgement 1.
Excessive liquid refrigerant inside piping at low pressure end.
2.
Expansion valve open too far.
Remedy 1.
Check mounting of heat sensing tube.
2.
If there is no abnormality in l), test the expansion valve as an individual part and adjust it. If it can not be adjusted, replace it.
WA700-3L
20-1137 1
TROUBLESHOOTING 12 DEFECTIVE
TROUBLESHOOTING
COMPRESSION BY COMPRESSOR
Conditions 1.
No cooling.
Symptoms in refrigeration system 1.
Pressure at low pressure end too high.
2.
Pressure at high pressure end too low.
Cause 1.
Leakage inside compressor.
Judgement 1.
Defective compression by compressor - leakage from valve, damage, damage to sliding parts (piston, cylinder, gasket, connecting rod, etc.).
Remedy 1.
Replace compressor as assembly.
20-1138 1
WA700-3L
30
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 ENGINE, DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27 PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33 TORQUE CONVERTER, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 30-50 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64 TRANSMISSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
WA700-3L
30-1 1
DISASSEMBLY AND ASSEMBLY LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117 FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-126 REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146 ORBITROL STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-151 STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-152 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-152 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-154 STEERING DEMAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156 BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-157 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-157 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-158 BRAKE VALVE (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-159 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-159 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161 BRAKE VALVE (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-163 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-163 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165 SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167
30-2 1
WA700-3L
DISASSEMBLY AND ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-170 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-170 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-172 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183 PISTON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210 WORK EQUIPMENT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215 DUMP CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 30-217 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217 LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219 STEERING, LIFT, DUMP CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222 CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237 BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240 FLOOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-245 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-248 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-248
WA700-3L
30-3 1
DISASSEMBLY AND ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-250 STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-251 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-251 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-251 ACCUMULATOR CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-253 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-254 PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256 DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-259 EMERGENCY STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-261 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-261 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-261 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 30-262 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-263 PARKING BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-264 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-264 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-266 PARKING BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-268 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-268 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-268 REAR TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-269 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-269 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-269 AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-270 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-270 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-270 AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-271 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-271 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-272 AIR CONDITIONER RECEIVER TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-273 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-273 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-273 AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-275 MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-276 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-276 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-277 MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-278 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-278 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-278 ENGINE, APS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279
30-4 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
12 METHOD OF USING MANUAL 1.
When removing or installing unit assemblies A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. Example
Explanation
(COMPONENT) REMOVAL
Title of operation
WARNING!
Safety precautions to observe when performing an operation
1. XXX
Text of or name of procedural step
A.
Text of procedural step if 1 was procedural name
â&#x2DC;&#x2026;
Technique or important point Reference to a special technique during assembly or installation (note that this symbol is right-aligned).
(COMPONENT) INSTALLATION
Title of operation
â&#x20AC;˘
Overall directive
Installation is the reverse of removal.
Special technique during assembly or installation (note that this symbol is left-aligned). (Component/assembly)
Specification
2.
General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out the operation.
3.
Listing of special tools For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOL LIST later in this section.
WA700-3L
30-5 1
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or assembly) of units.
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK • • • •
If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws alternately. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations. A. Hoses and tubes using sleeve nuts Nominal number
Plug (nut end)
Sleeve nut (elbow end) Use the two items below as a set
02
07376-50210
07221-20210 (Nut), 07222-00210 (Plug)
03
07376-50315
07221-20315 (Nut), 07222-00312 (Plug)
04
07376-50422
07221-20422 (Nut), 07222-00414 (Plug)
05
07376-50522
07221-20522 (Nut), 07222-00515 (Plug)
06
07376-50628
07221-20628 (Nut), 07222-00616 (Plug)
10
07376-51034
07221-21034 (Nut), 07222-01018 (Plug)
12
07376-51234
07221-21234 (Nut), 07222-01219 (Plug)
B. Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
30-6 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS DURING OPERATION
12 3) If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal number
Part Number
06
D
d
L
07049-00608
6
5
8
08
07049-00811
8
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14
11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK • • • • • • • • • • • • •
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press-fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
WA700-3L
30-7 1
DISASSEMBLY AND ASSEMBLY 12 PRECAUTIONS • • •
•
PRECAUTIONS DURING OPERATION
WHEN COMPLETING THE OPERATIONS
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed air from the system after reassembling the parts. ★ For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS •
To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are clean. • To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when disassembling or assembling. • Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be disassembled. • Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling. • Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that have failed. • When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely. • Do not use seal tape for the thread of the plug mounts or connections. • If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits. • When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air from piston pump. Remark After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows after completion of installation. A.
Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.) ★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air inside the cylinder will cause damage to the piston packing.
B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter. C. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air comes out from the plugs. D. After completing bleeding the air, tighten the plugs. Plug: 11.3 ± 1.5 Nm (8.33 ± 1.10 lbf ft) E. After repair or long storage, follow the same procedure.
30-8 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
12 SPECIAL TOOL LIST Remark Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured). Remark ■: . . . . . . . Cannot be substituted, should always be installed (used) Necessity: ●: . . . . . . . Extremely useful if available, can be substituted with commercially available part Remark New/remodel: N: . . . . . . . . Tools with new part numbers, newly developed for this model R: . . . . . . . . Tools with upgraded part numbers, remodeled from items already available for other models Blank: . Tools already available for other models, used without any modification Remark Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS).
Component
Symbol 1
2
Disassembly, assembly of engine assembly
Assembly of damper assembly
Disassembly, assembly of torque converter and PTO assembly
A 3
B
Part Name
Necessity
Qty
New Remodeled
Sketch
Nature of work, remarks
792-400-1110
Bracket
■
1
Engine sling
795-902-1410
Sleeve
■
1
Installation of front seal
01050-32235
Bolt
■
3
795-902-1430
Push tool
■
1
01050-32240
Bolt
■
3
795-902-1420
Sleeve
■
1
795-902-1450
Bolt
■
2
01582-02016
Nut
■
2
Installation of rear seal
795-902-1440
Push tool
■
1
01050-32050
Bolt
■
4
4
790-331-1110
Wrench
■
1
5
795T-871-1110
Adapter
■
2
6
795-601-1110
Push tool
■
1
Removal of water tube
1
793-612-1110
Guide
■
1
Press fitting of bearing
2
793-612-1120
Push tool
■
1
3
790-201-2670
Plate
■
1
4
790-201-2320
Push tool
■
1
1
790-413-1110
Centering tool
2
790-501-5000 or 790-501-5200
1
Unit repair stand (100 V)
■
1
Unit repair stand (110 - 120 V or 220 - 240 V)
■
1
Tightening of cylinder head O
Removal, installation of fuel injection pump
Press fitting of oil seal Centering of parts between engine and torque converter Torque converter and PTO repair stan
790-901-4110
Bracket
■
1
790-901-4231
Plate
■
1
3
790-102-1011
Nut wrench
■
1
Removal, installation of PTO gear bearing nut
4
792-201-7211
Wrench
■
1
Removal, installation of round set nut of pump fixture bearing
790-101-5401
Push tool kit C
■
1
Press fitting of retainer oil seal
.790-101-5461
.Plate
■
1
C
5
WA700-3L
Part Number
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
30-9 1
DISASSEMBLY AND ASSEMBLY Component
Disassembly, assembly of transmission assembly
Symbol
New Remodeled
Sketch
Nature of work, remarks
■
1
Check of operation of clutch piston
2
793-615-1200
Centering tool
■
1
Centering of transmission and center support
793-615-1100
Wrench assembly
■
1
Adjustment of pre-load on transfer bearing
793-615-1130
Spline wrench
■
1
793-673-1110
Push tool
■
1
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
2
3
4
793-673-1120
Push tool
■
1
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
790-101-5401
Push tool kit C
■
1
.790-101-5491
.Plate
■
1
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
Unit repair stand (100 V)
■
1
Unit repair stand (110 - 120 V or 220 - 240 V)
■
1
Bracket
■
1
793-623-1110
Plate
■
1
790-201-2860
Spacer
■
1
793T-815-1120
Plate
■
1
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
793T-622-1160
Plate
■
1
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
793T-622-1160
Plate
■
1
793T-622-1170
Spacer
■
1
790-501-5000 or 790-501-5200 790-901-5110
5 6
7
H 8
Press fitting of center support oil seal
Press fitting of bearing inner race
Press fitting of bearing outer race and oil seal to housing
Differential repair stand
Press fitting of bearing inner race O
Press fitting of bearing inner race
N
O
Press fitting of cage oil seal
N
O
Press fitting of cage dust seal
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
790-425-1660
Wrench
■
1
Adjustment of pre-load on side bearing
10 793-623-1120
Plate
■
1
Positioning of pinion gear of differential
11 793-623-1130
Fixture
■
2
Holding of brake assembly and wheel hub Installation of floating seal
9
12
791-585-1510
Installer
■
1
792-530-1700
Push tool
■
1
793T-833-1110
Plate
■
1
13 .790-101-5421 .01010-51240 14 793-520-1805
30-10 1
Qty
Oil leak tester kit
1
Disassembly, assembly of differential assembly
Necessity
799-301-1600
D
H
Part Name
1
3
Disassembly, assembly of center support assembly
Part Number
SPECIAL TOOL LIST
.Grip
■
1
.Bolt
■
1
Brake tester
■
1
O
Press fitting of oil seal to wheel hub
Check of brake oil for leakage
WA700-3L
DISASSEMBLY AND ASSEMBLY Component
Symbol
1
Installation of center hinge bearing
K 2 3 4 5 1
2
Disassembly, assembly of hydraulic cylinder assembly
U 3
4
5
WA700-3L
Part Number
Part Name
SPECIAL TOOL LIST Necessity
Qty
■
1
790-101-2501
Push tool kit
.790-101-2510
.Plate
1
.790-101-2520
.Screw
1
.791-112-1180
.Nut
1
.790-101-2540
.Washer
1
.790-101-2610
.Leg
2
.790-101-2570
.Plate
4
.790-101-2560
.Nut
2
.790-101-2740
.Adapter
2
793-646-1110
Push tool
■
1
793-646-1120
Guide
■
1
793-646-1130
Push tool
■
1
793-646-1140
Guide
■
1
790-201-1310
Spacer
■
1
790-101-2102
Puller (30 ton)
■
1
790-101-1102
Hydraulic pump
■
1
790-502-1003
Cylinder repair stan
●
1
■
New Remodeled
Sketch
Nature of work, remarks Installation of center hinge bearing
Upper part
Lower part
Disassembly, assembly of cylinder
790-201-1702
Push tool kit
.790-101-5021
.Grip
Press fitting of wound bushing
.01010-50816
.Bolt
1
.790-201-1881
.Push tool
1
Boom cylinder
.790-201-1940
.Push tool
1
Steering cylinder
790-201-1910
Push tool
■
1
Bucket cylinder
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
■
1
Applicable to all cylinders
790-201-1500
Push tool kit
1
Press fitting of dust seal
.790-201-1690
.Plate
1
Boom cylinder
.790-101-5021
.Grip
1
.01010-50816
.Bolt
1
790-201-1980
Plate
■
1
.790-101-5021
.Grip
■
1
.01010-50816
.Bolt
■
1
790-201-1920
Plate
■
1
Steering cylinder
Bucket cylinder
.790-101-5421
.Grip
■
1
.01010-51240
.Bolt
■
1
790-720-1000
Expander
●
1
Installation of piston ring (All cylinders) Boom cylinder
796-720-1720
Ring
■
1
07281-02429
Clamp
■
1
796-720-1670
Ring
■
1
07281-01279
Clamp
■
1
796-720-1730
Ring
■
1
07281-02909
Clamp
■
1
Steering cylinder Bucket cylinder
30-11 1
DISASSEMBLY AND ASSEMBLY Component
Pulling out work equipment connecting pins
Collection and reproduction of new Freon gas
Symbol
V
X
Y
Disassembly, assembly of piston pump assembly
Z
AA
BB
30-12 1
1
1
Part Number
Part Name
SPECIAL TOOL LIST Necessity
Qty
New Remodeled
Sketch
Nature of work, remarks Pulling out pin connecting bucket and boom connecting and pulling out boom cylinder end pin
793T-870-1110
Sleeve
■
1
O
793T-870-1120
Plate
■
1
O
791-745-2110
Adapter
■
1
790-438-1110
Screw
■
1
790-101-2540
Washer
■
1
02215-11622
Nut
■
1
01010-81655
Bolt
■
3
790-101-2102
Puller (30 ton)
■
1
790-101-1102
Hydraulic pump
■
1
799-703-1200
Service tool kit
■
1
799-703-1100
Vacuum Pump (100 V)
■
1
Collection and supply of air conditioner gas For Japanese market
799-703-1110
Vacuum Pump (220 V)
■
1
For overseas market
790-703-1120
Vacuum Pump (220 V)
■
1
For overseas market
■
1
799-703-1400
Gas leak tester
1
790-501-5000
Unit repair stand
1
2
790-901-2110
Bracket
1
3
790-901-1330
Plate
1
4
790-345-1020
Plate
1
1
790-445-3400
Gauge
1
(for minimum swash plate angle) HPV
2
790-445-3300
Gauge
1
(for maximum swash plate angle) HPV, HPF090+090 common
3
790-445-3500
For front
1
HPF076+071
4
790-445-3600
For rear
1
HPF076+071
1
796-720-3520
Cap
1
2
796-720-2220
Socket
1
3
796-730-2120
Screwdriver
1
1
795-630-1803
Torque wrench
1
2
796-720-3800
Wrench
1
WA700-3L
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
12 SKETCHES OF SPECIAL TOOLS Remark Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A5 ADAPTER
H6 PLATE
WA700-3L
30-13 1
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
12 H7 PLATE
H8 SPACER
30-14 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
12 H13 PLATE
V1 SLEEVE
WA700-3L
30-15 1
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
12 V1 PLATE
30-16 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
ENGINE
12 ENGINE Remark As for the disassembly and assembly of engine components (see the following list). Refer to the ENGINE SHOP MANUAL.
ALTERNATOR CYLINDER HEAD ENGINE FRONT SEAL ENGINE OIL COOLER ENGINE REAR SEAL FUEL INJECTION PUMP NOZZLE HOLDER STARTING MOTOR THERMOSTAT TURBOCHARGER WATER PUMP
WA700-3L
30-17 1
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER 12
HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Drain cooling water. Cooling water: 190 L (50.19 gal)
2.
Remove handrail (1).
3.
Remove exhaust tube (2).
4.
Lift off side cover (3) and engine hood (4).
5.
Remove mount bolts and lift off radiator mask (5).
6.
Disconnect working lamp wiring connector (6) (GR1).
7.
Remove 8 radiator guard mount bolts (7).
8.
Remove U-bolt (8) to remove bracket (9).
9.
Open radiator check covers (10) on both sides.
10. Lift off radiator guard (11). Radiator guard assembly: 230 kg (508 lb)
11. Disconnect hose between turbocharger and aftercooler, then remove tube (12). 12. Disconnect hose between aftercooler and intake manifold, then remove tube (13). 13. Disconnect radiator upper tube (14). 14. Disconnect aeration hose (15).
30-18 1
WA700-3L
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER 12 15. Disconnect hydraulic oil cooler outlet/inlet tube (16). 16. Remove hydraulic oil cooler lock bolts (on both sides) (17). 17. Sling hydraulic oil cooler temporarily and remove mount bolts (on both sides) (18). 18. Lift off hydraulic oil cooler assembly (19). Hydraulic oil cooler assembly: 350 kg (772 lb)
19. Disconnect radiator lower hose (20). 20. Remove fan guard (21). 21. Remove supports (on both sides) (22). 22. Sling radiator and aftercooler assembly (24) temporarily and remove both mount bolts (23). 23. Lift off radiator and aftercooler assembly (24). Radiator and aftercooler assembly: 644 kg (1420 lb)
24. Lift off shroud (25) and aftercooler (27) from radiator and aftercooler assembly (24). Aftercooler assembly: 65 kg (144 lb)
INSTALLATION â&#x20AC;˘ â&#x20AC;˘
Carry out installation in the reverse order to removal. Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.
WA700-3L
30-19 1
DISASSEMBLY AND ASSEMBLY
DAMPER
12
DAMPER REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove bulkhead assembly. For details, see BULKHEAD ASSEMBLY - REMOVAL.
2.
Remove hydraulic oil cooler, radiator, and aftercooler assembly. For details, see HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER ASSEMBLY - REMOVAL.
3.
Disconnect engine oil drain valve (1) from fuel tank.
4.
Disconnect starting motor cable (2).
5.
Disconnect ground cable (3) between engine and vehicle body.
6.
Disconnect engine wiring connectors (4) (ER3), (5) (ER4), (6) (ER1), and (7) (ER2).
7.
Disconnect ground cable (8) (E02) from vehicle body.
8.
Disconnect slow-blow fuse wire (9) (E01).
9.
Disconnect hoses (10) and (11) between engine and torque converter.
10. Disconnect hoses (12) (return) and (13) (supply) between air conditioner unit and engine. ★ (12): Located at suction opening of water pump. ★ (13): Located near upper turbocharger.
30-20 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
DAMPER
12 11. Disconnect air conditioner compressor pipes (14) and (15). ★ Take measures to prevent dust, water, etc. from entering the pipes. 12. Disconnect fuel spill hose (16). ★ Located on the top of the fuel tank.
13. Disconnect hose (17) between engine oil full flow filter and bypass filter. 14. Disconnect hose (18) between engine and fuel tank.
15. Disconnect hose (19) between engine oil bypass filter and engine. ★ Oil flows out less if this hose is disconnected on the bypass filter side. 16. Disconnect hose (20) between fuel strainer and hand priming pump.
17. Disconnect drive shaft (21) between engine and torque converter.
Drive shaft: 52 kg (115 lb)
WA700-3L
30-21 1
DISASSEMBLY AND ASSEMBLY
DAMPER
12 18. Remove both front mounts (22) and both rear mounts (23) of engine.
19. Using tool Al, lift off engine and damper assembly (24). ★ Checking that the all hoses, harnesses, etc. are disconnected, sling the assembly slowly. Engine and damper assembly: 3,270 kg (7210 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 156.9 - 196.1 Nm (115.0 - 144.6 lbf ft)
Mount bolt: 824.0 - 1030.0 Nm (607.7 - 759.6 lbf ft) •
• •
Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again. Bleeding air Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part. Charging air conditioner with gas Using tool X1, charge the air conditioner circuit with new Freon gas (R134a).
30-22 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
DAMPER
12 DAMPER
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove bulkhead assembly. For details, see BULKHEAD ASSEMBLY - REMOVAL.
2.
Remove covers (1) and (2) under air cleaner.
3.
Sling drive shaft (3) temporarily and disconnect mount bolts.
Drive shaft assembly: 52 kg (114.6 lb)
4.
Sling damper cover (4) temporarily and remove mount bolts, then remove damper cover, pulling out output shaft.
Cover assembly: 113 kg (249.1 lb)
5.
Using a sling, sling damper assembly (5) temporarily and remove mount bolts.
Damper assembly: 122 kg (268.9 lb)
â&#x2DC;&#x2026; Slowly lift off the damper assembly.
WA700-3L
30-23 1
DISASSEMBLY AND ASSEMBLY
DAMPER
12 INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 156.9 - 196.1 Nm (115.7 - 144.6 lbf ft)
Apply grease to the oil seal lip. Shaft spline: Lubricant (LM-P) Mount bolt: 110.8 ± 11.8 Nm (81.7 ± 8.7 lbf ft)
Mount bolt: 277.5 ± 31.4 Nm (204.6 ± 23.1 lbf ft)
30-24 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
DAMPER
12 DISASSEMBLY 1.
Cover A. Set cover and shaft assembly (1) on support stand, and remove oil seal (2). B. Pull out snap rings (3) and (4). ★ When removing the snap rings of the cover, be careful not to let the cover fall over.
C. Set cover and shaft assembly stand, and pull out shaft (6). ★ Put wooden blocks at the bottom to prevent damage to the shaft when it comes out and drops.
D. After pulling out shaft (6), turn over cover (5), then pull out oil seal (7). ★ When removing the oil seal, be careful not to damage the seal press-fitting portion.
2.
Bearings Pull out bearings (8) and (10), and spacer (9) from cover (5). ★ Be careful not to apply too much force when removing.
WA700-3L
30-25 1
DISASSEMBLY AND ASSEMBLY
DAMPER
12 3. Damper A. Remove cover (12) from inner body assembly (14). ★ When turning over the inner body assembly, be careful not to damage the outside circumference of spacer (13).
B. After removing cover, turn over inner body assembly (14), install forcing screws (Thread dia. = 12 mm, Pitch = 1.75 mm, Length = 110 mm) to portion a of flange (11), and remove flange (11). ★ Tighten the left and right forcing screws uniformly, raise the flange, and remove. ★ The forcing screws are used also when assembling. ★ Do not remove spacer (13) unless necessary.
C. Remove rubber (15). D. Remove inner body (14) from outer body (16). E. Turn over outer body (16), then install forcing screws to portion b of flange, and remove flange (17). ★ Remove the flange in the same way as in Step B.
30-26 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
DAMPER
12 ASSEMBLY 1.
Damper A. Set flange (17) on work stand, and install guide bolts (Thread dia. = 12 mm, Pitch = 1.75 mm, Length = 110 mm).
B. Coat mating surface f of flange (17) and pilot of outer body (16) with gasket sealant uniformly. ★ Clean the surface and remove all grease before coating with gasket sealant. ★ When aligning the outer body and the flange, be careful not to squeeze out the gasket sealant on the inside. Mating surface of flange and outer body: Gasket sealant (LG-4) C. Align with guide bolts of flange (17), and assemble outer body (16). D. Assemble inner body (14) to outer body (16), then assemble rubber (15). ★ See the diagram for details of the positioning of the assembling the rubber. ★ When replacing spacer (13), coat inside circumference of the spacer with adhesive (Loctite 601), and press fit. Whole surface of rubber: Grease (G2-LI)
Outside circumference of inner body: Grease (G2-LI)
Inside circumference of outer body: Grease (G2-LI)
Between inner body and rubber: Grease (G2-LI)
★ Fill clearance e (4 places) with grease (130 cc).
WA700-3L
30-27 1
DISASSEMBLY AND ASSEMBLY
DAMPER
E. Remove grease from mating surface g of flange (11) in same way as in Step B, coat with gasket sealant, then align with guide bolt, and assemble flange. Contact surface of flange and outer body: Gasket sealant (LG-4) Mount bolt: 110.3 ± 12.3 Nm (81.3 ± 9.0 lbf ft)
F.
Turn over outer body assembly (16), then set on the support stand, and fill portion h of cover (12) with grease. Cover (portion h): 30 cc (ENS grease)
G. Install cover (12) to inner body (14). Mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.4 lbf ft)
2.
Bearing A. Set tool B1 on press stand, and set damper cover (1) on tool. ★ Be careful not to set the damper cover at an angle. B. Coat outside circumference of bearing (8) with adhesive, then assemble to press-fitting portion of damper cover (5), and press fit with tool B2. Outside circumference of bearing: Adhesive (Loctite 601)
C. Align with inside diameter of bearing, and assemble spacer (9). D. Repeat procedure in Step B to press fit bearing (10). ★ When press fitting the bearing, check that the inside diameter of the spacer and the inside diameter of the bearing match. ★ After press fitting the bearing, check with a feeler gauge that the clearance is within the standard value.
30-28 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
DAMPER
12 3. Cover A. Turn over cover (5), then assemble oil seal (7), and use tool B3 to press fit. ★ Be careful not to press fit the oil seal at an angle. B. Fill clearance i between oil seal (7) and bearing with grease. Clearance between oil seal and bearing: 70 cc (ENS grease) ★ Coat the lip of the oil seal also with grease. C. Set tool B2 to bottom of cover bearing (10), clean outside circumference of shaft (6) and inside circumference of bearing (8), and remove all grease. D. Coat inside circumference of bearing (8) with adhesive. Inside of inner race of bearing: Adhesive (Loctite 601)
E. Assemble shaft (6) from top of cover (5). ★ Be careful not to let the tip of the shaft hit the lip of the oil seal. F.
To prevent lip of oil seal (7) from turning over, rotate cover (5) slowly and press fit shaft (6).
G. Turn over cover and shaft assembly (1), and assemble snap rings (3) and (4). ★ Fit the snap rings in the groove securely. ★ Check with a feeler gauge that the clearance between the snap ring and the bearing is within the standard value.
H. Assemble oil seal (2) to cover, set tools B4 and B2 on top surface, then press fit oil seal. ★ Be careful not to press fit the oil seal at an angle.
WA700-3L
30-29 1
DISASSEMBLY AND ASSEMBLY
DAMPER
12 I.
After press fittings oil seal (2), fill clearance j with grease. Lip of oil seal (Portion j): 100 cc (ENS grease)
J.
Remove plug (18), and fill with grease through plug hole. Bearing, grease chamber (portion K): 530 ± 30 cc (ENS grease) Plug: 8.8 ± 2.9 Nm (6.5 ± 2.1 lbf ft)
Shaft spline (portion m): Molybdenum disulphide dry lubricant (LM-P) (Leave to dry naturally for 2 - 3 minutes after coating, then install.) Lip of seal (Portion i): ENS grease
Inner body cover (Portion h): 30 cc (ENS grease)
★ Always keep to the specified amount of grease in the grease chambers (h, i, j, K). ★ Remove all other grease before using the ENS grease. Do not mix other grease with ENS grease. Use different grease guns for each kind of grease. ★ Part No. of ENS grease: 427-12-11871 (2 kg can)
30-30 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
PTO
12 PTO
DISASSEMBLY Preparatory work •
Remove PTO assembly. For details, see TORQUE CONVERTER ASSEMBLY - DISASSEMBLY. ★ The procedure for disassembly and assembly of the gear and shaft assemblies is the same, but for gear and shaft assemblies I, II and III, the shaft and bearing are different. 1.
Retainer A. Using forcing screws ➀ (Dia. = 10 mm, Pitch = 1.5 mm), remove retainer (1). B. Remove oil seal (2).
2.
Snap ring Remove snap ring (3).
3.
Bearing A. Turn over PTO case assembly (4). B. Remove bearing (5).
WA700-3L
30-31 1
DISASSEMBLY AND ASSEMBLY
PTO
12 4. Shaft assembly A. Remove snap ring (6). B. Remove snap ring (6A). C. Using push tool ➀ (outside diameter: 45 mm), tap shaft assembly and remove.
D. Remove snap ring (7). E. Set shaft assembly in position, then using push tool ➁, pull out bearing (8) from shaft (9). ★ Push tool ➁
Unit: mm
Gear, shaft assembly No.
Push tool outside diameter
I, II
70
III
60
5.
Inner race Remove inner race (10).
6.
Spacer, gear A. Lift up gear (11) and remove. B. Remove spacer (12). ★ Gear (11) must be installed facing in the correct direction, so remember the direction.
7.
Snap ring, bearing A. Turn over case. B. Remove snap ring (13). C. Turn over case again, and remove bearing (14).
30-32 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
PTO
12 ASSEMBLY Preparatory work •
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. ★ The procedure for disassembly and assembly of the gear and shaft assemblies is the same, but for gear and shaft assemblies I, II, III, the shaft and bearing are different.
1.
Bearing, snap ring A. Using push tool ➅ (outside diameter: 120 mm), press fit bearing (14).
B. Install snap ring (13).
2.
Spacer, gear A. Install spacer (12). B. Set gear (11) in position. ★ Be careful to install gear (11) facing in the correct direction.
WA700-3L
30-33 1
DISASSEMBLY AND ASSEMBLY
PTO
12 3. Shaft assembly A. Using push tool ④, press fit bearing (8) in shaft. ★ Push tool ④
Unit: mm
Gear, shaft assembly No.
Push tool outside diameter
I, II
70
III
60
B. Install snap ring (7). C. Using push tool ➄, press fit shaft assembly (9). ★ Push tool ➄
Unit: mm
Gear, shaft assembly No.
Push tool outside diameter
I, II
65
III
60
4.
Snap ring Install snap ring (3).
5.
Bearing Using push tool ➅, press fit bearing (5) in case.
6.
Retainer A. Using tool C5, press fit oil seal (2) to retainer. Oil seal press-fitting surface: Gasket sealant (LG-4)
B. Fit O-ring, then using guide bolts ➆, install retainer (1). Lip of oil seal: Grease (G2-LI)
30-34 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
PTO
12 7. Inner race A. Turn over PTO case assembly (4). B. Set bottom of shaft on stand ➇. ★ Set the PTO case assembly so that there is no play.
C. Using push tool ➈ (inside diameter: 70 mm), press fit inner race (15).
D. Install snap ring (6). ★ Check that the gear rotates smoothly.
WA700-3L
30-35 1
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
12
TORQUE CONVERTER, TRANSMISSION REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove floor frame assembly. For details, see FLOOR FRAME ASSEMBLY - REMOVAL.
2.
Remove drain valve (1) and loosen valve (2) gradually to drain hydraulic oil. Hydraulic oil: 490 L (129.4 gal)
3.
Open bulkhead cover (3).
4.
Remove transmission inspection cover (4).
5.
Lift off floors (5) and (6).
6.
Remove hydraulic pump upper cover (7).
7.
Remove clamp (8) and disconnect heater hose from side cover (9).
8.
Remove side covers (9) and (10).
9.
Remove drain valve (11) and loosen valve (12) gradually to drain transmission oil. Transmission oil: 105 L (27.7 gal)
10. Disconnect transmission oil level gauge hose (13). 11. Disconnect hoses (14) and (15) between diverter valve and emergency steering pump.
30-36 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
12 12. Remove tube clamp (16). 13. Disconnect hose (17) between filler tube and transmission oil gauge. 14. Remove filler tube (18) from transmission. 15. Remove mount bolts of tubes (19) and (20), then remove those tubes from emergency steering pump. 16. Disconnect drain hose (21) from emergency steering pump. 17. Disconnect loader pump drain hose (22) and switch pump drain hose (23). 18. Disconnect torque converter oil temperature sensor wiring connector (24) (T06). 19. Disconnect hose (25) between differential pressure valve and PPC relief valve.
20. Disconnect transmission control valve wiring connector (26) (T01). 21. Disconnect hose (27) between torque converter and torque converter oil cooler. 22. Disconnect hose (28) between transmission and torque converter oil cooler. 23. Disconnect hose (29) between transmission and transmission oil filter.
24. Disconnect 4 discharge hoses (30) of loader pump and switch pump. 25. Disconnect loader pump suction tube (31) and switch pump suction tube (32). 26. Disconnect control pump suction hose (33).
WA700-3L
30-37 1
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
12 27. Remove grease supply hose clamp (34), and disconnect hose (35). 28. Disconnect cooling pump discharge hose (36).
29. Disconnect tube (37) between brake pump and brake oil tank. 30. Disconnect tube (38) between brake pump and brake oil strainer. 31. Disconnect cooling pump suction tube (39). 32. Disconnect hose (40) between transmission pump and transmission filter.
33. Sling rear drive shaft (41) temporarily, then remove mount bolts to remove drive shaft.
Rear drive shaft: 83 kg (183 lb)
â&#x2DC;&#x2026; Install a sling of sufficient length to the drive shaft so that the drive shaft can be balanced well.
34. Sling center drive shaft (42) temporarily, then remove mount bolts to remove drive shaft.
Center drive shaft: 90 kg (199 lb)
30-38 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
12 35. Sling upper drive shaft (43) temporarily, then remove mount bolts to remove drive shaft.
Upper drive shaft: 52 kg (115 lb)
36. Remove transmission mount bolts (44) and trunnion mount bolts.
★ Sling the torque converter and transmission assembly temporarily. 37. Sling the torque converter and transmission assembly so that the mount bracket can be removed.
38. Remove mount bolts (45), then remove mount brackets (46).
★ Remove both mount brackets. ★ When removing the mount brackets, take care of the dowel pins. 39. Disconnect transmission revolution sensor wiring connector (47) (T05). ★ Bundle the harnesses and place them on the transmission.
40. Lift off torque converter and transmission assembly (48) slowly. ★ When slinging the assembly, check that the all hoses, harnesses, etc. are disconnected. Torque converter and transmission assembly: 2630 kg (5799 lb)
WA700-3L
30-39 1
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
12 INSTALLATION â&#x20AC;˘
Carry out installation in the reverse order to removal.
Mount bolt: 156.9 - 196.1 Nm (115.7 - 144.6 lbf ft)
Trunnion mount bolt: 156.9 - 196.1 Nm (115.7 - 144.6 lbf ft)
â&#x2DC;&#x2026; Measure the parallelism and adjust the shim. Parallelism: 0.15 max. A. Set the torque converter and transmission assembly on the frame, then tighten the front and rear mount bolts temporarily. B. Install tools D2 to the upper and lower center hinge pins, then set a dial gauge to the coupling on the transmission side. Measure the parallelism of the coupling to the shaft of tool D2. C. Insert shims in the mount. D. Position the mount bracket and tighten the mount bolts. Bracket mount bolt: 490.0 - 608.0 Nm (361.4 - 448.4 lbf ft) Mount bolt: 490.0 - 608.0 Nm (361.4 - 448.4 lbf ft)
30-40 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER
12 TORQUE CONVERTER
DISASSEMBLY Preparation work • •
Remove the torque converter and PTO assembly. For details, see TRANSMISSION ASSEMBLY - DISASSEMBLY. Set torque converter and PTO assembly (1) to tool C1. Torque converter and PTO assembly: 610 kg (1345 lb)
1.
Valve assembly A. Remove tubes (2) and (3) and block (4). B. Remove valve assembly (5). C. Remove tube (6) and block (7).
2.
PTO assembly A. Remove holder (8) and coupling (9).
B. Using eyebolts ➀ (Dia. = 16 mm, Pitch = 2.0 mm), sling PTO assembly. C. Screw in forcing screws ➁, and lift off PTO assembly (10).
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TORQUE CONVERTER
12 3. Turbine case assembly A. Remove plug (11), and drain oil inside turbine case. B. Leave 2 bolts on opposite sides, and remove all remaining pump mount bolts (12). C. Set case side at top, and remove 2 remaining mount bolts. D. Using eyebolts ➂ (Dia = 16 mm, Pitch = 2.0 mm), lift off turbine case assembly (13).
E. Disassemble turbine case assembly as follows. i.
Remove mount bolts, then remove pilot (14) and gear (15).
ii.
Remove snap ring (16) and plate (17).
iii. Using forcing screws ④ (Dia. = 10 mm, Pitch = 1.25 mm), remove turbine (18). ★ Use the forcing screws to push the inner race of the bearing.
iv. Remove bearing (20) from case (19). v.
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Remove bearing (21) from input shaft.
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DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER
12 4. Stator A. Remove snap ring (22). B. Remove stator (23).
5.
Pump assembly A. Using tool C3, loosen nut (24). â&#x2DC;&#x2026; Leave the nut in position to prevent the bearing and pump from flying off.
B. Remove 2 plugs (25) at stator shaft end. C. Remove inner race of bearing from hole where plug was removed, then remove pump assembly (26).
D. Remove bolts, then remove collar (27), pump (28) and cage. E. Remove bearing (29) from cage (30).
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TORQUE CONVERTER
12 6. Stator shaft A. Remove 8 mount bolts (31).
B. Remove stator shaft (32) from case (33).
C. Remove seal ring (34). D. Remove sleeve (35).
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TORQUE CONVERTER
12 ASSEMBLY Preparatory work • •
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Set torque converter case (33) on tool C1.
1.
Stator shaft A. Expand fit sleeve (35) to stator shaft. B. Install seal ring (34) to stator shaft. ★ Make the protrusion of the seal ring from the shaft uniform.
C. Operate repair stand, rotate torque converter case 90°, install stator shaft (32), then tighten mount bolts (31) from opposite side. Mount bolt: Adhesive (LT-2)
Mount bolt: 110.3 ± 12.3 Nm (81.3 ± 9.0 lbf ft)
2.
Pump assembly A. Using push tool ➄ (outside diameter: 190 mm), press fit bearing (29) in cage.
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TORQUE CONVERTER
12 B. Install cage (30) and collar (27) to pump (28). Mount bolt: Adhesive (LT-2)
Mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.4 lbf ft)
C. Using push tool ➅ (inside diameter: 105 mm), press fit inner race (36) to stator shaft. ★ Be careful to install the inner race facing in the correct direction.
D. Set pump assembly (26) in position. ★ Be careful not to damage the seal ring. ★ Coat the seal ring with grease (G2-LI), make the amount of protrusion from the shaft uniform, and fix in position. E. Using push tool ➆ (inside diameter: 105 mm), press fit inner race (36) to stator shaft. ★ Be careful to install the inner race facing in the correct direction.
F.
Using push tool C3, install nut (24) to stator shaft. Nut: Adhesive (LT-2)
Nut: 612.9 ± 24.5 Nm (452.0 ± 18.0 lbf ft)
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TORQUE CONVERTER
12 3. Stator A. Align spline, and install stator (23). B. Install snap ring (22).
4.
Turbine case assembly A. Using push tool ➇ (outside diameter: 180 mm), press fit bearing (20) in case (19).
B. Set turbine (18) in push tool ➈ (outside diameter: 105 mm, height: 165 mm). C. Using push tool ➉ (inside diameter: 105 mm), press fit case (19) to turbine (18).
D. Fit plate (17) and install snap ring (16). E. Using push tool (21) in pilot.
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(inside diameter: 85 mm), press fit bearing
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TORQUE CONVERTER
12 F.
Install gear (15).
G. Install pilot (14). Mount bolt: Adhesive (LT-2)
Mount bolt: 277.0 ± 31.9 Nm (204.3 ± 23.5 lbf ft)
H. Using eyebolts ➂ (Dia. = 16 mm, Pitch = 2.0 mm), raise turbine case assembly (13), align oil groove of case with drain hole of pump, then install. I.
Tighten pump mount bolts temporarily. Mount bolt: Adhesive (LT-2)
J.
Rotate repair stand 90° and tighten mount bolts (12). Mount bolt: 53.9 ± 4.9 Nm (39.7 ± 3.6 lbf ft)
K. Tighten drain plug (11). Drain plug: 11.3 ± 1.5 Nm (8.3 ± 1.1 lbf ft)
L. Tighten 2 plugs (25). Plug: 7.4 ± 2.5 Nm (5.4 ± 1.8 lbf ft)
5.
PTO assembly A. Fit O-ring, then using eyebolts ➀ (Dia. = 16 mm, Pitch = 2.0 mm), install PTO assembly (10). ★ Be careful not to damage the oil seal when installing.
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DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER
12 B. Install coupling (9). C. Fit O-ring and install holder (8). Mount bolt: 277.0 ± 31.9 Nm (204.3 ± 23.5 lbf ft)
6.
Valve assembly A. Fit O-ring and install block (7) and tube (6). B. Fit O-ring and install valve assembly (5). C. Fit block (4) and install tubes (3) and (2). Valve assembly mount bolt: 59.8 ± 4.9 Nm (44.1 ± 3.6 lbf ft) Tube mount bolt: 24.5 ± 4.9 Nm (18.0 ± 3.6 lbf ft)
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TRANSMISSION
12
TRANSMISSION DISASSEMBLY Preparatory work •
Using eyebolts, remove torque converter and PTO assembly (1) from transmission assembly.
1.
Transmission control valve assembly Lift off transmission control valve (2).
2.
Plate Remove plate (3).
3.
Sleeve Using eyebolt ➀ (Dia. = 18 mm, Pitch = 2.5 mm), remove sleeve (4).
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TRANSMISSION
12 4. Transmission A. Set with transfer at bottom. B. Using eyebolts ➁ (Thread dia. = 12 mm, Pitch = 1.75 mm), sling transmission assembly. C. Screw in forcing screw (Thread dia. = 12 mm, Pitch = 1.75 mm), and lift off transmission assembly (5).
5.
Tie bolts Remove 17 tie bolts (6). ★ Using tool D1, check operating condition of piston before disassembling.
★ Leave two tie bolts with mark ❈, so that transmission assembly can be removed from transfer case.
6.
Input shaft, carrier assembly Using eyebolts ④ (Thread dia. = 12 mm, Pitch = 1.75 mm), lift out input shaft and carrier assembly (7).
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TRANSMISSION
12 7. Disassemble input shaft and carrier assembly according to following steps: A. Remove snap ring (8). B. Support housing and push out shaft (9) with press and remove.
C. Remove snap ring (10). D. Support housing and push out carrier assembly (11) with press and remove.
E. Remove pins, then remove planetary gears (12). bearing (13) and thrust washers (14) from carrier case.
8.
Spring Remove springs (15) and (16). â&#x2DC;&#x2026; Springs (16) are inserted between each plate,
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TRANSMISSION
12 9. Disc, plate Remove spring disc (17), and plates (18).
10. Ring gear Remove ring gear (19).
11. No. 1 piston housing Using eyebolts ➄ (Thread dia. = 18 mm, Pitch = 2.5 mm), lift out piston and housing (20).
★ Remove piston (22) from housing (21).
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TRANSMISSION
12 12. Spring Remove springs (23) and (24). ★ Springs (24) are inserted between each plate.
13. Disc, plate Remove discs (25) and (26).
14. Guide pin Remove guide pin (27).
15. No. 2 piston, housing Lift out piston and housing (28). 16. Drum carrier assembly Using eyebolts ➄ (Thread dia. = 12 mm, Pitch = 1.75 mm), lift out No. 2 piston and housing (28) and drum carrier assembly (29) as one unit.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 17. Disassemble drum and carrier assembly according to following steps: A. Remove bolt (30), then remove plate (31). B. Remove snap ring (32), then remove drum (33). C. Remove bearing (35) from carrier case (34).
D. Remove pins, then remove planetary gears (36), bearing (37) and thrust washers (38) from carrier case.
18. Sun gear Remove sun gear (39). 19. Spring Remove springs (40) and (41). â&#x2DC;&#x2026; Springs (41) are inserted between each plate.
20. Disc, plate Remove discs (42) and plates (43).
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TRANSMISSION
12 21. No. 3 piston housing A. Using eyebolts ➄ (Thread dia. = 18 mm, Pitch = 2.5 mm), lift out piston and housing assembly (44).
22. Sun gear Remove sun gear (45). 23. Sleeve Remove sleeve (46).
24. Rotating clutch assembly A. Remove snap ring (47). B. Using eyebolts ➅ (Thread dia. = 12 mm, Pitch = 1.75 mm), lift off rotating clutch assembly (48).
C. Disassemble rotating clutch assembly as follows. i.
Remove 22 mount bolts (49).
ii.
Using forcing screws, remove case (50).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 iii. Remove hub (51). iv. Using puller 1# and push tool 1$ (outer dia. = 115 mm), remove bearing (52).
v.
Remove disc (53), spring (54) and plate (55).
vi. Using push tool 1% (inside diameter: 130 mm), hold down belleville spring (56) and remove snap ring (58), then remove spacer (57) and belleville spring (56). WARNING! Be careful when removing the spring, because the spring is installed with 217 kgf (478 lbf) tension.
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TRANSMISSION
12 vii. Remove piston (59). viii. Using push tool 1^ (outer dia. = 105 mm), remove bearing (60).
25. Housing, carrier assembly A. Using eyebolts ➆ (Thread dia. = 18 mm, Pitch = 2.5 mm), lift off housing, carrier assembly (61).
B. Disassemble housing, carrier assembly as follows. i.
Remove snap ring (62).
ii.
Using push tool ➄ (outer dia. = 120 mm), remove carrier assembly (63).
iii. Pull out roll pin, remove pin (64), then remove thrust washers (65), planetary gear (66) and needle bearing (67).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12
iv. Remove 3 mount bolts, then using forcing screw, remove collar (68).
v.
Remove snap ring (69).
vi. Using push tool 1& (outer dia. = 180 mm), remove bearing (70).
26. Guide pin Remove guide pins (71). 27. Spring Remove spring (72). 28. Disc, plate, spring Remove disc (73), plate (74) and spring (75).
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TRANSMISSION
12 29. Sun gear Remove snap ring (76), then remove sun gear (77).
30. Shaft, carrier assembly A. Using pin (thread dia. = 8 mm, length = more than 95 mm), insert pin in hole of shaft, then lift off shaft, carrier assembly (78).
B. Disassemble shaft, carrier assembly as follows. i.
Remove snap ring (79).
ii.
Remove snap ring (80), then remove ring gear (81).
iii. Remove snap ring (82). iv. Using push tool 1* (inner dia. = 100 mm), remove carrier assembly (83).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 v.
Remove snap ring (84).
vi. Using push tool 1( (inner dia. = 100 mm), remove sun gear (85).
vii. Remove snap ring (86), then using push tool (outer dia. = 130 mm), remove bearing (87).
viii. Using push tool (outer dia. = 95 mm), remove collar (88).
ix. Pull out roll pin, remove pin (89), then remove thrust washers (90), planetary gear (91) and needle bearing (92).
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TRANSMISSION
12 31. No. 5 piston, housing A. Using eyebolts â&#x17E;&#x2020; (thread dia. = 18 mm, pitch = 2.5 mm), lift off No. 5 piston, housing (93). B. Remove piston (95) from housing (94).
32. Guide pin Remove guide pin (96).
33. Spring Remove spring (97). 34. Disc, plate, spring Remove disc (98), plate (99) and spring (100).
35. Ring gear Remove ring gear (101).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 36. No. 6 piston, housing A. Using eyebolts â&#x17E;&#x2020; (thread dia. = 18 mm, pitch = 2.5 mm), lift off No. 6 piston, housing (102). B. Remove piston (104) from housing (103).
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TRANSMISSION
12 ASSEMBLY ★ Caution before assembling • Coat rotating and sliding surface of each parts with engine oil (EO10-CD) before assembling. • Coat seal ring with grease (G2-LI), assemble seal ring uniformly without inclination. • Coat outer and inner install surface of bearing with adhesive (Threebond 1373B) before assembling. • Align notch of discs. • Check that snap rings is inserted in groove securely. Preparatory work Clean all parts and check for dirt or damage before assembling.
1.
No. 6 piston, housing A. Fit seal ring, install piston (104) in housing (103). ★ Install seal ring with seal ring groove facing housing end as shown in diagram. B. Fit O-ring to transfer case, using eyebolts ➆ (thread dia. = 18 mm, pitch = 2.5 mm), align dowel pin, then install No. 6 piston, housing assembly (102).
2.
Guide pin Install guide pin (96). ★ Length of guide pin: 162 mm.
3.
Ring gear Install ring gear (101).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 4. Disc, plate, spring Install disc (98), plate (99) and spring (100). ★ Spring (100) is different from others, install it carefully. ★ Free height of spring (100): 6.7 mm 5.
Spring Install spring (97).
6.
No. 5 piston, housing A. Fit seal ring, install piston (95) in housing (94). ★ Referring to Step l - A, install seal ring. B. Using eyebolts ➆ (thread dia. = 14 mm, pitch = 2.0 mm), align dowel pin and install No. 5 piston and housing (93). ★ Check the spring through the clearance between the housing and transfer case, then install No. 5 piston and housing, taking care not to let the spring (97) fall out.
C. The dowel pin is stiff, so using bolts 2) (Thread dia. = 14 mm, Pitch = 2.0 mm, Length = 300 mm) and nut, fit No. 5 housing in tight contact with No. 6 housing.
7.
Shaft, carrier assembly A. Assemble shaft, carrier assembly as follows. i.
Fit seal ring, set needle bearing (92), planetary gear (91), and thrust washers (90) in position, then assemble pin (89), and install roll pin A.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 ii.
Expand fit collar (88).
iii. Using push tool â&#x17E;&#x2021; (outer dia. = 140 mm), press fit bearing (87) from No. 6 sun gear. iv. Install snap ring (86).
v.
Install snap ring (84) on shaft.
vi. Using push tool 1( (inner dia. = 100 mm), press fit sun gear (85).
vii. Install carrier assembly (83) to shaft 2!. viii. Install snap ring (82).
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TRANSMISSION
12 ix. Assemble ring gear (81), then install snap ring (80) x.
Assemble sun gear (77), then install snap ring (76).
xi. Install snap ring (79).
B. Insert pin in hole of shaft, install shaft, carrier assembly (78). â&#x2DC;&#x2026; Align planetary gear with ring gear, then install.
8.
Disc, plate, spring Install disc (78), plate (74) and spring (75). Then remove bolt 2).
9.
Spring Install spring (72).
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TRANSMISSION
12 10. Housing, carrier assembly A. Assemble housing, carrier assembly as follows. i.
Using push tool 2@ (outer dia. = 180 mm), press fit bearing (70).
ii.
Install snap ring (69).
iii. Install collar (68), then tighten 3 mount bolts. V groove of outer circumference of collar: Gasket sealant (LG-1) Mount bolt: 13.7 ± 1.0 Nm (10.1 ± 0.7 lbf ft)
iv. Assemble needle bearing (67), planetary gear (66), thrust washers (65) and pin (64), the install roll pin.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 v.
Using push tool 2# (inner dia. = 95 mm), press fit carrier assembly (63).
vi. Install snap ring (62).
B. Using eyebolts â&#x17E;&#x2020; (thread dia. = 18 mm, pitch = 2.5 mm), install housing, carrier assembly (61).
11. Rotating clutch assembly A. Assemble rotating clutch assembly as follows. i.
Fit seal ring, using push tool 2$ (outer dia. = 130 mm), press fit bearing (60).
ii.
Fit seal ring and install piston (59).
iii. Set belleville spring (56) and spacer (57) in position, then install snap ring (58).
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TRANSMISSION
12 WARNING! Set on the press, and use push tool 1% (inside diameter: 130 mm) to push down the belleville spring.
iv. Set on press, and use push tool 2$ (inside diameter: 95 mm) to press fit bearing (52) in hub (51). v.
Set hub (51) to rotating drum.
vi. Disc, plate, spring Install disc (53), plate (55) and spring (54).
vii. Install case (50), then tighten mount bolts (49). Mount bolt: 112.8 ± 9.8 Nm (83.1 ± 7.2 lbf ft)
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TRANSMISSION
12 B. Using eyebolts ➅ (thread dia. = 12 mm, pitch = 1.75 mm), install rotating clutch assembly (48). ★ Push in rotating clutch assembly until snap ring groove of shaft come out. C. Install snap ring (47).
12. Sleeve Fit seal ring, install sleeve (46). 13. Sun gear Install sun gear (45).
14. No. 3 piston, housing A. Using eyebolts ➄ (Thread dia. = 18 mm, Pitch = 2.5 mm), sling and install piston and housing assembly (44). B. Install sleeve.
15. Guide pin Install guide pin (29).
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TRANSMISSION
12 16. Disc, plate Install plates (43) and discs (42).
17. Spring Install springs (41) and (40). â&#x2DC;&#x2026; Insert springs (41) between each plate.
18. No. 2 piston, housing Sling No. 2 piston and housing (28) and install.
19. Ring gear Install ring gear (27).
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TRANSMISSION
12 20. Disc, plate Install plates (26) and discs (25).
21. Spring Install springs (24) and (23). ★ Insert springs (24) between each plate.
22. Drum and carrier assembly ★ Assemble drum and carrier according to following steps: A. Install thrust washers (38), bearing (37) and planetary gear (36) to gear case, insert shaft and tap in pin.
B. Install bearing (35) to gear case (34). C. Install drum (33) and secure with snap ring (32). ★ Check that snap ring is completely inserted in ring groove. D. Assemble plate (31) and install bolt (30).
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TRANSMISSION
12 E. Install sun gear (28). F.
Using eyebolts ➅ (Thread dia = 10 mm, Pitch = 1.5 mm), sling and install drum and carrier assembly (29). ★ Align teeth face of planetary gear and ring gear and install.
23. No. 1 piston, housing A. Install piston (22) to housing (21).
B. Using eyebolts ➄ (Thread dia. = 18 mm, Pitch = 2.5 mm), sling and install piston and housing (20).
24. Ring gear Install ring gear (19).
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TRANSMISSION
12 25. Disc, plate Install plates (18) and discs (17).
26. Spring Install springs (16) and (15). ★ Insert snap rings (16) between each plate.
27. Input shaft, carrier assembly ★ Assemble input shaft and carrier assembly according to following steps: A. Install thrust washers (14), bearing (13) and planetary gear (12) to gear case, insert shaft and secure with pin.
B. Install bearing to housing. C. Support carrier assembly (11) and press fit housing. D. Install snap ring (10). ★ Check that snap ring is completely inserted in ring groove.
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TRANSMISSION
12 E. Support housing and press fit shaft (9).
F.
Install snap ring (8).
G. Using eyebolts ④ (Thread dia. = 12 mm, Pitch = 1.75 mm), sling and install input shaft and carrier assembly (7). ★ Align teeth face of planetary gear and ring gear and install.
28. Tie bolt Tighten tie bolt (6). Tie bolt: 166.7 ± 9.8 Nm (123.0 ± 7.2 lbf ft)
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TRANSMISSION
12 29. Checking operation of piston Using tool Dl, check operation and stroke of pistons. ★ Air pressure: 3 - 5 kgf/cm2 (42.67 - 71.1 lbf/in2) ★ Piston stroke: mm Piston
Stroke
No. 1 (Reverse)
6.0
No. 2 (Forward)
6.0
No. 3 (4th)
3.2
No. 4 (2nd)
5.0
No. 5 (3rd)
3.2
No. 6 (1st)
3.0
30. Transmission case A. Using eyebolts ➁ (Thread dia. = 12 mm, Pitch = 1.75 mm), sling transmission case (5). B. Fit O-ring and install transmission case.
31. Sleeve Fit O-ring and install sleeve (4).
32. Plate Fit O-ring and install plate (3).
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TRANSMISSION
12 33. Transmission control valve assembly Fit O-ring and install transmission control valve assembly (2).
34. Fit O-ring, sling torque converter assembly (1), connect to transmission assembly, and tighten mount bolts.
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TRANSMISSION VALVE
12 TRANSMISSION VALVE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove transmission inspection cover (1).
2.
Disconnect transmission control valve wiring connector (2) (T01).
3.
Disconnect hose (3) between filter and transmission.
4.
Remove tubes (4), (5), (6), (7), and (8) around valve.
5.
Lift off transmission control valve (9).
Transmission valve: 81 kg (179 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 49.0 ± 4.9 Nm (36.1 ± 3.6 lbf ft) ★ Match the holes of the gasket on the fitting face securely. ★ Tighten the mount bolts in diagonal order so that the valve will not be strained.
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TRANSMISSION CONTROL VALVE
12
TRANSMISSION CONTROL VALVE LOWER VALVE
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TRANSMISSION CONTROL VALVE
12 DISASSEMBLY 1.
Remove solenoid valve assembly and filter assembly.
2.
Remove spring (1), shims (2), valves (3), (4), and (6), and spring (5).
3.
Remove spring (7), stopper (8), and valve (9).
4.
Remove covers (10) and (11).
5.
Remove spring (12) and valve (13).
6.
Remove spool (14) and stopper (15).
7.
Remove spring (16), stopper (17), and valve (18).
8.
Remove plug (19) and spool (20).
9.
Remove spring (21), stopper (22), and valve (23).
ASSEMBLY 1.
Assemble valve (23) and stopper (22) in valve body, and install spring (21).
2.
Assemble spool (20), then fit O-ring and tighten plug (19).
3.
Assemble valve (18) and stopper (17), then install spring (16).
4.
Install stopper (15), then install spool (14). ★ Align the hole of stopper (15) with the hole of the body, and secure stopper (15) with the roll pin.
5.
Install valve (13) and spring (12).
6.
Install gasket, then install covers (11) and (10). Mount bolt: 22.1 ± 2.5 Nm (16.3 ± 1.8 lbf ft)
7.
Assemble valve (9) and stopper (8), then install spring (7).
8.
Assemble valves (4) and (6), spring (5), shims (2), and spring (1) in valve (3), and install to valve. ★ Standard shim thickness: 3 mm
9.
Install solenoid valve assembly. Mount bolt: 46.6 ± 2.5 Nm (34.3 ± 1.8 lbf ft)
10. Install solenoid valve assembly and filter assembly.
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TRANSMISSION CONTROL VALVE
VALVE
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE
12 DISASSEMBLY 1.
Remove cover (1).
2.
Remove guide (2), then remove spring (3), shims (4), valves (5), (6), and (8). and spring (7) as one set.
3.
Remove valves (9), (11), and (12), and spring (10) as one set.
4.
Remove stopper (13), then remove quick return valve (14).
5.
Remove spool (15).
6.
Remove cover (16).
7.
Remove guide (17), then remove spring (18), shims (19), valves (20), (21), (23) and spring (22) as one set, then remove stopper (24).
8.
Remove valve (25), shims (26), and springs (27) and (28).
9.
Remove valves (29) and (30), and shims (31) from block.
10. Remove plug (32), then remove spring (33), shims (34), valves (35), (36), (38) and spring (37) as one set.
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12 UPPER VALVE
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE
12 ASSEMBLY 1.
Assemble valves (38), (36), and (35), spring (37), shims (34), and spring (33) in valve body (39), then fit O-ring and install plug (32). ★ Standard shim thickness: 3.5 mm Plug: 107.9 ± 14.7 Nm (79.5 ± 10.8 lbf ft)
2.
Assemble shims (26) and springs (27) and (28) in valve (25), and install to valve body. ★ Standard shim thickness: 1 mm
3.
Install stopper (24), and assemble valves (23) and (21), spring (22), shims (19) and spring (18) as one set, then assemble in valve (20), then install guide (17). ★ Standard shim thickness: 6 mm ★ Align the hole of stopper (24) with the hole of the body then install with roll pin.
4.
Fit O-ring and install cover (16) and block.
5.
Assemble shims (31) and valves (30) and (29) in block, then fit O-ring and install cover. ★ Standard shim thickness: 2.5 mm
6.
Install quick return valve (14) and stopper (13).
7.
Assemble valves (11) and (9) and spring (10) in valve (12), then assemble in valve body. ★ When assembling in the body, check that springs (27) and (28) are assembled in valve (12) securely.
8.
Assemble valves (8) and (6), spring (7), shims (4) and spring (3) in valve (5), then assemble in body, and install guide (2). ★ Standard shim thickness: 2 mm
9.
Fit gasket and install cover (1). Mount bolt: 22.1 ± 2.5 Nm (16.3 ± 1.8 lbf ft)
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DISASSEMBLY AND ASSEMBLY 12 MAIN
TRANSMISSION CONTROL VALVE
RELIEF VALVE
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WA700-3L
DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE
12
DISASSEMBLY 1.
Remove covers (1) and (2).
2.
Remove spring (3).
3.
Remove shims (4), valves (5), (6), (8) and spring (7) as one set.
ASSEMBLY 1.
Assemble valves (8), (6), (5), spring (7), shims (4) and spring (3) as one set, then assemble in valve body (9). â&#x2DC;&#x2026; Standard shim thickness: 2 mm
2.
Fit O-ring and install covers (2) and (1).
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12
TRANSFER DISASSEMBLY Preparatory work Sling torque converter assembly (1), then remove the mount bolts, and disconnect the torque converter assembly from the transmission assembly.
1.
Transmission valve assembly Lift off transmission valve (2).
2.
Plate Remove plate (3).
3.
Sleeve Using eyebolt â&#x17E;&#x20AC; (Thread dia. = 18 mm, Pitch = 2.5 mm), remove sleeve (4).
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 4. Transmission case A. Set with transfer assembly facing down. B. Using eyebolts ➁ (Thread dia. = 12 mm, Pitch = 1.75 mm), sling transmission case. C. Screw in forcing screws (Thread dia. = 12 mm, Pitch = 1.75 mm), and remove transmission case (5).
5.
Tie bolts ★ Using tool D1, check the operating condition of the piston before disassembling. Remove 15 tie bolts (6) (except those marked ❈), then lift off transmission assembly (7).
6.
Cage assembly A. Remove 6 mount bolts, then using forcing screws, remove cage assembly (8) and shim (9). ★ Check the number and thickness of the shims, and keep in a safe place.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 B. Remove outer race (10) from cage (11).
7.
No. 1 gear assembly A. Remove gear assembly (12). B. Using puller, remove 2 bearings (13) from gear (14).
8.
Cage assembly A. Remove mount bolts, then use forcing screws to remove joined portion of cage. B. Using eyebolts ➀ (Thread dia. = 12 mm, Pitch = 1.5 mm), lift off cage assembly (15). ★ The cage is thick, so raise it straight.
C. Remove outer race (16) from cage (17).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
TRANSFER
12 9. No. 3 gear assembly A. Remove No. 3 gear assembly (18). B. Using puller, remove bearings (19) from gear (20).
10. Coupling Remove coupling (21).
11. Cage assembly A. Remove cage assembly (22). B. Remove oil seal (23) from cage (24).
12. Strainer A. Remove cover (25). â&#x2DC;&#x2026; The cover may fly out under the force of the spring, so hold it down by hand when removing the mount bolts. B. Remove spring (26) and strainer (27), then remove flange (28).
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 13. Coupling cage â&#x2DC;&#x2026; Turn over the transfer case, and set it on the block. A. Remove mount bolts (29), then remove plate (30). B. Remove 8 mount bolts, and using forcing screws, lift off coupling cage assembly (31).
14. Cage assembly A. Using forcing screws (Thread dia. = 12 mm, Pitch = 1.75 mm), remove cage assembly (32). B. Remove outer race (33) from cage (34).
15. Cage assembly A. Remove mount bolts, then use forcing screws (Thread dia. = 12 mm, Pitch = 1.75 mm) to remove cage assembly (35) and shim (36). â&#x2DC;&#x2026; Check the number and thickness of the shims, and keep in a safe place. B. Remove outer race (37) from cage (38).
16. Cage assembly A. Remove mount bolts, then use forcing screws (Thread dia. = 12 mm, Pitch = 1.75 mm) to remove cage assembly (39) and shim (40). B. Check the number and thickness of the shims, and keep in a safe place. C. Remove outer race (41) from cage (42).
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 17. No. 2 gear assembly A. Remove No. 2 gear assembly (43). B. Using puller, remove bearings (44) from gear (45).
18. Outer race Remove outer race (46) from transfer case.
19. Shaft assembly Using push tool, remove shaft assembly (47). 20. Bearing Remove bearing (48) from transfer case.
21. No. 4 gear, collar Remove No. 4 gear (49) and collar (50) from transfer case.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 22. Shaft assembly Using push tool ➂, remove inner race (51) from shaft (52).
23. Disassembly of coupling assembly A. Remove mount bolts (53), then use push tool ④ (outside diameter: 125 mm) to remove coupling assembly (54) and shim (55) from cage assembly (56). ★ Check the number and thickness of the shims, and keep in a safe place.
B. Remove collar (57) and outer race (58) from cage (59).
C. Using push tool ➄ (outside diameter: 105 mm), remove coupling (60). D. Remove bearings (61) and (62), and outer race (63), then remove oil seal (64) from cage (65).
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 ASSEMBLY Preparatory work •
Clean all parts, and check for dirt or damage before installing.
1.
Cage assembly A. Using push tool ➈ (outside diameter: 210 mm): press fit outer race (33) in cage (34).
B. Fit O-ring and install cage assembly (32) to transfer case. 2.
Cage assembly A. Using push tool ➈ (outside diameter: 190 mm), press fit outer race (37) in cage (38).
B. Fit O-ring and install cage assembly (35) and shim (36). ★ Standard shim thickness: 2 mm
3.
No. 1 gear assembly A. Using push tool ➉ (inside diameter: 140 mm), press fit 2 bearings (13) on gear (14). B. Install gear assembly (12). ★ Turn over the transfer case.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 4. Cage assembly A. Using push tool ➈ (outside diameter: 210 mm), press fit outer race (10) in cage (11).
B. Fit O-ring and install shim (9) and cage assembly (8). ★ Standard shim thickness: 2 mm
5.
Adjusting bearing preload of No. 1 gear Set tool D3 in position, then using torque wrench, measure preload. Standard value for preload: 0.5 - 1.0 Nm (0.36 - 0.73 lbf ft) ★ If the measurement is not within the standard value, adjust with shim (9).
6.
No. 4 gear, collar Set No. 4 gear (49) and collar (50) inside transfer case.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 7. No. 3 gear assembly A. Using push tool ➉ (inside diameter: 105 mm), install bearing (19) on gear (20). B. Install No.3 gear assembly (18).
8.
Cage assembly A. Using push tool ➈ (outside diameter: 180 mm), press fit outer race (16) in cage (17).
B. Fit O-ring, then using eyebolts ➀ (thread dia. = 10 mm, pitch = 1.5 mm), raise cage assembly (15) and install.
9.
Adjusting bearing preload of No. 3 gear A. Turn over transfer case, and remove inspection cover. B. Set tool D3 in position, then using torque wrench, measure preload. Standard value for preload: 0.5 - 1.0 Nm (0.36 - 0.73 lbf ft) ★ If the measurement is not within the standard value, adjust with shim (36). ★ Move so that the teeth of No. 4 gear do not contact.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 10. Outer race A. Using push tool ➈ (outside diameter: 180 mm), press fit outer race (46) in transfer case.
11. No. 2 gear assembly A. Using push tool ➉ (inside diameter: 105 mm), press fit 2 bearings (44) on gear (45). B. Install No. 2 gear assembly (43).
12. Cage assembly A. Using push tool ➈ (outside diameter: 190 mm), fit outer race (41) in cage (42).
B. Fit O-ring and install shim (40) and cage assembly (39). ★ Standard shim thickness: 2 mm
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 13. Adjusting bearing preload of No. 2 gear A. Set tool D3 on No. 3 gear, then using torque wrench, measure preload. B. Standard value of preload Standard value
Actual adjusted measurement value
Shaft 1 preload
As individual part 0.5 - 1.0 Nm (0.36 - 0.73 lbf ft)
T1
Shaft 3 preload
As individual part 0.5 - 1.0 Nm (0.36 - 0.73 lbf ft)
T3
Measure the preload for the combination with shaft 3 after assembling shaft 2. Preload of shaft 2 = (T1 + T3 + (0.5 to 1.0 Nm) (Measure at shaft 3) ★ Bring the shaft 4 gear close and take care that the teeth do not contact. ★ If the measurement is not within the standard value, adjust with shim (40). C. Install inspection cover. ★ Check that there is not play in any gear. 14. Coupling, cage assembly A. Assemble coupling and cage assembly as follows. i.
Using push tool 1! (outside diameter: 180 mm), install oil seal (64) to cage (65). Oil seal press-fitting surface: Gasket sealant (Three Bond 110B) Lip of oil seal: Grease (G2-LI)
★ Coat the oil seal press-fitting surface on the cage side thinly with gasket sealant, and wipe off any sealant which is squeezed out. ii.
Using push tool 1@ (outside diameter: 185 mm), press fit outer race (63) in cage (59).
iii. Assemble bearing (62), collar (57) and bearing (61), then using push tool 1@ (outside diameter: 185 mm), press fit outer race (58) in cage (59). iv. Fit O-ring and install cage assembly (65) to cage assembly (56), then using feeler gauge, measure clearance S.
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DISASSEMBLY AND ASSEMBLY v.
TRANSFER
Install shim (55). Standard shim thickness = Clearance S + (0.05 to 0.10 mm)
vi. Using push tool 1# (outside diameter: 125 mm), press fit coupling (60) in cage assembly (54). B. Fit O-ring and install coupling and cage assembly (31) to transfer case.
15. No. 4 gear, collar Turn over transfer case, and set No. 4 gear (49) and collar (50) in position.
16. Bearing Using push tool 1$ (outside diameter: 180 mm), press fit bearing (48) in transfer case.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 17. Shaft assembly A. Using push tool 1% (inside diameter: 100 mm), press fit inner race (51) on shaft (52).
B. Align spline and assemble shaft assembly (47), then install O-ring and plate (30), and tighten mount bolts (29). Mount bolts: 1127.8 ± 29.8 Nm (831.8 ± 21.9 lbf ft)
18. Cage assembly A. Using push tool 1^ (outside diameter: 160 mm), install oil seal (23) to cage (24). Oil seal press-fitting surface: Gasket sealant (Thread Bond 110B) Lip of oil seal: Grease (G2-LI)
★ Coat the oil seal press-fitting surface on the cage side thinly with gasket sealant, and wipe off any sealant which is squeezed out. B. Install cage assembly (22) to transfer case. 19. Coupling Align spline of shaft and install coupling (21). ★ Install so that it is in the same position as the front output coupling.
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 20. Strainer assembly A. Fit flange (28), and install strainer (27) and spring (26). B. Install cover (25).
21. Transmission assembly Fit seal ring, then using eyebolts ➄ (thread dia. = 14 mm, pitch = 2.0 mm), raise transmission assembly (7), align dowel pin, and install. ★ Be careful to install the seal ring uniformly and not to one side.
22. Tie bolts Install 15 tie bolts (6). Tie bolt: 166.7 ± 9.8 Nm (122.9 ± 7.2 lbf ft)
23. Checking operation of piston Using tool D1, check operation and stroke of pistons. ★ Air pressure: 3 - 5 kgf/m2 (0.00426 - 0.00711 lbf/in2) ★ Piston stroke: mm
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Piston
Stroke
No. 1 (Reverse)
6.0
No. 2 (Forward)
6.0
No. 3 (4th)
3.2
No. 4 (2nd)
5.0
No. 5 (3rd)
3.2
No, 6 (1st)
3.0
WA700-3L
DISASSEMBLY AND ASSEMBLY
TRANSFER
24. Transmission case Install transmission case (5).
25. Sleeve Fit O-ring and install sleeve (4).
26. Plate Install plate (3).
27. Transmission valve Install transmission valve (2).
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DISASSEMBLY AND ASSEMBLY
TRANSFER
12 28. Torque converter assembly Install torque converter assembly (1) to transmission assembly.
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 CENTER SUPPORT
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Release residual pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Disconnect center drive shaft (1).
Center drive shaft assembly: 90 kg (198.4 lb)
2.
Sling front drive shaft (2) temporarily, and disconnect it. ★ Move the drive shaft toward the front differential to separate the socket and spigot.
Front drive shaft assembly: 112 kg (247 lb)
3.
Sling front and rear flanges (4) of center support (3) and remove mount bolts.
4.
Check that flanges can pass by the front frame mount, then sling and remove the center support assembly, pulling it toward the rear. ★ If shims are inserted between the center support and frame, check its quantity to use shims of the same quantity when assembling. ★ When removing the center support assembly, prevent it from interfering with the steering cylinder. Center support assembly: 67 kg (148 lb)
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 156.9 - 196.1 Nm (115.7 -144.6 lbf ft)
★ Clean the fitting faces. ★ Measure the parallelism of the flanges according to the following procedure, then install the center support. ★ Set tools D2 to the upper and lower center hinge pins and install dial gauge ➀ to the flange on the center support side to measure the parallelism of the flange to the shaft. ★ Insert shims between the center support fitting faces to adjust the parallelism. ★ Parallelism: 0.1 mm max.
Mount bolt: 823.8 - 1029.3 Nm (607.6 - 759.1 lbf ft)
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 DISASSEMBLY 1.
Retainer bolt Remove mount bolts (2) of retainer (1). ★ Rotate the coupling and remove all mount bolts. ★ Turn over the center support.
2.
Coupling Remove center bolt (3), then remove holder (4), O-ring and coupling (5). ★ Check the number and thickness of the shims between the holder and shaft. ★ After removing the coupling, pull out the oil seal from the housing.
3.
Shaft A. Set shaft and housing assembly (6) on press stand. B. Remove shaft (7) with press. ★ Be extremely careful as the shaft will drop out suddenly. C. After pulling out shaft (7), remove bearing cone (8) from housing (6).
D. Remove bearing cone (9) and retainer (1) from shaft (7).
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 4. Oil seal Remove oil seal (10) from retainer (1).
5.
Housing Using puller, pull out bearing cups (11) from housing (6).
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 ASSEMBLY 1.
Housing Press fit bearing cups (11) to housing (6). ★ Check that the cup is press fitted securely.
2.
Oil seal A. Set oil seal press-fitting portion a of retainer (1) facing up, and set on press stand. ★ Replace the oil seal with a new part. B. Assemble oil seal (10) to tool H1, then press fit oil seal (10) to retainer (1) with press. C. Fill lip portion b of oil seal (10) with grease. Lip (portion b): Grease (G2-LI)
3.
Shaft A. Set coupling end of shaft (7) facing down, and set perpendicularly on press stand. B. Assemble retainer assembly (12) to shaft (7), and insert bearing cone (9). C. Using tools H2, press fit bearing cone (9). ★ Press fit the shaft portion c fully.
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 D. Set retainer and shaft assembly (14) on press stand, and assemble bearing cup and housing (6) to shaft. ★ Fill portion d with grease. Housing (portion d): Grease (G2-LI)
E. Coat bearing cone (8) with grease, then assemble in housing (6), and use tool H2 to press fit. ★ When press fitting bearing cone (8), press fit while rotating the housing. ★ Shim adjustment is carried out in a later process, so leave an end play of approximately 1.0 mm when press fitting the bearing cone. Bearing cone: Grease (G2-LI)
F.
Before press fitting oil seal (15), fill portion e with grease. ★ Be careful not to get the O-ring caught. Portion e: Grease (G2-LI)
G. Using tool H3, press fit oil seal (15) until it is the standard dimension. ★ Standard dimension: 11 ± 1 mm ★ Coat the lip of the oil seal with grease. Lip of oil seal: Grease (G2-LI)
4.
Coupling A. Coat shaft spline portion f with grease. Shaft spline (portion f): Grease (G2-LI)
B. To align center of key groove of left and right couplings (5), align match marks (●) at end face of shaft (7), and assemble coupling (5).
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DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
12 C. Measure thickness g of holder (4), then assemble in coupling (5), and install bolt (3). D. Turn over center support assembly (16), and tighten mount bolts of retainer (1). Mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.4 lbf ft)
E. Select shim as follows. • Rotate housing (6) and tighten bolt (3) until starting torque is 7.8 - 11.7 Nm (5.7 - 8.6 lbf ft)
•
F.
Measure clearance X between holder (4) and shaft (7) at holes in holder at 3 places, take the average clearance, and select shims of a thickness equal to the average clearance + 0.1 to 0.15.
Assemble coupling (5), install O-ring (17), shim (18) selected above and holder (4), then tighten bolt (3). ★ Check that the match marks on the shaft and coupling are aligned. ★ Rotate the case and tighten the bolts to the specified torque. Mount bolt: 1716 ± 196 Nm (1265 ± 144.5 lbf ft) (width across flats: 46 mm)
5.
End play Check that end play is within specified range. ★ End play: 0.05 - 0.15 mm ★ Carry out greasing after installing the center support to the chassis.
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DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
12
DRIVE SHAFT DISASSEMBLY 1.
Splined yoke Loosen retainer (1) and remove splined yoke (2).
2.
Bearing Remove mount bolts (3), then remove bearing assembly (4). ★ Make match marks on the yoke and bearing.
3.
Bearing cap A. Remove bearing cap (5) from bearing assembly. ★ Remove strap (6) of cap.
B. Remove bearing (7), seal (8) and washer (9) from bearing cap.
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DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
12 4. Sleeve yoke A. Remove mount bolts (11) from sleeve yoke (10), then remove bearing assembly (4). â&#x2DC;&#x2026; Make match marks on the yoke and bearing.
B. Remove bearing cap (5) from bearing assembly.
C. Remove bearing (7), seal (8), and washer (9) from bearing cap.
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DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
12 ASSEMBLY 1.
Bearing cap A. Install bearing (7), and seal (8) to bearing cap (5). Bearing, seal: Grease (G2-LI)
B. Assemble washer (9) and bearing cap (5) to bearing assembly (4). Bearing cap: Grease (G2-LI)
2.
Bearing Assemble bearing assembly (4) to sleeve yoke (10). ★ Align the match marks correctly. ★ Wipe the mount face of the bearing cap with a clean cloth. Mount bolt: 214 ± 6.9 Nm (157 ± 5.0 lbf ft)
3.
Splined yoke A. Assemble bearing (7) and seal (8) in bearing cap (5). Bearing seal: Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
12 B. Assemble washer (9) and bearing cap (5) to bearing assembly (4). ★ Do not weld the strap. The heat when welding will damage the bearing.
C. Assemble bearing assembly (4) to splined yoke (2). ★ Align the match marks carefully. ★ Wipe the mount face of the bearing cap with a clean cloth. Mount bolt: 214 ± 6.9 Nm (157 ± 5.0 lbf ft)
D. Align match marks, insert splined yoke in sleeve yoke (10), and secure with retainer (1). ★ Check that the yokes are facing in the same direction. ★ If the spline is worn, replace the whole drive shaft assembly.
E.
Upper drive shaft Bearing cap mount bolt (11): 214 ± 6.9 Nm (157 ± 5.0 lbf ft)
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE
12
FRONT AXLE REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the work equipment to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. • • •
1.
Block the rear tires and apply the parking brake securely. Insert blocks ➀ between the top face (1) of the rear axle housing and frame (2) (both left and right). Jack up the machine and set blocks ➁ under the front frame on the left and right.
Tires, wheels Sling left and right tires and wheels (3) temporarily, remove mount nuts, then lift off.
Tire, wheel: 2,490 kg (5490 lb)
2.
Drive shaft Lift off front drive shaft (4).
★ Make match marks on the drive shaft coupling to act as a guide when assembling. ★ Move the drive shaft towards the front differential, then move the center support end to the side and remove the pilot portion at the differential end. Front drive shaft: 112 kg (247 lb)
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE
12 3. Brake hose A. Disconnect parking brake cylinder hose (3).
B. Disconnect both front brake hoses (4).
4.
Front axle A. Sling front axle assembly temporarily and remove both mount bolts (5).
B. Remove front axle assembly (6). Front axle assembly: 5532 kg (12196 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Hub nut: 823.8 ± 88.3 Nm (607.6 ± 65.1 lbf ft)
Drive shaft mount bolt: 176.5 ± 19.6 Nm (130.1 ±14.4 lbf ft)
★ Bleed air from the parking brake cylinder and front brake. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
Front axle mount bolt: 3521.0 ± 353.0 Nm (2596.5 ± 260.3 lbf ft)
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DISASSEMBLY AND ASSEMBLY
FRONT DIFFERENTIAL
12
FRONT DIFFERENTIAL REMOVAL 1.
Remove front axle assembly. For details, see FRONT AXLE ASSEMBLY - REMOVAL.
2.
Remove drain plugs (1) from both final drives to drain oil. Axle oil: 245.4 L (64.7 gal) each
3.
Remove mount bolts (2) to remove cover (3). ★ Remove the cover with the top mark up.
4.
Install bolt ➀ to end of drive shaft (4) and pull out drive shaft.
5.
Lift off drive shaft (4). Drive shaft: 70 kg (154.3 lb)
6.
Loosen locknut and remove tension bolt (5).
7.
Remove parking brake disc cover (6).
8.
Remove plate (7), then remove pad (8).
9.
Remove caliper and spring cylinder assembly.
10. Remove plate (10).
11. Remove mount bolts to remove disc plate (11).
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DISASSEMBLY AND ASSEMBLY
FRONT DIFFERENTIAL
12 12. Remove mount bolts (12).
13. Sling front differential assembly (13) temporarily and separate it from axle by using forcing bolts â&#x17E; . 14. Lift off front differential assembly (13). Front differential assembly: 826 kg (1821 lb)
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DISASSEMBLY AND ASSEMBLY
FRONT DIFFERENTIAL
12 INSTALLATION •
Carry out installation in the reverse order to removal.
Cover mount bolt: 98.0 - 123.0 Nm (72.2 - 90.7 lbf ft)
★ Adjustment of tension bolt Press tension bolt (14) end against the back of the gear, then return it by l/2 turn. Locknut: 343.0 - 441.0 Nm (252.9 - 325.2 lbf ft)
Plate mount bolt: Adhesive (LT-2)
Plate mount bolt: 824.0 - 1030.0 Nm (607.7 - 759.6 lbf ft)
Disc mount bolt: Adhesive (LT-2)
Disc mount bolt: 490.0 - 608.0 Nm (361.4 - 448.4 lbf ft)
Disc mount bolt: 490.0 - 608.0 Nm (361.4 - 448.4 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE
12 REAR AXLE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Release residual pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. WARNING! Disconnect the cable from the negative (-) terminal of the battery.
1.
Exterior parts and counterweight A. Lift off grille (1). B. Sling counterweight (2) temporarily and remove mount bolts (3) and (4) on both sides.
Counterweight assembly: 2510 kg (5534 lb)
C. Lift off handrail, guard, and ladder (5). 2.
Rear frame support Jack up rear frame and place stand ➄ under it. Rear frame assembly: 27000 kg (59525 lb)
★ ★ ★ ★
Put block ➁ between the top of the rear axle housing and rear frame (on each side). Place a steel plate under the stand for safety. Use the stand used for transportation. (When making a new stand, see step 7.) Tighten the mount bolts of the rear frame support stand securely. Mount bolt: 2451.8 - 3040.2 Nm (1808.3 - 2242.3 lbf ft)
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REAR AXLE
12 3. Tire & wheel Lift off tire and wheel (6) on both sides.
Tire & wheel assembly: 2490 kg (5489.5 lb)
4.
Drive shaft Disconnect rear drive shaft (7).
Rear drive shaft assembly: 83 kg (183 lb)
★ Install a lever block to the upper drive shaft and sling it temporarily to disconnect the rear drive shaft.
5.
Brake piping Disconnect hoses (8) and (9) between slack adjuster and both brakes.
★ Plug the disconnected hoses and tubes.
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REAR AXLE
12 6. Thrust cover A. Install eyebolt to thrust cover (10) and sling it temporarily, then remove mount bolts to remove thrust cover.
Thrust cover: 64 kg (141.0 lb)
★ Disconnect the grease tubes at the thrust cover and rear support.
B. Since thrust cover (10) is heavy, handle it carefully by the following method. • Leave the bolt at the bottom and turn the cover slowly around this bolt. • Receive the cover on a pallet and remove the bolt. ★ Remove the thrust cover in advance so that it will not interfere with the fuel tank.
7.
Rear axle support A. Fix axle support (11) and rear axle (12) with chains, etc. ★ Fix the axle support and rear axle securely so that the former will not turn when the latter is removed.
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REAR AXLE
12 B. Remove mount bolts. Disconnect rear axle assembly (12) from front support (13) with crane and jack, balancing it.
â&#x2DC;&#x2026; Put the rear axle into a noose and balance it carefully.
C. Place steel plate under vehicle body and lower one side of axle onto roller (14).
D. Pull rear axle support (15) out of vehicle body.
8.
Axle and rear support A. Remove bolts from rear axle (12) to remove thrust washer (18) and thrust plate (17).
â&#x2DC;&#x2026; Remove thrust washer (16) after removing thrust plate. Thrust plate: 62 kg (137 lb)
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12 B. Lift off rear support (11). ★ Take care not to damage the packing. Rear support: 62 kg (137 lb)
C. Remove packing (19) and bushings (20) and (20A) from removed rear support (11). ★ Remove the bushings only when required. ★ For removal procedure of the bushings, see step 10.
9.
Axle front support A. Remove retainer (21) and pull out packing (22). B. Remove packing (23) and bushings (24) and (25) from front support (13). ★ Remove the bushings only when required. ★ For removal procedure of the bushings, see step 10.
10. Removal procedure of bushings A. Insert a knife tip, etc. between bushing and support to separate them from each other all round, then remove bushing. ★ If the adhesive is too strong to remove the bushing, heat the bushing with boiling water or a small torch to about 100° C, then remove it. B. Apply adhesive remover thickly to the adhesive sticking to the support. Wait for 2 - 3 minutes, then wipe off the adhesive with cloth. Sticking adhesive: Adhesive remover (Part No. 417-46-11890)
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REAR AXLE
12 INSTALLATION •
Carry out installation in the reverse order to removal.
Counterweight mount bolt: 2450.0 - 3040.0 Nm (1807 - 2242 lbf ft)
Hub nut: 735.5 - 912.1 Nm (542.4 - 672.7 lbf ft)
Drive shaft mount bolt: 156.9 - 196.1 Nm (115.7 - 144.6 lbf ft)
★ Bleed air from both brakes. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
Thrust cover: Lubricant (Grease G2-LI)
Thrust cover mount bolt: 490.4 - 608.0 Nm (361.7 - 448.4 lbf ft)
Support mount bolt: 3170.0 - 3870.0 Nm (2338 - 2780 lbf ft)
Thrust plate: Lubricant (Grease G2-LII
Thrust plate mount bolt: 490.4 - 608.0 Nm (361.7 - 448.4 lbf ft)
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REAR DIFFERENTIAL
12 REAR DIFFERENTIAL
REMOVAL 1.
Remove rear axle assembly. For details, see REAR AXLE REMOVAL.
2.
Remove drain plugs (1) from both final drives to drain oil. Axle oil: 245 L (65 gal) each
3.
Remove mount bolts (2) to remove cover (3). ★ Remove the cover with the top mark up.
4.
Install bolt ➀ to end of drive shaft (4) and pull out drive shaft.
5.
Lift off drive shaft (4). Drive shaft: 92 kg (203 lb)
6.
Loosen locknut and remove tension bolt (5).
7.
Remove bolt (6) to remove O-ring and holder (7).
8.
Pull out flange (8).
9.
Remove mount bolts and screw in forcing bolt (9) to remove differential assembly (10) from axle housing.
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REAR DIFFERENTIAL
12 10. Install eyebolt (11) to pinion gear and slowly lift off differential assembly (10). Rear differential assembly: 854 kg (1883 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Cover mount bolt: 98.0 - 123.0 Nm (72.2 - 90.7 lbf ft)
★ Adjustment of tension bolt (14) Press the tension bolt end against the back of the gear, then return it by l/2 turn. Locknut: 343.0 - 441.0 Nm (252.9 - 325.6 lbf ft)
Mount bolt: Adhesive (LT-2)
Mount bolt: 1716.2 ± 196.1 Nm (1265.8 ± 144.6 lbf ft)
Differential mount bolt: 490.4 - 608.0 Nm (361.7 - 448.4 lbf ft)
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DIFFERENTIAL
12 DIFFERENTIAL
DISASSEMBLY Preparation work A. Install differential assembly (1) on tool H4. ★ Install the coupling to install the differential to the stand. Front Differential: 816 kg (1799 lb)
Rear Differential: 854 kg (1883 lb)
B. Remove ring gear adjustment bolt (1A). C. After installing assembly to stand, turn over differential gear to set it up.
1.
Differential gear A. Loosen adjustment ring lock bolts and remove lock plates (2). ★ Turn the adjustment rings to separate the differential gears from the pinion gears. B. Remove bearing caps (3). ★ Check the match marks of both bearing caps. If they are not clear, make new ones.
C. Remove adjustment rings (4) and bearing caps (5).
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DIFFERENTIAL
12 D. Remove differential gear (6) from differential case. â&#x2DC;&#x2026; When lifting up the differential gear, lean it toward the plain half side so that the pilot bearing will not interfere with the carrier. Differential gear assembly: 365 kg (804.6 LB)
2.
Plain half A. Remove plain half (7). â&#x2DC;&#x2026; Check the match marks. If they are not clear, make new ones. B. Remove bearing (8).
C. Remove side gear (9), cross shaft (10), thrust washer (11), and pinion gear (12).
3.
Bevel gear and flange half A. Remove mount bolts to remove bevel gear (13) and flange half (14). B. Remove bearing (15).
4.
Turning over Turn over differential gear again.
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DIFFERENTIAL
12 5. Pinion gear A. Loosen mount bolts of coupling (16). â&#x2DC;&#x2026; Install the coupling temporarily.
B. Lift pinion gear (18) out of differential case (17). Pinion gear (Front): 174 kg (383.6 lb)
Pinion gear (Rear): 196 kg (432.1 lb)
C. Remove coupling (16), holder (19), and O-ring (20) from removed pinion gear (18).
D. Remove front cage (21) and rear support (22), then pull out oil seals (23) and (23A).
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DIFFERENTIAL
12 6. Pinion shaft A. Using press, pull out pinion shaft (24). ★ Take care not to apply too high pressure. B. After pulling out pinion shaft (24), remove bearing (25) and spacer (26).
C. Remove bearing cups (28) and (29) from cage (27).
D. Remove snap ring (30), pilot bearing (31), and bearing (32) from pinion shaft (24). ★ Remove pilot bearing (31) and bearing (32) only when required. ★ Disassemble the rear differential according to the above procedure.
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DIFFERENTIAL
12 ASSEMBLY ★ When the pinion or ring gear needs to be replaced, be sure to replace both of them as a set. Do not mix them with those of another set. Replace the flange half and plain half as a set, too. 1.
Pinion shaft A. Press fit pilot bearing (31) to pinion shaft and install snap ring. ★ Press fit the pilot bearing with its C 0.5 part on the snap ring side. B. Press fit bearing (32) to pinion shaft (24). ★ Press fitting pressure of bearing (32), pilot bearing (31): 98.1 kN (10 ton) C. Press fit bearing cups (28) and (29) to cage (27). ★ Press fitting pressure of bearing cup: 98.1 kN (10 ton) Inside and outside surfaces of cage: Axle oil
★ After press fitting the bearing cup, check that there is not clearance at part a. D. Install cage (27) to pinion shaft (24), then install spacer (26).
2.
Adjustment of pre-load A. Press fit bearing (25) to pinion shaft (24).
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DIFFERENTIAL
12 B. Press bearing with press and measure torque of cage (27) with spring balance. Bearing: Axle oil
★ Apply sufficient amount of oil to the bearing and run in the bearing, then measure the torque. ★ Pressure of press: 295.2 kN (30.1 ton) Torque at bolt hole of cage: (Reference) 0 - 8.8 kN (0 - 900 kg) C. If measured value is out of standard value range, replace bearing (25) and spacer (26), then measure again. D. If measured value is in standard value range, check that end play of cage is in standard value range. ★ End play: 0 - 0.266 mm max.
3.
Pinion gear A. Press fit oil seals (23) and (23A) to front cage (21) and rear support (22). ★ Use new oil seals. ★ Press fitting dimension a: 62 -10 mm. ★ Press fitting dimension b: 78 -10 mm. Seal lip: Grease (G2-LI)
B. Install O-rings (33) and (34) to cage (27), then install front cage (21) or rear support (22) and tighten bolt temporarily (M20 x 40 mm). ★ Take care that the O-rings will not be caught or projected. C. Install coupling (16), O-ring (20), and holder (19), then tighten bolt temporarily. ★ Tighten the bolt permanently after installing the differential case. ★ Install the differential case on tool H4.
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DIFFERENTIAL
12 D. Install pinion gear (18) to differential case (17) without shim. Mount bolt: 549.2 ± 58.8 Nm (405.0 ± 43.3 lbf ft) (Width across flats: 30 mm)
E. Install tool H6 to differential case (17). F.
Measure dimension “L” between tool H6 and pinion gear, then calculate thickness of shim. ★ If the bearing, pinion gear, bevel gear, etc. has been replaced, adjust the shim according to the following procedure. Shim thickness = Standard value - (L - Tool thickness) Standard value: (371 + a) - (167.8 + b) ★ Dimensions a and b are l/100 of the values indicated at the end of the pinion shaft. (Take care of the symbols of + and -.) ★ The relationship between dimensions a and b is shown in the following figure.
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DIFFERENTIAL
12 G. Install pinion gear (18) and shim to differential case (17), then tighten the mount bolt. ★ After adjusting the shim, install the O-ring to the cage. ★ Take care that the O-ring will not be caught. Mount bolt: 549.2 ± 58.8 Nm (405.0 ± 43.3 lbf ft) (Width across flats: 30 mm) 4.
Bevel gear and flange half A. Press fit bearing (15) to flange half (14). ★ Apply axle oil to the bearing fitting part. ★ Press fit the bearing so that clearance will not be made at part c under the bearing.
B. Install flange half (14) to bevel gear (13). ★ Install the flange half so that clearance will not be made between the gear and flange half. Mount bolt: Adhesive (LT-2)
Mount bolt: 549.2 ± 58.8 Nm (405.0 ± 43.3 lbf ft) (Width across flats: 30 mm) C. Turn over ring gear and flange half assembly (34).
5.
Plain half A. Drive pin (35) in flange half. Apply oil to fitting parts of washer (36) and side gear (9), then install them. ★ When installing the thrust washer, match it to the pin. Fitting faces of thrust washer and gear: Axle oil
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DIFFERENTIAL
12 B. Install pinion gear (12) and thrust washer (11) to cross shaft (10).
C. Install cross shaft and pinion gear assembly (37) to flange half (14), then install side gear (9). ★ Apply oil to the fitting face of the thrust washer.
D. Press fit bearing (8) to plain half (7), then drive in pin (38). ★ Press fit the bearing so that clearance will not be made at part d. E. Install thrust washer (39) matching it to pin of plain half (7). ★ Apply oil to fitting faces of thrust washer and gear. Fitting faces of thrust washer and gear: Axle oil
F.
Install plain half (7) and flange half (14), matching their matching marks. ★ After installing the plain half and flange half, check that the side gear turns smoothly. Mount bolt: 549.2 ± 58.8 Nm (405.0 ± 43.3 lbf ft) (Width across flats: 30 mm)
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DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL
12 6. Differential gear A. Sling gear (6) and install bearing cup (5) to bearing, then install them to case. ★ When installing the differential gear, take care that it will not interfere with the pilot bearing.
B. Install adjustment ring (4), matching it to threads of differential case (17). C. Install bearing cap (3), matching its match mark. ★ Take care not to damage the threads of the cap. Mount bolt: 926.8 ± 102.9 Nm (683.5 ± 75.8 lbf ft) (Width across flats: 36 mm)
7.
Adjustment of pre-load on bearing A. Set lock groove on bevel gear side to position to install lock plate in advance, and turn bevel gear (13) until it turns smoothly. ★ Turn the bearing sufficiently so that it will fit to the other parts and hit the bevel gear lightly with a copper hammer, etc. ★ Apply sufficient amount of oil to the bearing.
B. Adjust torque of bevel gear (13) at large end to target value with adjustment ring on plain half side. ★ Measure the torque in the backlash range.
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DIFFERENTIAL
12 C. Hook spring balance on bevel gear (13) and measure force at this time. • Free force: 36.3 - 57.9 N (8.1 - 13.0 lbf) ★ Target value: 47.1 N (10.5 lbf) D. Check that force is within target range and match groove of adjustment ring on plain side.
8.
Adjustment of tooth contact and backlash Adjust backlash according to the following procedure. A. Adjust bevel gear with adjustment ring. ★ At this time, turn the adjustment rings on both sides by the same degrees in the same direction. B. Apply dial gauge to outermost tooth surface of bevel gear and adjust tooth contact and backlash, turning adjustment ring. ★ Measure the backlash at 3 - 4 places and keep the pinion gear fixed during measurement. ★ Backlash: 0.46 - 0.66 mm ★ During steps A and B, match the lock groove carefully so that the pre-load on the bearing will not change. Adjust tooth contact according to the following procedure. A. Mix red lead with oil and apply mixture to surfaces of 7 - 8 teeth of bevel gear. B. Turn pinion gear in forward and backward directions to check tooth contact. ★ Adjust the tooth contact according to the following procedure.
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DIFFERENTIAL
12 9. Adjust tooth contact Coat face of 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to brake it, and rotate the bevel pinion forward and backward and inspect the pattern left on the teeth. Adjust the tooth contact as follows. Tooth contact
Cause
Procedure for adjustment
Correct contact The tooth contact pattern should start from about 5 mm from the toe of the bevel gear and cover about 50% of the length of the tooth. It should be in the center of the tooth height.
Adjust the bevel pinion by adjusting the shims at the bevel pinion cage. Adjust the bevel gear in the same way as when adjusting backlash.
Bevel pinion is too far from bevel gear.
Bevel pinion is too close to bevel gear.
Bevel gear is too close to bevel pinion
Bevel gear is too far from bevel pinion.
1.
Reduce shims at bevel pinion to bring closer to bevel gear.
2.
Move bevel gear further away from bevel pinion and adjust backlash correctly.
1.
Increase shims at bevel pinion to move away from bevel gear.
2.
Move bevel gear closer to bevel pinion and adjust backlash correctly.
1.
Reduce shims at bevel pinion to bring closer to bevel gear.
2.
Move bevel gear further away from bevel pinion and adjust backlash correctly.
1.
Increase shims at bevel pinion to move away from bevel gear.
2.
Move bevel gear closer to bevel pinion and adjust backlash correctly.
â&#x2DC;&#x2026; When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and right. Always keep the same total thickness of shims.
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DIFFERENTIAL
12 10. Lock plates After completing adjustment of tooth contact, wipe off the red lead, and install lock plates (2). Lock bolt: 110.3 ± 12.3 Nm (81.3 ± 9.0 lbf ft)
11. Adjustment bolts After adjusting all parts, screw in bolt (1) until it contacts back surface of ring gear, then turn back l/2 turn, and tighten locknut (40). Adjustment bolt: Adhesive (LG-5)
Lock bolt: 392.3 ± 49.0 Nm (289.3 ± 36.1 lbf ft)
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FINAL DRIVE
12
FINAL DRIVE DISASSEMBLY WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1.
Tires, wheel Jack up axle, and lift off tire and wheel (1). ★ After removing the tire and wheel, insert the support stand under the axle. Tire, wheel: 2490 kg (5490 lb)
2.
Draining oil Remove drain plug (2) and drain oil from case. ★ There is a large amount of oil drained, and the oil spurts out suddenly, so be careful when draining. Axle assembly: Approximately 245 L (64.7 gal)
3.
COVERS Remove cover (3) and O-ring (4). ★ The cover is heavy, so sling it and lift it off. Cover: 41 kg (90.4 lb)
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FINAL DRIVE
12 4. Axle shaft assembly A. Insert a bar in gear of axle shaft (5), and pull out shaft. ★ When inserting the bar and levering, set a pad on the corner of the housing. ★ Screw a bolt into the screw hole (M20 x P2.5) in the end face of the shaft, then raise and lift up the gear.
B. Raise axle shaft (5) and pull out from spline of differential assembly. ★ When lifting off the shaft, be careful not to let the gear drop out. Shaft assembly: 98 kg (217 lb)
5.
Planetary carrier assembly Remove hexagonal bolts (6), and lift off planetary carrier (7). ★ Be careful of the center of gravity, and lift off slowly. Planetary carrier assembly: 199 kg (439 lb)
★ Do not remove the stud bolts except when replacing.
6.
Ring gear assembly A. Using tool H11, secure wheel hub (8) and brake assembly (9).
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DISASSEMBLY AND ASSEMBLY 12
FINAL DRIVE
★ Fit tool H11 on both sides at diagonally opposite places and use the wheel mount washer to adjust clearance a. ★ Leave tool H11 installed.
B. Remove retainer (10), then remove shim (11). ★ Check the number and thickness of the shims, and keep in a safe place.
C. Lift off ring gear assembly (12). ★ When removing the ring gear assembly, insert a bar in the casting hole in the ring gear, and adjust the balance while pulling out. Ring gear assembly: 198 kg (437 lb)
7.
Disassembly of planetary carrier A. Using press, pull out shaft (13), then remove pinion gear (14). ★ Lock ball (15) is assembled to the shaft, so be careful not to lose the ball. ★ Write the number on the case to distinguish the parts that are removed and to prevent them from being mixed with other parts.
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FINAL DRIVE
12 B. Remove bearing cups (16) and (17), cones (18) and (18A), spacer (19), and snap ring (20) from pinion gear (14). â&#x2DC;&#x2026; The bearing and other parts are settled together in sets, so mark the parts to prevent them from being mixed with parts from other sets.
â&#x2DC;&#x2026; Keep the bearing cups as a set.
8.
Disassembly of ring gear A. Remove lock plate (22) from ring gear hub (21) then remove ring gear (23). Ring gear hub and bearing: 71 kg (157 lb)
Ring gear: 96 kg (212 lb)
B. Using puller, remove bearing (24) from ring gear hub (21).
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FINAL DRIVE
12 ASSEMBLY 1.
Assembly of ring gear A. Press fit bearing (24) to ring gear hub (21). ★ After press fitting the bearing, there must be no clearance around the whole circumference of portion a of the ring gear hub.
B. Install ring gear (23) to ring gear hub (21), and secure with lock plate (22). ★ Be careful to assemble the lock plate facing in the correct direction. Mount bolt: Thread tightener (LT-2)
Mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.4 lbf ft)
★ Remove all oil and grease from the mount holes and bolt threads.
2.
Assembly of planetary carrier A. Assemble snap ring (20) and spacer (19) to pinion gear (14). B. Press fit bearing cup (16) to pinion gear (14). ★ After press fitting the cup, check that there is no play in the spacer.
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FINAL DRIVE
12 C. Set bearing cone (18A) inside planetary carrier (7), then install pinion gear (14), and assemble bearing cone (18) on top. D. Align hole of gear and carrier, then press fit shaft (13). ★ Align the lock ball hole, and press fit, then stop just before the hole and align the hole again. E. Assemble lock ball (15) to shaft, and press fit shaft again. ★ After press fitting the shaft, check that the gear rotates smoothly. ★ The shaft must be sunk 0.1 - 0.5 mm below the planet cover mount surface. 3.
Ring gear assembly A. Raise ring gear assembly (12) and set in mount position, then insert in axle housing. ★ Align the spline groove, and insert slowly.
B. Tighten retainer (10) temporarily with 3 mount bolts, and remove tool H11. ★ Measure thickness “b” of the retainer before starting.
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DISASSEMBLY AND ASSEMBLY 12
FINAL DRIVE
★ Remove all the grease from the retainer mount bolt hole. ★ Rotate the wheel hub to settle the bearing, then tighten until the torque is constant. Retainer mount bolt: 103 ± 4.9 Nm (75.9 ± 3.6 lbf ft)
C. Using depth micrometer through measuring hole of retainer (10), measure clearance “a” from end face of housing to end face of retainer. ★ Measure at 2 places and take the average. D. Select shim thickness of clearance a + 0.3 mm. ★ Select the combination of shims to give the required thickness of a + 0.3 mm with the minimum number of shims. ★ Shim thickness: 1.0 mm, 0.5 mm, 0.2 mm, 0.05 mm (Round the measurement up to the nearest 0.1 mm.)
E. Check that tool H11 is installed to brake assembly and wheel hub securely, then remove retainer, assemble selected shims (11), and install retainer (10). ★ When assembling the shims, tool H11 must be installed. ★ Rotate the wheel hub and tighten the mount bolts uniformly to the specified torque. Mount bolt: Thread tightener (LT-2)
Mount bolt: 549.2 ± 58.8 Nm (405.0 ± 43.3 lbf ft) ★ After assembling the shims, remove tool H11. 4.
Planetary carrier assembly Assemble O-ring (7A) to planetary carrier (7), then raise planetary carrier assembly, align teeth of ring gear and planetary gear (7B), set in mount position, and secure with hexagonal bolts. Hexagonal bolt: 56.4 ± 7.4 Nm (41.5 ± 5.4 lbf ft)
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FINAL DRIVE
12 5. Axle shaft assembly Raise axle shaft assembly (5) at two points and install. ★ If the sun gear cannot be aligned, rotate the wheel hub to align the position.
6.
Cover Fit O-ring (4) in cover groove, and install cover (3). Mount bolts: 110.3 ± 12.3 Nm (81.3 ± 9.0 lbf ft)
7.
Refilling with oil Tighten drain plug and add oil through level plug (25) to the specified level. ★ Set with the drain plug at the bottom when refilling with oil. Axle assembly: 245 L (64.7 gal)
8.
Tires, wheel Install tire and wheel (1) and remove support stand. Mount nut: 823.8 ± 88.3 Nm (607.6 ± 65.1 lbf ft)
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DISASSEMBLY AND ASSEMBLY
ORBITROL STEERING VALVE
12
ORBITROL STEERING VALVE REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove boot (1).
2.
Remove joint lock bolt (2).
3.
Disconnect drain hose (3).
4.
Disconnect hose (4) connected to left stop valve.
5.
Disconnect hose (5) connected to accumulator.
6.
Disconnect hose (6) connected to right stop valve.
7.
Remove mount bolts (7) to remove orbit roll assembly (8).
8.
Remove 4 lock bolts (9) to remove joint assembly (10).
9.
Remove mount bolts (11) to remove bracket (12) from orbit roll assembly (8).
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ORBITROL STEERING VALVE
12 INSTALLATION •
Carry out installation in the reverse order to removal.
Joint lock bolt: 55.9 ± 7.8 Nm (41.2 ± 5.7 lbf ft)
Bracket mount bolt: 51.9 ± 7.8 Nm (38.2 ± 5.7 lbf ft) •
After installing the orbitrol, check the steering operation.
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DISASSEMBLY AND ASSEMBLY
STEERING CYLINDER
12
STEERING CYLINDER REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. 1.
Remove 4 bolts (1) to remove cover (2). ★ Since the available space is narrow, work carefully.
2.
Remove grease fitting (3).
3.
Remove 2 mount bolts (4) to remove plate (5).
4.
Remove 3 pin mount bolts (7) and 2 plate mount bolts (8) to remove plate (9).
5.
Pull out pin (11) and remove bushings (6) and (10).
★ Apply a pad to the top of pin (11) and drive out the pin with a large hammer or press it out with a jack from underside. 6.
Start engine and retract piston (12).
★ Check the place and quantity of shims (13), then remove it.
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STEERING CYLINDER
12 7. Disconnect hose (14) on steering cylinder head side and hose (15) on bottom side. ★ Plug the disconnected hoses.
8.
Disconnect grease supply tube (16) and remove connector (17).
9.
Remove 2 mount bolts (18) to remove plate (19).
10. Remove 2 pin mount bolts (21) and 3 plate mount bolts (22) to remove plate (23).
★ Sling the cylinder assembly temporarily.
11. Pull out pin (25). then remove bushings (20) and (24).
★ Apply a pad to the top of pin (25) and drive out the pin with a large hammer, or press it out with a jack from underside.
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DISASSEMBLY AND ASSEMBLY
STEERING CYLINDER
12 12. Lift off steering cylinder assembly (27). ★ Check the place and quantity of shim (26), then remove it.
Steering cylinder assembly: 156 kg (344 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: Liquid adhesive (LOCTITE 262)
Mount bolt: 157 - 196 Nm (116 - 144 lbf ft)
★ Set the slit in the lateral direction of the vehicle body.
★ Adjust the clearance in the cylinder fitting parts to the specified value. Head side: a + b = 1.0 mm max. Bottom side: c + d = 3.2 mm max.
•
Bleeding air Bleed air from the steering cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
STEERING DEMAND VALVE
12 STEERING DEMAND VALVE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove step (1).
2.
Lift off left fender (2). Fender: 160 kg (353 lb)
3.
Open inspection cover (3).
4.
Disconnect drain tube (4).
5.
Disconnect tube (5) connected to stop valve.
6.
Disconnect tube (6) connected to work equipment valve. ★ Before removing each tube, disconnect it from the brackets and U-bolts.
7.
Disconnect tubes (7) and (8) connected to steering cylinder. ★ When disconnecting these tubes, take care not to drop the check valve and orifice.
8.
Disconnect tube (9) connected to stop valve.
9.
Disconnect tube (10) connected to switching pump.
10. Disconnect tube (11) connected to steering pump.
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DISASSEMBLY AND ASSEMBLY
STEERING DEMAND VALVE
12 11. Lift off steering demand valve assembly (12). Steering demand valve assembly: 40 kg (88.2 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
•
When installing the check valve and orifice, take care of their direction.
•
After installing the tubes, tighten the U-bolts to secure them.
•
Before connecting the tubes and hoses, check their O-rings for breakage and deterioration, then connect them securely.
•
Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE
12 BRAKE VALVE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Removal of right brake valve assembly A. Remove clamp (1) and disconnect drain tube (2). B. Disconnect hoses (3) and (4) connected to accumulator (pump). C. Disconnect tubes (5) and (6) connected to front and rear brakes. D. Disconnect hose (7) (pilot) connected to left brake valve.
2.
Removal of left brake valve assembly A. Disconnect hose (1) connected to accumulator. B. Disconnect pilot hose (2). C. Disconnect drain hose (3). D. Disconnect transmission cut-off switch wiring connector (4). E. Remove joint tubes (5) and (6).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE
12 3. Removal of upper part of brake valves A. Pull out pin (9). ★ Take care not to lose the L-pin. B. Remove pedal (10). C. Remove plunger (11), then remove boot (12). D. Remove 4 mount bolts (13) to remove left brake valve assembly (7) and right one (8).
INSTALLATION • •
Carry out installation in the reverse order to removal. After installing the brake valves, check the operation of the brake.
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (RIGHT)
12 BRAKE VALVE (RIGHT)
DISASSEMBLY (TANDEM BRAKE VALVE) 1.
Remove snap pin (1) and L-pin (2), then pull out pedal plate fitting pin (3). â&#x2DC;&#x2026; Take care not to lose the L-pin.
2.
Remove pedal plate (4).
3.
Remove seat (5), boot (6) and pedal stopper (7).
4.
Remove mount bolt (8), then remove bracket (9).
5.
Remove mount bolt (10), then disconnect flange (11) and cylinder (12).
6.
Remove holder (13) and springs (14), (15) and (16) from cylinder (12).
7.
Pull rod (17) out of flange (11).
8.
Pull pilot piston (18) out of rod (17).
9.
Remove the snap ring from pilot piston (18), then remove retainers (20) and (21).
10. Remove dust seal (22) and O-ring (23) from flange (11).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (RIGHT)
12 11. Disconnect cylinders (24) and (25). 12. Remove return spring (26) and O-ring (27).
13. Pull spool (28) out of cylinder (24). 14. Remove piston (29) and spring (30) from spool (28). 15. Remove snap ring (31) from spool (28), then remove retainer (32).
16. Remove nut end (33) from cylinder (25), then remove spring (34). 17. Remove O-ring (35) from nut end (33).
18. Pull spool (36) out of cylinder (25). 19. Pull piston (37) out of spool (36). 20. Remove snap ring (38) from spool (36), then remove retainer (39).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (RIGHT)
12 ASSEMBLY (TANDEM BRAKE VALVE) 1.
Install retainer (39) to spool (36), then secure it with snap ring (38).
2.
Insert piston (37) in spool (36). ★ Apply engine oil.
3.
Insert spool (36) in cylinder (25).
4.
Install O-ring (35) to nut end (33).
5.
Install spring (34) to nut end (33), then install them to cylinder (25). Nut end: 152.0 ±. 24.5 Nm (112.1 ± 18.0 lbf ft)
6.
Install retainer (32) to spool (28), then install snap ring (31).
7.
Install spring (30) and piston (29) to spool (28).
8.
Insert spool (28) in cylinder (24).
9.
Install O-ring (27) to cylinder (24).
10. Set spring (26) to cylinder (25).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (RIGHT)
12 11. Press fit dust seal (24) to flange (11), then install O-ring (23). 12. Install retainers (21) and (20) to pilot piston (18), then install snap ring (19). 13. Insert pilot piston (18) in rod (17).
14. Set holder (13) to cylinder (12), then install springs (14), (15) and (16). 15. Assemble cylinders (25) and (12) and flange (11), and secure them with mount bolt (10). Mount bolt: 66.2 ± 7.3 Nm (48.8 ± 5.3 lbf ft)
16. Set bracket (9) on flange (11), then secure it with mount bolt (8). Mount bolt: 66.2 ± 7.3 Nm (48.8 ± 5.3 lbf ft)
17. Install pedal stopper (7) and boot (6) to bracket, then set seat (5). 18. Set pedal plate (4) to bracket (9), then insert pin (3). 19. Install snap pin (1) and L-pin (2) to pin (3).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (LEFT)
12 BRAKE VALVE (LEFT)
DISASSEMBLY (SINGLE BRAKE VALVE) 1.
Remove snap pin (1) and L-pin (2), then pull out pedal plate fitting pin (3). â&#x2DC;&#x2026; Take care not to lose the L-pin.
2.
Remove pedal plate (4)
3.
Remove seat (5), boot (6) and pedal stopper (7).
4.
Remove mount bolt (8), then remove bracket (9).
5.
Remove mount bolt (10), then disconnect flange (11) and cylinder (12).
6.
Remove holder (13) and springs (14), (15) and (16) from cylinder (12).
7.
Pull rod (17) out of flange (11).
8.
Remove snap ring (18) from rod (17), then remove retainers (19) and (20).
9.
Remove dust seal (21) and O-ring (22) from flange (11).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (LEFT)
12 10. Remove nut end (23) from cylinder (12), then remove spring (24). 11. Remove O-ring (25) from nut end (23).
12. Pull spool (26) out of cylinder (12). 13. Remove piston (27) out of spool (26). 14. Remove snap ring (28) from spool (26), then remove retainer (29).
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (LEFT)
12 ASSEMBLY (SINGLE BRAKE VALVE) 1.
Install retainer (29) to spool (26), then secure it with snap ring (28).
2.
Insert piston (27) in spool (26). ★ Apply engine oil.
3.
Insert spool (26) in cylinder (12).
4.
Install O-ring (25) to nut end (23).
5.
Install spring (24) to nut end (23), then install them to cylinder (12). Nut end: 152.0 ± 24.5 Nm (112.1 ± 18.0 lbf ft)
6.
Install dust seal (21) and O-ring (22) to flange (11).
7.
Install retainers (20) and (19) to rod (17), then install snap ring (18).
8.
Insert rod (17) in flange (11).
9.
Install holder (13) to cylinder (12), then set springs (16), (15) and (14).
10. Install flange (12) to flange (11), then secure them with mount bolt (10). Mount bolt: 66.2 ± 7.3 Nm (48.4 ± 5.3 lbf ft)
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DISASSEMBLY AND ASSEMBLY
BRAKE VALVE (LEFT)
12 11. Set bracket (9) to flange (11), then secure them with mount bolt (8). Mount bolt: 66.2 ± 7.3 Nm (48.4 ± 5.3 lbf ft)
12. Install pedal stopper (7), boot (6) and seat (5). 13. Set pedal plate (4) and insert pin (3), then install L-pin (2) and snap pin (1).
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DISASSEMBLY AND ASSEMBLY
SLACK ADJUSTER
12 SLACK ADJUSTER
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
Front side WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove front cover (1) and open rear right side cover (6).
2.
Disconnect tube (2) connected to brake valve.
3.
Disconnect tubes (3) and (4) connected to both brakes.
4.
Remove mount bolts to remove slack adjuster assembly (5).
INSTALLATION •
Carry out installation in the reverse order to removal. Tube sleeve nut: 68.6 ± 9.8 Nm (50.5 ± 7.2 lbf ft)
Rear side •
Bleeding air Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
SLACK ADJUSTER
12 DISASSEMBLY 1.
Bleeder Remove bleeder (2) from body (1).
2.
Cylinder Remove mount bolts, then disconnect body (1) from cylinders (3) and (4). WARNING! Cylinder has spring tension inside. Carefully remove them holding two parts together.
3.
Piston A. Remove spring (5) and O-ring (6). B. Push out piston (7) and remove O-ring. ★ Gently push out the piston with a rod (diameter 10 mm) when remove it. ★ Pay attention not to give damage to screw portion with the rod.
4.
Poppet ★ Do not disassemble poppet unless necessary. If disassembled, replace poppet and cylinder as assembly. A. Remove cover (8) from cylinder (4), then remove plug (9), spring (10) and poppet (11). ★ Remove the poppet by air blowing through the oil hole of the cylinder. ★ Hold the oil port of the cylinder by hand and pay attention not to blow air hard. ★ If replace poppet (11) or cylinder (4), replace them as a set. B. Remove O-ring (12) from the poppet.
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DISASSEMBLY AND ASSEMBLY
SLACK ADJUSTER
12 ASSEMBLY 1.
Poppet A. Fit O-ring (12) to poppet (11). B. Install poppet (11), spring (10), plug (9) and cover (8), then assemble into the cylinder (4).
2.
Piston A. Fit O-ring (13) to piston (7). B. Insert piston (7) into cylinder (4). ★ Confirm that the piston moves smoothly.
3.
Cylinder A. Install O-ring (6) and spring (5) to cylinder. ★ Spring installation load: 43.1 N (9.68 lbf)
B. Install cylinders (4) and bracket (3) to body (1). 4.
Bleeder Install bleeder (2).
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DISASSEMBLY AND ASSEMBLY
BRAKE
12
BRAKE REMOVAL WARNING! Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. ★ Referring to FINAL DRIVE - DISASSEMBLY, perform the work up to "Removal of ring gear assembly".
1.
Brake tube Disconnect brake tube (1) from brake assembly. ★ Plug the tube to prevent brake fluid from flowing out.
2.
Wheel hub and brake assembly A. Check that wheel hub (2) and brake assembly (3) are locked securely with tool H11. B. Sling wheel hub and brake assembly (4) temporarily. ★ Install 2 slings to the assembly.
C. Remove mount bolts (5) and lift off wheel hub and brake assembly (4).
★ When the brake assembly is removed, the internal bearing may come out. Take care. Wheel hub and brake assembly: 1260 kg (2778 lb)
★ Before removing the brake assembly, make match marks on it and the axle housing.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 3. Axle housing Remove retainer (7) and bearing (8) from axle housing (6).
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 926.8 ± 103.0 Nm (683.5 ± 75.9 lbf ft) ★ Referring to FINAL DRIVE - DISASSEMBLY, perform the work of "Removal of ring gear assembly" and after. •
Bleeding air from brake Bleed air from the brake and check its operation. ★ For air bleeding procedure, see TESTING AND ADJUSTING.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 DISASSEMBLY 1.
Cylinder, piston A. Set wheel hub and brake assembly (1) perpendicular with wheel hub side facing down. ★ Make match marks at 3 places on the outside circumference of the outer gear and the cylinder assembly.
B. Screw eyebolts in forcing screw hole (Thread dia. = 20 mm, Pitch = 2.5 mm) of cylinder assembly (2), then lift off cylinder assembly (2). ★ Raise at 3 points, and lower onto the wooden block. ★ Be careful not to damage the piston surface when setting in position. Cylinder assembly: Approximately 165 kg (364 lb)
C. Push in piston return spring (3) and guide shaft (4) of cylinder assembly (2), then pull out pin (5). ★ The pin is small, so be careful not to lose it.
D. Blow in air from brake oil filler port (6) to push out piston (7). ★ Support the piston at one end with a wooden block and blow in air carefully to prevent the piston from flying out. ★ Be careful not to damage the piston. Cylinder assembly: 42 kg (92.5 lb)
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 E. Remove seal (9) from piston (8).
2.
Plate, disc A. Remove plate (10).
B. Remove disc (11). ★ When removing the discs and plates, make match marks on the inner gear and disc, and the outer gear and plate, then remove. ★ The disc are made of a soft material, so be careful not to scratch them when removing them. ★ Remove the disc and plates in turn.
3.
Outer gear A. Remove tool H11 holding outer gear (12) and wheel hub (13). ★ Remove tool H11 only from the outer gear end, and loosen the nuts at the wheel hub end.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 B. Using lifting tool or bolt (Thread dia. = 20 mm, Pitch = 2.5 mm), lift off outer gear and brake hub (14). Outer gear, brake hub assembly: Approximately 171 kg (377 lb)
C. Turn over outer gear and brake hub (14), and set so that outer gear (12) is facing down. â&#x2DC;&#x2026; Set the bottom of the outer gear on wooden blocks.
D. Using 3 forcing screws (Thread dia. = 20 mm, Pitch = 2.5 mm), disconnect brake hub (14-1) and outer gear (12), then use eyebolts (Thread dia. = 20 mm, Pitch = 2.5 mm) to lift off brake hub (14-1). Brake hub: 93 kg (205 lb)
E. Remove O-ring (15), oil seal (16), seal ring, and O-ring assembly (17) from brake hub (14-1).
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 4. Inner gear Remove mount bolts, then lift off inner gear (18). ★ Carry out the operation for removing the inner gear with two workers. Determine fixed signals for the operation, and be extremely careful when removing. Inner gear: 43 kg (94.8 lb)
5.
Retainer A. Remove seal ring and O-ring assembly (19) from wheel hub (13). B. Remove bolts, then remove retainer (20). ★ Carry out the operation with two workers. Determine fixed signals for the operation, and be extremely careful when removing. Retainer: 29 kg (63.9 lb)
C. Remove O-ring (21) from wheel hub (13). D. Remove bearing cups (22) and (23) from wheel hub (13). ★ Do not remove bearing cups (22) and (23) unless necessary.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 ASSEMBLY 1.
Retainer A. Press fit bearing cups (23) and (22) to wheel hub (13). ★ Cool the bearing cup with dry ice to a temperature of -40° C, then press fit. ★ Press fit the bearing cups so that there is no clearance at portion a.
B. Coat O-ring (21) with grease thinly, then assemble to wheel hub (13). ★ Assemble the O-ring without twisting. Outside circumference of O-ring: Grease (G2-LI)
C. Install retainer (20) to wheel hub (13), then tighten flange bolts. ★ Be careful that the O-ring does not get caught. ★ Tighten the bolts on the opposite sides in turn. ★ Be careful not to damage the portion b of the retainer.
2.
Inner gear A. Raise inner gear (18) and set in mount position, then tighten mount bolts. ★ Clean surface c of the wheel hub. ★ Tighten the bolts on the opposite sides uniformly. Mount bolt: 1520 - 1912.3 Nm (1121.09 - 1410.44 lbf ft) ★ Wipe off the O-ring assembly groove of the retainer with a paper towel.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 B. Assemble O-ring (19-1) to seal ring (19-2). ★ Using alcohol, remove all the white powder from the O-ring surface.
C. Assemble seal ring and O-ring assembly (19) to retainer (20). ★ Do not hit the seal ring with a hammer. ★ Remove all the grease from the seal ring and O-ring contact surface of the retainer. ★ Assemble uniformly so that the O-ring of the seal ring does not twist. After press fitting, measure height t at 4 places around the circumference and check that the difference in height is within 1 mm. If it is more than 1 mm, assemble again. ★ When assembling the seal ring and O-ring assembly to the retainer, carry out the operation with two workers and be careful that the O-ring does not fall out. 3.
Outer gear A. Assemble O-ring (17-2) to seal ring (17-1). ★ Using alcohol, remove all the white powder from the O-ring surface. ★ Remove all the grease from the seal ring and O-ring contact surface of the retainer. ★ Assemble uniformly so that the O-ring of the seal ring does not twist. After press fitting, measure height t at 4 places around the circumference and check that the difference in height is within 1 mm. ★ If it is more than 1 mm, assemble again. ★ When assembling the seal ring and O-ring assembly (17) to brake hub (14-1), be careful that the O-ring does not fall out when inserting.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 B. Press fit oil seal (16) to brake hub (14-1). ★ Coat the inside circumference of the oil seal press-fitting portion of the brake hub with adhesive, then press fit. Oil seal press-fitting portion: Adhesive (Loctite #648)
Lip of oil seal: Grease (G2-LI)
★ Be careful not to damage surface d of the seal ring.
C. Assemble O-ring (15) to brake hub (14-1). ★ Fit the O-ring in the groove securely, and assemble it without twisting. D. Sling brake hub (14-1), and set outer gear (12) in mount position, then tighten mount bolts. ★ Two bolt holes on a diagonal line are for installing tool H11 later, so install the bolts temporarily. ★ After assembling the seal ring, coat portion e with oil. Contact surface of seal ring: Axle oil
Mount bolt: 490.4 - 608 Nm (361.7 - 448.4 lbf ft)
E. Turn over outer gear and brake hub (14), and install eyebolts (Thread dia. = 20 mm, Pitch = 2.5 mm) to outer gear end. ★ Turn over slowly and be careful that the seal ring and O-ring do not fall out. F.
Raise outer gear and brake hub (14) slowly, then install to wheel hub (13). ★ When assembling, be careful not to let the seal ring hit the inner gear. ★ After assembling the outer gear and brake hub, check that it is not at an angle.
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 G. Secure outer gear (12) and wheel hub (13) with tool H11.
4.
Plates, discs Align spline of inner gear (18) and outer gear (12), then assemble plate (10), disc (11), and plate in order. ★ Before assembling the disc, soak them in brake oil for at least 30 minutes. ★ Always assemble the plates and disc in turn. ★ Fit the last plate securely to the inner gear spline.
5.
Cylinder, piston A. Install seal (9) to piston (8). ★ Coat thinly with grease. ★ Install the seal in the groove without twisting. Outside circumference of seal: Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 B. Assemble seal (2-2) to cylinder (2-1). ★ Coat thinly with grease. ★ Install the seal in the groove without twisting. Outside circumference of seal: Grease (G2-LI)
C. Align return spring guide shaft hole of piston (7) and cylinder (2-1), then press fit piston (7). ★ Assemble so that casting holes A’ and B’ of the piston are in the positions shown in the figure on the right. ★ When press fitting the piston, tap with a plastic hammer. Do not hit with a steel or copper hammer.
D. Turn over cylinder assembly (2), and set so that piston (7) is facing down. ★ Use pads to prevent damage to the side face of the piston. ★ When installing plugs (25) and (26), coat the thread with gasket sealant, then install. Plug thread: Gasket sealant (LG-5)
E. Assemble return spring (3) to guide shaft (4), and insert in cylinder (2-1). F.
Screw in eyebolts (Thread dia. = 20 mm, Pitch = 2.5 mm), then use a bar to push spring, and install pin (5).
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DISASSEMBLY AND ASSEMBLY
BRAKE
12 G. Assemble O-ring (4-l), screw in eyebolts (Thread dia. = 20 mm, Pitch = 2.5 mm), then raise. Outside circumference O-ring: Grease (GZ-LI)
H. Set guide bolts in outer gear (12).
I.
Align match mark of outer gear (12). and install cylinder assembly (2). ★ Be careful that the O-ring is not caught or twisted when installing. ★ Wipe the side face of the piston with a clean paper towel. Mount bolt: 460.4 - 608 Nm (339.5 - 448.4 lbf ft)
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12
HYDRAULIC PUMP REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Release residual pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Open bulkhead cover (1).
2.
Remove transmission inspection cover (2).
3.
Remove support (3) and cover (4).
4.
Removal of steering and switching pump assembly A. Disconnect hoses (5) and (6) connected to steering demand valve. B. Disconnect hose (7) connected to hydraulic tank. C. Disconnect suction tube (8). D. Remove mount bolts and lift off steering and switching pump assembly (9). Steering, switching pump assembly: 145 kg (320 lb)
5.
Removal of loader pump assembly A. Disconnect hoses (10) and (11) connected to work equipment control valve. â&#x2DC;&#x2026; These two hoses join at a block, then the flow is divided for the steering demand valve and work equipment control valve.
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12 B. Disconnect hose clamp (12). C. Disconnect drain hose (13) connected to hydraulic tank. D. Disconnect hoses (14) and (15) connected to differential pressure valve. E. Disconnect suction tube (16). F.
Disconnect control pump suction, tube (17).
G. Remove mount bolts and lift off loader pump assembly (18). Loader pump assembly: 150 kg (331 lb)
6.
Removal of 4-spool pump (Torque converter charging, cooling, PPC, brake) A. Disconnect transmission oil suction tube (19). B. Disconnect hose (20) connected to transmission oil filter. C. Disconnect hydraulic oil suction tube (21). D. Disconnect brake oil suction tube (22). E. Disconnect tube (23) connected to brake oil strainer. F.
Disconnect tube (24) connected to cooling line.
G. Remove mount bolts and lift off 4-spool pump assembly (25). 4-spool pump assembly: 37 kg (82 lb)
INSTALLATION • •
Carry out installation in the reverse order to removal. Bleeding air Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
PISTON PUMP
12
PISTON PUMP DISASSEMBLY HPV090+090, HPF090+090 ★ The disassembly procedure is the same for both the front and rear pumps, so the procedure for disassembly of the front pump is given below. If there are any differences, the different part is explained. Preparatory work Set pump assembly to tool Y1. 1.
ES valve assembly, hoses (HPV090+090 only) A. Remove ES valve assembly (3). B. Remove hoses (4) and (5).
2.
Rear pump assembly A. Sling rear pump assembly (7). B. Remove 4 nuts at front pump end, then remove rear pump assembly (7). ★ It separates between the end caps. ★ Only the HPV090+090 has a gear pump.
Disassembly of pump ★ The front pump is disassembled as it is, but for rear pump assembly (7), install plate Y4 and disassemble.
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DISASSEMBLY AND ASSEMBLY
PISTON PUMP
12 3. Impeller A. Remove bolt (15), then remove plate (9) and shim (17). ★ Check the number and thickness of the shims, and keep in a safe place. B. Remove impeller (8).
4.
Servo valve assembly (HPV090+090 only) Remove servo assembly (12). ★ For the HPF pump, remove the cover.
5.
End cap A. Remove snap ring (13), then remove washer (14).
B. Remove inner race (20) and bearing (21). C. Remove end cap (23). D. Remove valve plate. ★ It is stuck to the cylinder block, so be careful not to scratch or damage it. Remark If the cylinder block and valve plate are to be used again, keep them in a safe place as a set. E. Remove outer race and bearing from end cap.
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PISTON PUMP
12 6. Valve plate Remove valve plate (45). ★ It is stuck to the cylinder block, so be careful not to scratch or damage it.
7.
Pump sub-assembly Support cylinder block and shaft, and remove pump sub-assembly (49).
8.
Servo piston A. Using forcing screw ➀ (Thread dia.=10 mm, Pitch=1.5 mm) and nut ➁, remove cap (27) and shim (28). B. Remove spring (31). ★ The spring and forcing screw are for the HPV090+090 only.
C. Screw in forcing screw and remove cap (29) and shim (30). D. Remove servo piston (32). ★ The servo pistons for the front and rear pumps are different parts, so mark them with a distinguishing mark. ★ With the HPF pump, there is a spacer on the right side as seen from the rear of the pump.
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PISTON PUMP
12 Disassembly of pump sub-assembly 9.
Cylinder, shaft A. Set pump sub-assembly (49) in vice. ★ Be careful not to damage the flange surface of the cradle. B. Remove slider (38) and cylinder block (35).
C. Screw in forcing screw and remove housing (40) and shim. ★ Check the number and thickness of the shims, and keep in a safe place. ★ The control pump is installed to the rear pump. Therefore, collar (10) assembled to the pilot pump must be removed. (HPV090+090 only) ★ Remove the cover of the HPF pump.
D. Knock out drive shaft assembly (41) from piston end and remove.
10. Piston Remove 4 screws (56), then remove retainer bearing (57), shoe retainer (58), spacer (59), and piston (60).
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PISTON PUMP
12
When using pump drive shaft and cylinder block again •
Removal of bearing from pump drive shaft A. Remove snap ring (55), then remove washer (54), inner race A (53), and bearing (68).
B. Using bearing race puller ➂, remove inner race B (52).
Disassembly of cylinder block A. Remove snap ring (34).
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PISTON PUMP
12 B. Remove washer (36) and spring (37) from cylinder block (35).
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PISTON PUMP
12 ASSEMBLY HPV090+090, HPF090+090 Precautions when assembling A. Clean all parts and remove all burrs. B. Coat the rotating and sliding surfaces of all parts with engine oil (EO-10CD) before assembling. ★ Always use the following parts as a set. i.
Cradle and rocker cam
ii. Cylinder block and valve plate ★ The disassembly procedure is the same for both the front and rear pumps, so the procedure for disassembly of the front pump is given below. If there are any differences, the different part is given.
1.
Cradle, piston assembly A. Fit dowel pin, then install rocker cam stopper (64) to cradle (65). Stopper bolt: Thread tightener (LT-2) (Loctite #262)
Stopper bolt: 13.24 ± 1.47 Nm (9.76 ± 1.08 lbf ft)
B. Fit dowel pin to cradle, set rocker cam (62) in position, then install plate (63). ★ Set the side of the rocker cam with the groove facing the oil hole in the cradle. Plate bolt: Thread tightener (LT-2) (Loctite #262)
Plate bolt: 30.89 ± 3.53 Nm (22.78 ± 2.60 lbf ft) ★ After tightening the bolts, check that the rocker cam moves smoothly.
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PISTON PUMP
12 C. Select spacer thickness as follows. i.
Assemble piston (60) to shoe retainer (58), then set on surface plate ④ and measure dimension a to top of shoe retainer.
ii.
Select spacer size as follows. Measured dimension a + (0.03 to 0.07 mm) ★ There are 3 types of spacer.
D. Fit spacer (59) selected in Steps C, i and ii, then install piston (60), shoe retainer (58), and retainer bearing (57). Bearing retainer bolt: Thread tightener (LT-2) (Loctite #262) Bearing retainer bolt: 13.24 ± 1.47 Nm (9.76 ± 1.08 lbf ft)
E. Hold rocker cam (69) in position, pull piston (60) with a force of 19.6 - 29.4 N (4.40 - 6.60 lbf), and measure clearance x between piston shoe and rocker cam. ★ When measuring, measure at position b or c of rocker cam (69), and measure for all 9 pistons. ★ Clearance x: 0.03 – 0.07 mm ★ If clearance x is not within the standard range, carry out the spacer adjustment again.
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PISTON PUMP
12 2. Shaft assembly A. Press fit inner race B (52) (inside diameter 45 mm) to shaft (41) using a press.
B. Fit bearing (68) and install inner race A (53).
C. Select washer as follows. i.
Install snap ring (55). ★ Check that the snap ring is not deformed or damaged, and remove any burrs. Install with the cut inside portion facing away from the inner race.
ii.
Use clearance gauge to measure clearance d between snap ring (55) and inner race. ★ Push the snap ring securely into the groove on the opposite side from the inner race.
iii. Select washer of following thickness and install. Thickness = measured thickness + (0 to 0.1 mm). ★ Check that there is no play between snap ring (55) and washer (54). There are 3 types of washer. Washer: 2.0 mm, 2.1 mm, 2.2 mm
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PISTON PUMP
12 D. Install drive shaft (41) to cradle (65).
E. Install oil seal (50) to housing (40). Lip of oil seal: Grease (G2-LI)
F.
Fit O-ring and shim (39), and install housing (40) to cradle. Mount bolt: 30.89 ± 3.43 Nm (22.78 ± 2.60 lbf ft) ★ Wind the shaft with tape to prevent damage to the lip surface of the oil seal. ★ Install the cover of the rear pump. Cover mount bolt: 110.32 ± 12.26 Nm (81.36 ± 9.04 lbf ft)
Remark Do not install the control pump to the rear pump at this point. If it is installed, it will be impossible to prevent the shaft from turning when adjusting the bearing end play.
G. Select housing shim as follows. i.
Push in drive shaft (41) completely, then measure end face dimension e of cradle and bearing outer race.
ii.
Measure dimension f of housing (40).
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PISTON PUMP
12 iii. Select shim of following thickness. ★ Shim thickness = f - e = g + (0.05 to 0.15) mm ★ This will produce a clearance of 0.05 to 0.15 mm at portion h.
★ With the rear pump, install collar (66) to control pump (67), then measure dimension j of collar. (HPV090+090 only) ★ Measure the dimension of the collar portion of the cover on the HPF pump.
3.
Cylinder block Align with drive shaft and piston, and install cylinder block (35). ★ The valve plate forms a set with the cylinder block, so always mark with a distinguishing mark and keep as a set. ★ Install the spring and washer inside the cylinder block after adjusting the bearing preload.
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PISTON PUMP
12 â&#x2DC;&#x2026; The length from the center is different for the side where the spring is fitted and the side where no spring is fitted.
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PISTON PUMP
12 4. Servo piston (HPV090+090 only) A. Install pump case (33) to tool Y1. B. Install servo piston (32). ★ The servo pistons for the front and rear pumps are different parts, so be careful not to mistake them when installing. ★ See the diagram on the next page.
C. Adjust servo piston stroke as follows. i.
Align groove k for servo valve arm of servo piston with dowel pin, then set on tool Z. ★ The right side as seen from the rear (the side with the spring, the top when mounted on the machine) is the maximum angle side.
Remark Use the same tool and turn it over for the rear pump.
ii.
Measure dimension n between servo piston and case.
iii. Measure dimension p of cap (29). iv. Calculate shim thickness from dimension p of cap and dimension n of servo as follows to give a clearance of ± 0.05 mm. Shim thickness: p - n = q ± 0.05 mm ★ Keep the adjusted shim and the cap as a set.
★ When adjusting the minimum angle side, replace tool Z with the minimum angle tool, and repeat the procedure in Steps i - iv above. Remark Note that the direction of the case is the opposite from the maximum angle.
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PISTON PUMP
12
4.
Servo piston (HPF pump only) A. Install servo piston (32). ★ When installing the servo piston, set the shallow notch on the inside (the end where the spring is installed on the HPV pump) facing the left side as seen from the rear of the pump. B. Position servo piston as follows. i.
Align with servo piston groove k and dowel pin, then set tool Z in position. ★ It is offset from the center to the left side as seen from the rear of the pump.
ii.
Measure dimension n between servo piston and case.
iii. Measure dimension p of cap (29). iv. Calculate shim thickness from dimension p of cap and dimension n of servo as follows. Shim thickness: p - n = q ± 0.05 mm ★ Keep the adjusted shim and the cap as a set. ★ Assemble a spacer on the right side as seen from the rear of the pump, and measure. When measuring, push the spacer securely against the piston.
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PISTON PUMP
12
5.
Pump sub-assembly A. Install slider (38) and O-ring. ★ Fit the O-rings to the pilot portion and the joint portion. B. Install 2 joints to case. ★ Set with the small hole facing the cradle. C. Align slider with servo piston, support cylinder block and shaft, then install pump sub-assembly (49). ★ Be careful not to get the O-ring caught. Mount bolt: 112.78 ± 9.81 Nm (83.1 ± 7.2 lbf ft) ★ For the rear pump, set on the other plate and assemble.
6.
Adjusting of bearing end play A. Install following parts to end cap. i.
Install bearing (48) (outer diameter 42 mm). Bearing mount surface: Grease (G2-LI)
ii.
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Install outer race (46) to end cap (42). ★ Be careful not to damage the rolling surface of the roller.
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DISASSEMBLY AND ASSEMBLY
PISTON PUMP
iii. Coat with engine oil, align with pin and bearing, then install valve plate (45). iv. Install joint (44). ★ Set with the small hole facing the case. Install the joint with only one hole to the suction port end.
B. Install end cap (42) to case (33). Mount bolt: 68.65 ± 4.9 Nm (50.5 ± 3.6 lbf ft) (front) Mount nut: 235.36 ± 19.61 Nm (173.5 ± 14.4 lbf ft) (rear) Stud bolt: 132.39 ± 14.71 Nm (97.6 ± 10.8 lbf ft) (Tighten the nut of the stud bolt.)
C. Install bearing (21) and inner race (20).
D. Assemble any one of 5 types of washer (14), then install snap ring (13). E. Select and install washer so that clearance r between snap ring and washer is 0 - 0.01 mm.
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PISTON PUMP
12 F.
Set dial gauge ➁ to case, move shaft to front and rear, and measure end play. ★ End play: 0.1 - 0.3 mm ★ If the end play is not within the standard range, carry out the shim selection again.
G. After completion of measurement, remove end cap. ★ Be careful not to drop the valve plate when removing the end cap.
★ With the rear pump, after tightening the bolts, for holding the cradle bearing in position, install the control pump, set dial gauge ➁ to the end cap and measure. ★ HPV090+090 only
7.
End cap A. Assemble spring (37) and washer (36) to cylinder block (35), then install snap ring (34). ★ Be careful not to damage the contact surface of the valve plate. B. Install end cap. ★ For details, see Steps 6, A, iii, iv and B.
C. Fit bearing (21), inner race (20), spacer (18), boss (16), shim (15), plate (14) and tighten bolt (13). Bolt: Thread tightener (LT-2)
Bolt: 68.65 ± 4.9 Nm (50.6 ± 3.6 lbf ft)
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PISTON PUMP
12 ★ With the rear pump, fit an O-ring and install control pump assembly (40). (HPV090+090 only) Mount bolt: 112.78 ± 9.81 Nm (83.1 ± 7.2 lbf ft)
8.
Servo piston cap (HPV090+090 only) A. Install spring (31). ★ Install to the right side as seen from the rear of the pump (the top when installed on the machine). (The rear pump is the same.)
B. Fit shim (30) and O-ring, and install cap (29). C. Fit shim (28) and O-ring, then using forcing screw ➂ (Thread dia. = 10 mm, Pitch = 1.5 mm) and nut ④, install cap (27). ★ Use a forcing screw for HPV090+090 only. ★ Be careful not to change the cap and shim set when installing. Mount bolt: 68.65 ± 4.9 Nm (50.6 ± 3.6 lbf ft)
9.
Servo valve (HPV090+090 only) Fit O-ring and align arm with piston, then install servo valve assembly (12). ★ Be careful not to drop the O-ring. Tighten the bolts gradually on opposite sides in turn. Mount bolt: 30.89 ± 3.43 Nm (22.7 ± 2.5 lbf ft)
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PISTON PUMP
12 10. Adjusting impeller shim A. Install impeller (8) to coupling (26). Mount bolt: Thread tightener (LT-2)
Mount bolt: 4.9 ± 0.49 Nm (3.6 ± 0.36 lbf ft)
B. Adjust clearance between impeller and end cap portion s as follows. i.
Measure thickness t of plate (9).
ii.
Assemble plate (9) to coupling (26), and install impeller. ★ Check that the impeller and portion s of the end cap are in contact.
iii. Measure dimension from end face of coupling to end face of plate (9). iv. Measure dimension from end face of coupling to end face of shaft (41). v.
Calculate shim thickness from dimensions t, u and v as follows. Shim thickness = v – (u + t) + (0.5 ± 0.1) mm
vi. Assemble shim selected in Steps i - v, then install impeller (8). Mount bolt: Thread tightener (LT-2)
Mount bolt: 66.19 ± 7.35 Nm (48.8 ± 5.4 lbf ft)
vii. Check clearance w between impeller and end cap. ★ Clearance w: 0.5 ± 0.1 mm ★ If it is not within the standard range, adjust the shims again. C. Check for interference of impeller (8) and rear end cap as follows. i.
Measure dimension x of rear cap end face.
ii.
Measure protrusion dimension y of impeller vane from front end cap.
iii. Check that measured dimension is x > y. If the above dimensions are y > x, there is no clearance at portion a. This means that the impeller vane will contact the rear end cap, so repeat Step 10, B and carry out adjustment of shim (17) again.
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PISTON PUMP
12 D. Install selected spacer (10) to rear pump. E. Fit selected spacer (9) to front pump and install impeller (8).
11. Rear pump assembly A. Install each O-ring to front and rear end caps. B. Raise rear pump assembly (7), then align spline and install. Mount nut: 235.36 ± 19.61 Nm (173.5 ± 14.4 lbf ft) Stud bolt: 132.39 ± 14.71 Nm (97.6 ± 10.8 lbf ft) ★ Only HPV090+090 has a gear pump.
12. ES valve assembly, hoses (HPV090+090 only) A. Fit O-ring and install ES valve assembly (3). B. Install hoses (4)and (5).
★ Checking quality after completion of assembly After completing assembly of the pump assembly, use a test stand (A type or C type) and check the quality. ★ For details of the procedure for checking the quality, see the Testing Method.
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PISTON PUMP
12 CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE 1.
Checking contact between cylinder block and valve plate. A. Make a centering tool for the cylinder block and valve plate. ★ The tool can be made of a soft material such as plastic or bakelite. B. Remove grease from the parts to be checked. ★ Do not wipe with a cloth.
C. Set the tool in position, and coat the cylinder block side with inspection paint. ★ Apply the paint thinly. D. Put the valve plate on top, push with a force of 39 - 49 N (8.7 11.01 lbf), and rotate 2 - 3 times. E. Remove the valve plate, transfer the contact surface to tape, and check the contact surface. ★ The standards for the contact surface are as follows.
2.
Valve plate
a. Seal
Min.80%
Cylinder block
a. Seal
Min.80%
Checking contact between rocker cam and cradle. A. Remove grease from the parts to be checked. ★ Do not wipe with a cloth. B. Set the tool in position, and coat the cradle side with inspection paint. ★ Apply the paint thinly. C. Put the rocker cam on top, push with a force of 39 - 49 N (8.7 11.01 lbf), and move 2 - 3 times from the stopper contact position to the maximum angle. D. Remove the rocker cam, transfer the contact surface to tape, and check the contact surface. ★ The standards for the contact surface are as follows. Pump Model
Dimension a
Contact surface
Contact b from a to outside
HPV090
72 mm
Min. 80%
Min. 50%
★ If there is no contact at the center but only at the outside, the contact is no good. Reference: If the contact is not within the contact standard value, when carrying, always lap both parts together. ★ Parts with scratches cannot be reused.
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PISTON PUMP
12
MEMORANDUM
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HYDRAULIC TANK
12
HYDRAULIC TANK REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. ★ When disassembling and assembling the hydraulic devices, observe the following points to protect them. • Before disassembling, clean the vehicle body. In particular, clean around the devices to be disassembled. • When disassembling and assembling, do not let foreign matter in the hydraulic circuit. • Clean the parts. In particular, clean the circuits and parts of a troubled section very carefully. • After disassembling or cleaning, mask the openings of the piping and hydraulic parts.
WARNING! Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work equipment control lever 2 - 3 times to release the residual pressure from the piping. 1.
Draining oil Remove plug (1) and loosen plug (2) to drain hydraulic oil. Hydraulic oil: 490 L (129.5 gal)
2.
Remove step (3) from top of hydraulic tank. Step: 150 kg (331 lb)
3.
Remove ladder (4) from hydraulic tank (11). Ladder: 45 kg (100 lb)
4.
Disconnect tube (5) between hydraulic tank and hydraulic pump from hydraulic tank.
5.
Disconnect tube (6) between hydraulic tank and diverter valve.
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HYDRAULIC TANK
12 6. Remove tube (7) between hydraulic oil cooler and hydraulic tank. ★ Remove the tube mount bolts on the tank side and hydraulic oil cooler side to remove the tube. 7.
Remove tube (8) between diverter valve and hydraulic tank. ★ Disconnect the joint hose and remove the bolt on the tank side to remove tube.
8.
Remove tube (9) between work equipment control valve and hydraulic tank. ★ Remove bracket (10) and disconnect hose (split flange) connected to work equipment valve.
9.
Sling hydraulic tank assembly (11) temporarily.
10. Remove mount bolts (12) and (13) to remove hydraulic tank assembly (11).
★ Sling the hydraulic tank assembly slowly and move it outward horizontally to prevent it from interfering with the tubes. Hydraulic tank assembly: 665 kg (1467 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 824.0 - 1030.0 Nm (607.75 - 759.68 lbf ft) •
Refilling with oil A. Add oil through oil filler to specified level. B. Before starting engine, bleed air from steering pump, switching pump, and loader pump. (See TESTING AND ADJUSTING, Bleeding air from each part.) C. Run engine to circulate oil through system.Then, check oil level again. Hydraulic oil: 490 L (129.44 gal)
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PPC VALVE
12
PPC VALVE REMOVAL WARNING! Stop the machine on level ground and install the safety bar to the frame. Lower the work equipment to the ground and stop the engine and apply the parking brake, then put blocks under the wheels to prevent the machine from moving. ★ Observe the following points to protect the hydraulic equipment when disassembling and assembling it. • Before disassembling, clean the machine body, particularly around disassembling portions. • When disassembling and assembling the hydraulic equipment, do not let dust get into the hydraulic circuit. • Clean the parts, particularly the circuits and parts in the trouble section. • Before disassembling or after cleaning the hydraulic equipment, mask the all openings of the piping and hydraulic parts.
WARNING! Loosen the oil filler cap to release the pressure from the hydraulic tank, then operate the work equipment control lever over TILT and NEUTRAL at least 40 times to release the pressure from the accumulator and piping. 1.
Cover Remove the cover form the rear of the cab and console box cover (1) from the right side of the operator’s seat.
2.
Remove nut (2), then disconnect rod (3).
3.
Pull out pin (4), then disconnect plate (5) from lever (7).
4.
Remove nut (6), then remove lever (7). ★ Similarly, remove the nut and lever on the opposite side.
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PPC VALVE
12 5. Disconnect hose (8) between the PPC valve and control valve. (Identification color: Yellow) 6.
Disconnect hose (9) between the PPC valve and control valve. (Identification color: Blue)
7.
Disconnect hose (10) between the PPC valve and control valve. (Identification color: Green)
8.
Disconnect hose (11) between the PPC valve and control valve. (Identification color: Red)
9.
Disconnect hose (12) between the PPC valve and accumulator. (Identification color: White)
10. Disconnect PPC valve drain hose (13). 11. Remove mount bolt (14), then remove PPC valve (15). ★ Plug the disconnected hoses to prevent dirt from entering them.
INSTALLATION • •
Carry out installation in the reverse order to removal. Refilling with oil Add oil to the specified level of the hydraulic tank.
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DISASSEMBLY AND ASSEMBLY
PPC VALVE
12 DISASSEMBLY 1.
Remove snap ring (13).
2.
Remove retainer (14), spring (15), and valve (16) from body (17).
3.
Remove bolt (1), then remove plate (2).
4.
Remove seal (3), then remove collar (4).
5.
Remove piston (5).
6.
Disassembly of piston
7.
Remove the following parts from piston assembly (6). A. Push down retainers (8), and remove collar (7). B. Remove retainers (8), main spring (9), spring (10), shim (11), and piston (12).
ASSEMBLY 1.
Assembly of piston Assemble the following parts to piston (12). A. Assemble shim (11), spring (10), and main spring (9). B. Push down retainer (8), and install collar (7).
2.
Assemble valve (16), spring (15), and retainer (14) to body (17).
3.
Install snap ring (13).
4.
Assemble piston assembly (6).
5.
Install piston (5), then install collar (4) and seal (3).
6.
Align with dowel pin, and install plate (2), then install bolt (1). Bolt: 44.1 Âą 4.9 Nm (32.5 Âą 3.6 lbf ft)
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WORK EQUIPMENT CONTROL VALVE
12 WORK EQUIPMENT CONTROL VALVE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Release residual pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Drain hydraulic oil. Hydraulic oil: 490 L (129.5 gal)
2.
Remove cover (1) under bucket cylinder.
3.
Disconnect hose (2) connected to demand valve. ★ This hose is connected through a block on the way.
4.
Disconnect tubes (3) and (4) connected to boom cylinder bottom.
5.
Disconnect tubes (5) and (6) connected to boom cylinder head.
6.
Disconnect clamps (7) and (8).
7.
Disconnect tube (9) connected to hydraulic tank. ★ This tube is connected to a hose on the way.
8.
Disconnect tube (10) connected to boom cylinder head and tube (11) connected to boom cylinder bottom. ★ Take care since the clamps have been disconnected.
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CONTROL VALVE
12 9. Remove step (12). 10. Disconnect hose (13) connected to bucket cylinder head from tube. 11. Disconnect clamp (14) from front frame. 12. Disconnect hose (15) connected to bucket cylinder bottom from tube. 13. Disconnect clamp (16) from front frame.
14. Disconnect tube (17) connected to bucket cylinder bottom and tube (18) connected to bucket cylinder head. ★ Take care since the upper clamps have been disconnected. 15. Disconnect PPC hose (19) (Dump bucket), (20) (Raise boom), 21 (Tilt bucket), and 22 (Lower boom). 16. Remove mount bolts and lift off work equipment valve assembly (23).
Work equipment valve assembly: 95 kg (209.4 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 245.0 - 309.0 Nm (108.7 - 227.9 lbf ft) •
•
Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CONTROL VALVE
12 DISASSEMBLY 1.
Remove hose (2), T-piece (3) and valve (4) from valve body (1).
2.
Remove hose (5), T-piece (6) and joint (7) from valve body (1).
3.
Remove suction valve (8) and 2 safety valves (9) having the suction tube from valve body (1). â&#x2DC;&#x2026; Since the safety valve cannot be adjusted actually, do not disassemble it.
4.
Remove plug (10) from the valve body.
5.
Remove main relief valve (11) from valve body (1).
6.
Remove plate (12) from valve body (1), then remove spring (13) and check valve (14).
7.
Remove flange (15) from valve body (1), then remove spring (16), seal (17) and valve (18).
8.
Remove elbows (19) and (20) from cases (21) and (26).
9.
Remove case (21) from valve body (1). then remove springs (22) and (23), retainer (24) and spool (25).
10. Remove case (26) from valve body (1), then remove springs (27) and (28) and retainer (29). 11. Remove plug (30) from valve body (1).
12. Loosen nut (33) of main relief valve (11), then divide it into holder (31A) and sleeve (32A).
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CONTROL VALVE
12 13. Remove nut (33) from holder (31A). 14. Remove nut (34) from holder (31A), then remove screw (35), retainer (36), spring (37) and puppet (38).
15. Remove seat (39) and backup ring (40) from sleeve (32A). 16. Remove snap ring (41) from sleeve (32A), then remove valve (42), spring (43) and backup ring (44). â&#x2DC;&#x2026; If sleeve (32) or valve (42) has any trouble, replace as a set, since those parts are not supplied independently.
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WA700-3L
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CONTROL VALVE
12 ASSEMBLY 1.
Assembly of sleeve (32A) A. Install backup ring (44), spring (43) and valve (42) to sleeve (32), then secure them with snap ring (41). B. Install the O-ring to seat (39), then install them and backup ring (40) together to sleeve (32).
2.
Assembly of holder (31A) A. Install the O-ring and puppet (38), spring (37), retainer (36) and screw (35) to holder (31). B. Install nut (33) to holder (31A)
3.
Install holder (31A) to sleeve (32A), then lock them with nut (33).
4.
Insert retainer (29), springs (28) and (27) in valve body (1). Install the O-ring to case (26), then install them to the valve body.
5.
Insert spool (25), retainer (24) and springs (23) and (22). Install the Oring to case (21), then install them to the valve body.
6.
Install elbows (19) and (20) to cases (21) and (26). Elbows (19), (20): 96.7 ± 12.3 Nm (71.3 ± 9.0 lbf ft)
7.
Install plug (30) to valve body (1). Plug (30): 152 ± 24 Nm (112.1 ± 17.7 lbf ft)
WA700-3L
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CONTROL VALVE
8.
Insert valve (18), seal (17) and spring (16) in valve body (1), then install the O-ring to flange (15).
9.
Insert check valve (14) and spring (13) in valve body (1), then install the O-ring to plate (12).
10. Install main relief valve (11) to valve body (1). Main relief valve (11): 324 ± 44 Nm (238.9 ± 32.4 lbf ft)
11. Install plug (10) to valve body (1). Plug (10): 68.6 ± 9.8 Nm (50.5 ± 7.2 lbf ft)
12. Install safety valve (9) having the suction tube to valve body (1). Safety valve having suction tube (9): 186 ± 10 Nm (137.1 ± 7.3 lbf ft) 13. Install suction valve (8) to valve body (1). Safety valve having suction tube (9): 186 ± 10 Nm (137.1 ± 7.3 lbf ft) 14. Install joint (7) and T-piece (6) to valve body (1), then connect hose (5) between elbow (20) and T-piece (6). ★ When clamping the hose, be careful not to twist it. 15. Install valve (4) and T-piece (3) to valve body (1), then connect hose (2) between elbow (19) and T-piece (3). Valve (4): 68.7 ± 9.8 Nm (50.6 ± 7.2 lbf ft) T-pieces (31, (6): 34.3 ± 4.9 Nm (25.2 ± 3.6 lbf ft) Hoses (21, (5): 49.0 ± 19.0 Nm (36.1 ± 14.0 lbf ft) Joint (7): 34.3 ± 4.9 Nm (25.2 ± 3.6 lbf ft)
30-216 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
DUMP CYLINDER
12 DUMP CYLINDER
REMOVAL WARNING! Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving.
1.
Disconnect grease hose (1).
2.
Remove lock bolt (2), then remove pin (3). ★ Temporarily sling the cylinder. ★ Start the engine and retract the piston. WARNING! After retracting the piston, stop the engine and release the pressure from the piping.
3.
Disconnect bucket positioner piping connector (4) (F05).
4.
Disconnect hose (5) on the head side.
5.
Disconnect hose (6) on the bottom side.
6.
Remove clamp (8), then disconnect and remove grease tube (7).
7.
Remove lock bolt (9), then remove pin (10).
8.
Sling dump cylinder (11) and lift it off. ★ Check the quantity of the shims. Dump cylinder: 945 kg (2083.4 lb)
INSTALLATION •
Carry out installation in the reverse order to removal. WARNING! When aligning the position of the pin hole, use a bar. Never insert your fingers in the pin hole.
•
Adjustment of shim Adjust the clearance on each side of the bottom to 1.5 mm or less.
WA700-3L
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DISASSEMBLY AND ASSEMBLY
LIFT CYLINDER
12
LIFT CYLINDER REMOVAL WARNING! Stop the machine on level ground and install the safety bar to the frame, then put blocks under the wheels to prevent the machine from moving. 1.
Remove the bucket. For details, see BUCKET - REMOVAL.
2.
Remove fender (1). Fender: 170 kg (375 lb)
3.
Raise the lift arm until the pin on the cylinder head side can be pulled out, then sent stand ➀. WARNING! After stopping the engine, lower the lift arm slowly to eliminate the load on the lift cylinder.
WARNING! Loosen the cap of the hydraulic tank slowly to release the pressure from the hydraulic tank. 4.
Temporarily sling lift cylinder (3). ★ Be careful not to damage the tubes.
5.
Remove lock bolt (4), then pull out pin (5).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
LIFT CYLINDER
12 6. Retract piston rod (6). WARNING! After retracting the piston rod, stop the engine and release the pressure from the piping. 7.
Disconnect hose (7) on the bottom side and hose (8) on the head side.
8.
Remove lock bolt (9), then pull out pin (10).
9.
Sling lift cylinder (3) and lift it off.
★ Check the quantity of the shims. Lift cylinder: Approximately 1000 kg (2205 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Match the holes on the bottom side by assembling shims so that the clearance between the cylinder and frame will be in the specified range. Clearance a + b = 1.5 mm max.
WARNING! When aligning the position of the pin hole, use a bar. Never put your fingers in the pin hole.
WA700-3L
30-219 1
DISASSEMBLY AND ASSEMBLY
STEERING, LIFT, DUMP CYLINDER
12
STEERING, LIFT, DUMP CYLINDER DISASSEMBLY 1.
Cylinder assembly A. Set cylinder assembly (1) on tool U1.
B. Remove mount bolts (2) of head cover. Width across flats: Steering cylinder (24 mm) Dump cylinder (55 mm) Lift cylinder (41 mm)
C. Pull out piston rod (3) from cylinder. ★ When pulling out the rod, the oil remaining inside the cylinder will come out, so catch it in a container. ★ If the piston rod cannot be pulled smoothly out of the cylinder, rotate the piston rod slightly when pulling out. Steering cylinder piston rod assembly: 159 kg (351 lb)
Dump cylinder piston rod assembly: 945 kg (2084 lb)
Lift cylinder piston assembly: 674 kg (1486 lb)
★ Remove the cylinder from tool U1. 2.
Piston rod A. Remove spacer mount bolts (4), then remove spacer (5). B. Pull out piston (6) and head cover (19). C. Remove O-ring (8) and backup rings (7) and (9) from piston rod (3).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
STEERING, LIFT, DUMP CYLINDER
12 3. Piston A. Remove wear ring (10) from piston (6). B. Remove piston ring (11).
4.
Head cover A. Remove O-ring (12) and backup ring (13). B. Remove snap ring (14), then pull out dust seal (15), rod packing (16), buffer ring (17), and bushing (18) from head cover (19).
WA700-3L
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DISASSEMBLY AND ASSEMBLY
STEERING, LIFT, DUMP CYLINDER
12 ASSEMBLY ★ Coat the sliding surfaces of all parts with hydraulic oil before installing. Be careful not to damage U-packings, dust seals or O-rings when installing. 1.
Head cover A. Press fit bushing (18) in head cover (19), and install backup ring (17), rod packing (16), dust seal (15), and snap ring (14). ★ Be careful not to deform the bushing when press fitting. B. Install backup ring (13) and O-ring (12) to head cover (19). ★ Do not try to force the backup ring into position. Warm it in warm water (50 to 60° C) before fitting it.
2.
Piston A. Set piston ring (11) on tool U4 and expand it. ★ Set the piston ring on the expander and turn the handle 8 - 10 times to expand the ring. B. Remove piston ring. (11) from tool, and install on piston (6). C. Set ring ➀ of tool U5, then using clamp ➁, tighten piston ring (11). ★ Ring Part No. 796-720-1670 (Steering cylinder) 796-720-1720 (Lift cylinder) 796-720-1730 (Dump cylinder) ★ Clamp Part No. 07281-01279 (Steering cylinder) 07281-02429 (Lift cylinder) 07281-02909 (Dump cylinder) D. Install wear rings (10) to piston (6).
3.
Piston rod A. Install head cover (19) to piston rod (3). B. Install O-ring (8) and backup rings (7) and (9) to rod. ★ Coat the backup ring with grease to prevent it from protruding, and assemble it carefully. Backup ring, O-ring: Grease (G2-LI)
30-222 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
STEERING, LIFT, DUMP CYLINDER
12 C. Install piston (6). D. Set spacer (5) in position, and tighten spacer mount bolts (4). ★ Remove all oil and grease from the mount bolts and mount holes. Mount bolt: Adhesive (Loctite 262)
Mount bolt: (Steering cylinder) 110 ± 12.3 Nm (81.1 ± 9.0 lbf ft) Mount bolt: (Dump cylinder) 277 ± 31.9 Nm (204.3 ± 23.5 lbf ft)
Mount bolt: (Lift cylinder) 177 ± 19.6 Nm (130.5 ± 14.4 lbf ft) 4.
Cylinder assembly A. Set cylinder in tool U1. B. Assemble piston rod (3) in cylinder. C. Tighten head cover mount bolts (2). ★ Coat the O-ring and backup ring on the cover side with grease. Steering cylinder mount bolt: 220 ± 81 Nm (162.2 ± 59.7 lbf ft) (width across flats: 24 mm) Dump cylinder mount bolt: 2450 ± 245 Nm (1807.0 ±180.7 lbf ft) (width across flats: 55 mm) Lift cylinder mount bolt: 1180 ± 294 Nm (870.3 ± 216.8 lbf ft) (width across flats: 41 mm) D. Remove cylinder assembly (1) from tool U1.
WA700-3L
30-223 1
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12
CENTER HINGE PIN REMOVAL ★ Before starting the following work, remove the bucket. WARNING! Stop the vehicle on level ground and install safety bar ➀ to the frame and put blocks under the wheels to prevent the vehicle from moving.
WARNING! Release residual pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. WARNING! Disconnect the cable from the negative (-) terminal of the battery.
1.
Removal of floor frame assembly Remove floor frame assembly. For details, see FLOOR FRAME REMOVAL.
2.
Removal of pins on head side of both steering cylinders • Remove grease fitting (1). • Remove 2 mount bolts (2).
• •
Remove plate (3). Remove 3 plate mount bolts (5) and 2 pin mount bolts (6).
•
Remove plate (7).
•
Pull out pin (8), then remove bushings (4) and (9).
•
★ Apply a pad to the top of pin (8) and drive out the pin with a large hammer, or press it out with a jack from underside. Check the place and quantity of shim (11), then remove it.
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WA700-3L
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 3. Hydraulic piping • Disconnect hose (12) between work equipment valve and hydraulic tank. • Disconnect hose (13) between diverter valve and demand valve. • Disconnect hose (14) between loader pump and work equipment valve. • Disconnect hose (15) between loader pump and block (to divide flow into 2 for demand valve and work equipment valve). • Disconnect hoses (16) and (17) between switching pump and demand valve. • Disconnect hose (18) between demand valve and work equipment oil cooler. 4.
PPC, steering, and brake piping • Disconnect hose (19) between brake valve and front slack adjuster.
• • • • •
5.
Disconnect hose (20) between left steering stop valve and demand valve. Disconnect hose (21) between accumulator and parking brake solenoid valve. Disconnect hose (22) between brake oil tank and parking brake solenoid valve. Disconnect hose (23) between right steering stop valve and demand valve. Disconnect hoses (24) (Dump bucket), (25) (Lower boom), (26) (Raise boom), and (27) (Tilt bucket) between PPC valve and work equipment valve.
Drive shaft Lift off center drive shaft (28).
Center drive shaft: 90 kg (198.4 lb)
★ Remove the drive shaft guard in advance. 6.
Frame support A. Set jacks under both sides of front and rear frames and raise them and put blocks ➀ and ➁ under them.
WA700-3L
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DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 B. Put blocks ➂ in counterweight. C. Using lever block, move hydraulic hoses to right of vehicle.
7.
Lower hinge pin A. Remove the mount bolts to remove retainer (29).
★ Check the number and thickness of the shims between the retainer and frame.
B. Install hanging bolt to lower hinge pin (30), and lift off hinge pin. Lower hinge pin: 48 kg (106 lb)
★ Remove bolt (31) from the hinge pin, and install the hanging bolt instead.
C. Remove spacer (32).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 8. Upper hinge pin A. Remove mount bolts (33) and (34) to remove retainer (35).
B. Install hanging bolt ④ to upper hinge pin (36), and lift of hinge pin. Upper hinge pin: 30 kg (67 lb)
9.
Disconnection of frame Remove safety bar and move front frame forward to disconnect it. ★ Take care that the spacer above the lower hinge will not be caught in the rear frame. ★ Work carefully, balancing the frame. ★ Limit the movement of each time to about 100 mm. ★ Remove spacer (37) from the rear frame.
10. Lower hinge A. Remove mount bolts to remove retainer (38).
★ Check the number and thickness of the shims between the retainer and frame.
WA700-3L
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DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 B. Remove dust seal (39) from retainer.
C. Remove spacer (40) from front frame.
D. Remove plate (41) from front frame to remove dust seal (42).
E. Remove bearing (43).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 11. Upper hinge A. Remove retainer (44).
â&#x2DC;&#x2026; Check the number and thickness of the shims between the retainer and frame.
B. Remove dust seal (45) from retainer.
C. Remove plate (46) from front frame to remove dust seal (47).
D. Remove bearing (48).
WA700-3L
30-229 1
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 INSTALLATION 1.
Carry out installation in the reverse order to removal.
Mount bolt: Liquid adhesive (LOCTITE 262)
Mount bolt: 157 - 196 Nm (115.7 - 144.5 lbf ft)
★ Set the slit in the lateral direction of the vehicle body.
★ Adjust the clearance in the cylinder fitting parts to the specified value with shims. a + b = 1.0 mm max.
★ Bleeding air Bleed air from the brake system. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
Drive shaft mount bolt: 176.5 ± 19.6 Nm (130.1 ± 14.4 lbf ft)
★ Outside of lower hinge pin: Lubricant (G2-LI) ★ Install the retainer to the lower hinge pin without shim, and tighten it to the specified torque. ★ Jack up the front frame until the spacer comes in contact with the rear frame hinge. ★ Hit the lower hinge pin head with a copper hammer until the torque of the mount bolt reaches the specified level, then tighten to the specified torque. ★ Before installing the retainer, measure its thickness to select shims. Mount bolt: 549.0 ± 59.0 Nm (404.9 ± 43.5 lbf ft) ★ Remove the all mount bolts from the periphery and measure clearance c between the retainer and frame at 3 places, then obtain the average clearance. Select shims so that the average clearance will be 0.08 - 0.18 mm.
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WA700-3L
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 ★ The thickness of the selected shims must not exceed the clearance measured at the 3 places. ★ De grease the mount bolts and mount holes sufficiently. Mount bolt: Adhesive (LT-2)
Mount bolt: 927.0 ± 103.0 Nm (683.7 ± 75.9 lbf ft)
★ Insert the upper hinge pin and hit its head lightly 3 times with a copper hammer to fit it. ★ Do not apply grease to the fitting faces of the spacer, frame, and pin. Outside of hinge pin: Lubricant (G2-LI)
★ Hit the upper hinge pin head with a copper hammer until the torque of the mount bolt reaches the specified level, then tighten to the specified torque. ★ If the torque of the mount bolt is not increased to the specified level, grease, etc. may stick to the spacer. Accordingly, remove the grease and tighten again. Adhesive: (LT-2)
Mount bolt: 549.0 ± 59.0 Nm (404.9 ± 43.5 lbf ft)
★ ★ ★ ★ ★
Using tool K3, press fit the bearing and spacer to the front frame. Do not slant the bearing. Fill the bearing with sufficient amount of grease. When fitting the bearing, do not forget to install the spacer. Since the clearance of the bearing has been adjusted, do not change its mating spacer. ★ When the bearing needs to be replaced, replace it and the spacer as a set. ★ Press fit the dust seal with its lip side out. Dust seal lip surface: Lubricant (G2-LI)
WA700-3L
30-231 1
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 ★ Tighten the retainer with 10 mount bolts and insert shims so that clearance b between the retainer and hinge will be 0.08 - 0.18 mm less than the value measured at 4 places on the periphery. ★ The thickness of the selected shims must not exceed the clearance measured at the 4 places. ★ After selecting the shims, tighten the retainer to the specified torque. Mount bolt: 147.1 ± 14.7 Nm (108.4 ± 10.8 lbf ft) Mount bolt: 549.0 ± 59.0 Nm (404.9 ± 43.5 lbf ft) ★ Press fit the dust seal with its lip side out. Dust seal lip surface: Lubricant (G2-LI)
★ Install the spacer with its more chamfered side on the bearing side. Inside of spacer: Lubricant (G2-LI)
★ Install tool K1 to the top of the front frame upper hinge and set the bearing, then set them to the fitting part from above to press fit them. ★ Do not slant the bearing. ★ Fill the bearing with sufficient amount of grease. ★ When fitting the bearing, do not forget to install the spacer. ★ Since the clearance of the bear.ing has been adjusted, do not change its mating spacer. ★ When the bearing needs to be replaced, replace it and the spacer as a set. ★ Press fit the dust seal with its lip side out. Dust seal lip surface: Lubricant (G2-LI)
30-232 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
12 ★ Tighten the retainer with 6 mount bolts and insert shims so that clearance a between the retainer and hinge will be 0.08 - 0.18 mm less than the value measured at 4 places on the periphery. ★ The thickness of the selected shims must not exceed the clearance measured at the 4 places. ★ After selecting the shims, tighten the retainer to the specified torque. Mount bolt (For adjustment of shims): 78.5 ± 7.9 Nm (57.8 ± 5.8 lbf ft) Mount bolt: 549.0 ± 59.0 Nm (404.9 ± 43.5 lbf ft) ★ Press fit the dust seal with its lip side out. Dust seal lip surface: Lubricant (G2-LI)
•
Refilling with oil Add oil through oil filler to specified level. This is to bring system up to the required quantity, because of the loss of oil on disconnecting the hydraulic lines. Hydraulic oil: 490 L (129.44 gal) ★ Before starting the engine, bleed air from piston pump circuit, referring to TESTING AND ADJUSTING. ★ After bleeding air, run engine to circulate oil through system. Then, check oil level again.
WA700-3L
30-233 1
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12
WORK EQUIPMENT REMOVAL WARNING! Stop the vehicle on level ground and install the safety bar to the frame and put blocks under the wheels to prevent the vehicle from moving. 1.
Remove bucket link pin (1).
★ Remove the cord ring. ★ Secure the bucket link to the bell crank with wires, etc. ★ If the vehicle has been used for long hours and the pin is worn and cannot be removed easily, use tool V1 to remove it.
2.
Remove bucket mount hinge pin (2).
★ If the vehicle has been used for long hours and the pin is worn and cannot be removed easily, use tool V1 to remove it.
3.
Disconnect pin greasing hose (3).
4.
Sling dump cylinder (4) temporarily and pull out pin (5) to disconnect cylinder from bell crank. ★ Install a sling to the dump cylinder and secure to the ROPS so that it will not fall forward. ★ Move the vehicle back to disconnect the bucket. Dump cylinder assembly: 915 kg (2018 lb)
5.
Remove step (6).
6.
Disconnect lift cylinder head pin greasing hose (7).
7.
Disconnect lift arm pin greasing tube (8).
30-234 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12 8. Sling lift cylinder (9) temporarily and remove pin (10). ★ After removing the pin, retract the piston and slowly lower it to the block set on the front axle side. Lift cylinder assembly: 675 kg (1489 lb)
9.
Sling bell crank (11) temporarily, and remove pin (12) to disconnect bell crank from boom (13).
★ Remove the bell crank and bucket link together. Bucket link and bell crank assembly: 1800 kg (3969 lb)
★ If the vehicle has been used for long hours and the pin is worn and cannot be removed easily, use tool V1 to remove it.
10. Sling bucket link (14) temporarily, and pull out pin (15) to disconnect bucket link from bell crank (11).
★ Remove the cord ring. Link: 310 kg (684 lb)
★ If any shim is inserted, check its quantity.
11. Disconnect boom kick-out wiring connector (16) (F06) to remove kick-out switch (17).
WA700-3L
30-235 1
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12 12. Sling lift arm assembly (13), and pull out lift arm pin to disconnect lift arm assembly from front frame.
â&#x2DC;&#x2026; If any shim is inserted, check its quantity. Lift arm assembly: 5715 kg (12600 lb)
13. Pull dust sea (18) and bushing (19) out of lift arm (13).
14. Pull dust seal and bushing out of bell crank (11).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12 INSTALLATION 1.
Carry out installation in the reverse order to removal.
Bushing: Lubricant (LM-P)
★ Clearance i + j = 1.5 mm max. ★ Clearance B: 2.5 mm max. ★ Take care that cord ring (26) will not be caught.
Bushing: Lubricant (LM-P)
★ Clearance g + h = 1.5 mm max. ★ Clearance A: 2.5 mm max. ★ Take care that cord ring (25) will not be caught.
Bushing: Lubricant (LM-P)
★ Clearance e + f = 1.5 mm max.
Bushing: Lubricant (LM-P)
★ ★ ★ ★
Secure the link to the bell crank with wires, etc. Insert shims evenly on both sides. c + d = 1.5 mm max. Take care that the cord ring will not be caught.
WA700-3L
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12
Bushing: Lubricant (LM-PI)
★ Match the holes of the front frame and boom fitting hole, then insert shims so that the clearance will be even. ★ a + b = 1.5 mm max. ★ After installing the pin, set the support to the boom end. ★ Supply grease to each pin.
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WA700-3L
DISASSEMBLY AND ASSEMBLY
BULKHEAD
12 BULKHEAD
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Drain cooling water. Cooling water: 190 L (419 gal)
2.
Remove handrail (1).
3.
Remove exhaust tube (2).
4.
Lift off both side covers (3) and (4) and engine hood (5).
5.
Remove both side covers (6).
6.
Open bulkhead cover (7).
7.
Remove transmission inspection cover (8).
8.
Disconnect hose (9) between receiver tank and air conditioner unit.
â&#x2DC;&#x2026; Using tool X1 on the air conditioner compressor side, collect air conditioner refrigerant (R134a). 9.
Disconnect hose (10) between air conditioner compressor and condenser.
10. Disconnect window washer hose (11). â&#x2DC;&#x2026; Collect window washer detergent liquid from the tank. 11. Remove covers (12) and (13) from front of air cleaner.
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DISASSEMBLY AND ASSEMBLY
BULKHEAD
12 12. Disconnect high-temperature heater hose (14) (Outlet on engine side). 13. Disconnect low-temperature heater hose (15) (Return). ★ When the cooling water is not drained, close the valve and bend the hose at a point on the way, then disconnect and plug it.
14. Disconnect wiring connector (16) (BR1). 15. Remove covers (17) and (18) inside bulkhead. 16. Disconnect dust indicator wiring connectors (19) (B06, B07) and (20) (B08, B09).
17. Disconnect both supports (21) from bulkhead. 18. Remove mount bolts, then lift off bulkhead assembly (22). Bulkhead assembly: 235 kg (519 LB)
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Do not twist the hoses. ★ Do not let dirt, dust, water, etc. in the hoses. ★ Using tool X1, charge the air conditioner circuit with new refrigerant (R134a) •
Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.
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WA700-3L
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
12 FLOOR FRAME
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove front, rear, right, and left side covers (1) under cab.
2.
Remove ROPS cab assembly (2). For details, see CAB - REMOVAL. ROPS cab assembly: 1056 kg (2329 lb)
3.
Disconnect left brake valve drain hose (3) and right brake valve drain hose (4).
4.
Disconnect hose (5) between steering valve and right stop valve.
5.
Disconnect hose (6) between steering valve and left stop valve.
6.
Disconnect PPC valve drain hose (7).
7.
Disconnect hose (8) connected to PPC pump.
8.
Disconnect hoses (9) (Lower boom), (10) (Raise boom), (11) (Tilt bucket), and (12) (Dump bucket) connected to work equipment control valve.
9.
Disconnect stop valve drain hose (13). â&#x2DC;&#x2026; From the left stop valve to the block.
10. Disconnect hose (14) between right brake valve and front brake and hose (15) between right brake valve and rear brake.
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DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
12 11. Disconnect hose (16) between left brake valve and accumulator. 12. Disconnect hoses (17) and (18) between right brake valve and accumulator. ★ Before disconnecting these hoses, release the pressure from the accumulator. 13. Disconnect steering valve drain hose (19). 14. Disconnect hose (20) between steering valve and PPC relief valve.
15. Disconnect heater hoses (21) and (22) connected to air conditioner unit. ★ Plug the disconnected hoses. ★ Close the valves on the engine side. 16. Disconnect air conditioner hoses (23) and (24). ★ Using tool X1 on the air conditioner compressor side, collect air conditioner refrigerant (R134a). ★ Since the hose adapters are brittle, be sure to use double spanner to loosen them.
17. Disconnect 12 floor frame wiring connectors (25). ★ Connector No. LR1, 2, 3, 4, 5, 6, 7, 8 FR1, 2 LT1 GRE
18. Disconnect 2 window washer hoses (26). ★ These hoses have different colors. When connecting them again, observe their colors.
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DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
12 19. Disconnect ground cable (27). 20. Disconnect 4 nuts of floor frame mount (28).
21. Lift off floor frame assembly (29). ★ Checking that the all hoses, wires, etc. are disconnected, sling the assembly slowly. Floor frame assembly: 350 kg (772 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Mount nut: 245.0 - 308.7 Nm (180.7 - 227.6 lbf ft) •
Charging air conditioner with gas Using tool X1, charge the air conditioner circuit with refrigerant (R134a).
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DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
12
COUNTERWEIGHT REMOVAL WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1.
Sling counterweight (1), then remove mount bolts (2), and lift off.
★ When lifting off the counterweight, be careful to maintain the balance. Counterweight: 1040 kg (2293 lb)
2.
Sling counterweight (3), then remove mount bolts (4) and lift off.
★ When lifting off the counterweight, be careful to maintain the balance. Counterweight: 2510 kg (5534 lb)
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DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
12 INSTALLATION â&#x20AC;¢
Carry out installation in the reverse order of removal.
Mount bolt: 824 - 1030 Nm (607.7 - 759.6 lbf ft)
Mount bolt: 2460 - 3040 Nm (1814.4 - 2242.1 lbf ft)
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DISASSEMBLY AND ASSEMBLY
FUEL TANK
12
FUEL TANK REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Drain fuel. Fuel: Approximately 1060 L (280 gal) when full
2.
Remove handrail (1) on right side of engine.
3.
Remove bolt securing step (2) and battery box. â&#x2DC;&#x2026; Remove the bolt on the left side, too.
4.
Remove ladder handrail (3).
5.
Remove cover (4).
6.
Lift of ladder (5).
7.
Remove cover (6) at right top of fuel tank.
8.
Disconnect engine oil drain valve (7) and cooling water drain valve (8) from fuel tank.
9.
Remove cover (9) at left top of fuel tank.
10. Disconnect tube (10) between fuel tank and valve. 11. Disconnect tube (11) between valve and strainer. 12. Remove valve (12). 13. Disconnect hose (13) between fuel injection pump and fuel tank.
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DISASSEMBLY AND ASSEMBLY
FUEL TANK
12 14. Disconnect fuel level gauge wiring connector (14) (R05). 15. Disconnect hose clamp (15) from fuel tank. ★ Located at the left under the radiator.
16. Disconnect fuel spill hose (16). ★ Located under the engine oil bypass filter. 17. Set pallet ➀ under fuel tank. 18. Sling fuel tank assembly (17) temporarily and remove mount bolts.
★ Check the place and quantity of the shims on both sides of the fuel tank on the radiator side.
19. Lower fuel tank assembly (17) slowly to pallet. Fuel tank assembly: 650 kg (1433 lb)
★ Lower the fuel tank straight, taking care of the breather tube extended up.
INSTALLATION •
Carry out installation in the reverse order to removal.
Adjust the shims so that the clearance between the fuel tank and rear frame will be 0.5 mm maximum. Fuel tank mount bolt: 1520.1 - 1912.4 Nm (1121.09 - 1410.51 lbf ft)
•
Bleeding air After installing the fuel tank, bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
CAB
12
CAB REMOVAL WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1.
Remove covers (1) at bottom of floor frame.
2.
Remove the connector for the 24 V accessory power (CN-OP1). It is located behind a panel on the front, right side of the cab.
3.
Disconnect electric wiring connectors (3). Connectors: CN-CLI, CL2, CL3, CL4
4.
Disconnect window washer hose (4).
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DISASSEMBLY AND ASSEMBLY
CAB
12 5. Remove 2 steering post lock bolts (5).
6.
Remove plastic mount bolts and pull up rubber boot (6) at bottom of steering post.
7.
Remove 4 bolts (7), then tip steering post over fully towards operator’s seat. ★ At the same time, set the column tilt lever to the unlock position and tip the steering column over fully towards the operator’s seat.
8.
Remove 2 cab mount bolts (8) and 4 mount bolts (9) each at intermediate position and rear.
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DISASSEMBLY AND ASSEMBLY
CAB
12 9. Raise cab assembly (10) slowly and keep horizontal when lifting off.
★ Be careful that there is no interference with the electric wiring at the rear right of the floor frame. ★ Cover the steering post and plastic cover with a sheet to prevent any damage. Cab: 450 kg (993 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
When installing the cab assembly, do not forget to install the seal. ★ Coat the seal uniformly with adhesive. Seal: Adhesive (Cemedyne 366E)
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WA700-3L
DISASSEMBLY AND ASSEMBLY
STOP VALVE
12 STOP VALVE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Disconnect hose (1) connected to orbitrol.
2.
Disconnect hose (2) connected to steering valve.
3.
Disconnect return hose (3).
4.
Remove mount bolts to remove stop valve assembly (4).
INSTALLATION â&#x20AC;˘
Carry out installation in the reverse order to removal.
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DISASSEMBLY AND ASSEMBLY
ACCUMULATOR CHARGE VALVE
12
ACCUMULATOR CHARGE VALVE REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove brake oil tank cover (1).
2.
Disconnect tube (2) connected to brake oil tank.
3.
Disconnect hose (3) connected to brake valve.
4.
Disconnect hose (4) connected to brake pump.
5.
Disconnect tube (5) connected to brake oil tank.
6.
Disconnect hose (6) connected to brake valve.
7.
Remove mount bolts to remove accumulator charge valve assembly (7).
INSTALLATION • •
Carry out installation in the reverse order to removal. Bleeding air Bleed air from the circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
ACCUMULATOR CHARGE VALVE
12 DISASSEMBLY 1.
Remove PPC relief valve (2) from valve body (1).
2.
Remove O-ring (3) and 2 backup rings (4) from the PPC relief valve.
3.
Remove plug (6) from valve body (1), then remove spring (8) and spool (9).
4.
Remove the O-ring from plug (6). Remove bushing (10) from valve body (1).
5.
Remove snap ring (11), filter (12) and O-ring (13) from bushing (10).
6.
Remove locknut (14) from valve body (1), then remove adjustment screw (15).
7.
Remove retainer (16), spring (17), shim (18) and O-ring (19) from adjustment screw (15).
8.
Remove plug (20) from valve body (1), then remove retainer (21), piston (22) and valve seat (23).
9.
Remove O-ring (24) from plug (20).
10. Remove locknut (14) from valve body (1), then remove adjustment screw (15). 11. Remove ball (25), spring (26), shim (18) and O-ring (19) from adjustment screw (15). 12. Remove plug (27) from valve body (1), then remove orifice (28). 13. Remove snap ring (29) from valve body (1), then remove filter (30).
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DISASSEMBLY AND ASSEMBLY
ACCUMULATOR CHARGE VALVE
12 ASSEMBLY 1.
Insert filter (30) in valve body (1), then install snap ring (29).
2.
Install orifice (28) to valve body (1). Orifice: Loctite (#241)
Orifice: 3.14 - 3.9 Nm (2.3 - 2.8 lbf ft)
3.
Install plug (27). Plug: Three Bond (#1305)
4.
Install O-ring (19) to adjustment screw (15), then set shim (18), spring (26) and ball (25), and install them to valve body (1).
5.
Install locknut (14) to adjustment screw (15). Locknut: 9.8 - 11.8 Nm (7.2 - 8.7 lbf ft)
6.
Install valve seat (23), piston (22) and retainer (21) to valve body (1). Install O-ring (24) to plug (20), then install them. Plug: 30.4 - 37.3 Nm (22.4 - 27.5 lbf ft)
7.
Assemble O-ring (19) to adjustment screw (15). Set shim (18) and spring (17) and retainer (16), then install them to valve body (1).
8.
Install locknut (14) to adjustment screw (15). Locknut: 9.8 - 11.8 Nm (7.2 - 8.7 lbf ft)
9.
Insert filter (12) in bushing (10), then install snap ring (11).
10. Install O-ring (13) to bushing (10), then install them to valve body (1). Bushing: 29.4 - 39.2 Nm (21.6 - 28.9 lbf ft)
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DISASSEMBLY AND ASSEMBLY
ACCUMULATOR CHARGE VALVE
12 11. Assemble spring (7) to spool (8), then insert them in valve body (1). 12. Install O-ring (9) to plug (6), then install them to valve body (1). Plug: 53.9 - 68.6 Nm (39.7 - 50.5 lbf ft)
13. Install O-ring (5), backup ring (4) and ring (3) to PPC relief valve (2), then install them to valve body (1). PPC relief valve: 79 - 88 Nm (58.2 - 64.9 lbf ft)
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DISASSEMBLY AND ASSEMBLY PARKING BRAKE SOLENOID VALVE AND PRESSURE 12
PARKING BRAKE SOLENOID VALVE AND PRESSURE SWITCH REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove right inspection cover (1).
2.
Disconnect pressure switch wiring connector (2) (F12) and solenoid valve wiring connector (3) (F11).
3.
Remove pressure switch assembly (4).
4.
Remove solenoid valve assembly (5).
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Check the operation of the parking brake.
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DISASSEMBLY AND ASSEMBLY
DIVERTER VALVE
12 DIVERTER VALVE
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove drain valve (1), then loosen valve (2) gradually to drain hydraulic oil. Hydraulic oil: 490 L (129.4 gal)
2.
Disconnect emergency steering switch wiring connector (3).
3.
Disconnect hoses (4) and (5) between emergency steering pump and diverter valve.
4.
Disconnect tube (6) connected to steering circuit.
5.
Disconnect drain tubes (7) and (8) connected to hydraulic tank.
6.
Disconnect hose (9) connected to steering demand valve circuit.
7.
Lift off diverter valve assembly (10). Diverter valve assembly: 70 kg (154.3 lb)
INSTALLATION • •
•
Carry out installation in the reverse order to removal. Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY
DIVERTER VALVE
12 DISASSEMBLY 1.
Remove mount bolt (1), then disconnect selector valve (3) from check valve (2).
2.
Disassembly of check valve A. Remove spring (5) and check valve (4) from valve body (2).
B. Remove cover (6) from valve body (2), then remove spring (7) and check valve (8). C. Remove O-ring (9) and backup ring (10) from cover (6).
D. Remove cover (11) from valve body (2), then remove spring (12) and check valve (13). E. Remove O-ring (14) from cover (11), then remove backup ring (15).
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DISASSEMBLY AND ASSEMBLY
DIVERTER VALVE
12 3. Disassembly of selector valve A. Remove O-ring (17) and spool (18) from valve body (3).
B. Remove cover (19) from valve body, then remove spring (20) and retainer (21). C. Remove O-ring (22) from cover (19).
ASSEMBLY 1.
Assembly of check valve A. Assemble check valve (8) and spring (7) to valve body (2). B. Install backup ring (10) and O-ring (9) to cover (6), then install them to valve body (2).
C. Assemble check valve (13) and spring (12) to valve body (2). D. Install backup ring (15) and O-ring (14) to cover (11), then install them valve body (2).
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DISASSEMBLY AND ASSEMBLY
DIVERTER VALVE
12 E. Assemble check valve (4) and spring (5) to valve body (2). F.
Install the O-ring to selector valve body (3), then install bolt (1) to check valve (2). Mount bolt: 98.1 Nm (72.3 lbf ft)
2.
Assembly of selector valve A. Install spool (17) to valve body (3). B. Install O-ring (18) to valve body (3), then install cover (16). Mount bolt: 98 - 123 Nm (72.2 - 90.7 lbf ft)
C. Assemble retainer (21) and spring (20) to valve body (3). D. Install O-ring (22) to cover (19), then install them to valve body (3). Mount bolt: 58.8 - 73.6 Nm (43.3 - 54.2 lbf ft)
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DISASSEMBLY AND ASSEMBLY
EMERGENCY STEERING PUMP
12 EMERGENCY STEERING PUMP
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Loosen hydraulic oil drain valve (1) to drain hydraulic oil. Hydraulic oil: 490 L (129.4 gal)
2.
Disconnect hoses (2) between diverter valve and emergency steering pump.
3.
Remove clamps (3) and (4).
4.
Disconnect 2 tubes (5).
5.
Disconnect drain hose (6).
6.
Remove mount bolts (7) to remove emergency steering motor assembly (8). Emergency steering motor assembly: 30 kg (66.2 lb)
INSTALLATION • •
Carry out installation in the reverse order to removal. Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic oil: 490 L (129.4 gal)
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE
PARKING BRAKE REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove disc plate cover (1).
2.
Disconnect drive shaft (2).
Drive shaft assembly: 112 kg (247 lb)
3.
Turn adjustment bolt (3) counterclockwise to increase clearance between pad and disc.
4.
Pull out connecting pin (4).
5.
Disconnect hose (5).
6.
Remove spring cylinder (6).
7.
Disconnect plate (7).
★ Secure the calipers. ★ Since 2 dowel pins are fitted, raise the calipers a little to remove the plate. 8.
Remove pad (8).
9.
Remove calipers assembly (9).
10. Remove mount bolts (10) to remove disc (11).
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE
12 INSTALLATION •
Carry out installation in the reverse order to removal.
Mount bolt: 157 - 196 Nm (115.7 - 144.5 lbf ft)
★ Adjust the clearance. For details, see TESTING AND ADJUSTING, Testing and adjusting parking brake.
Mount bolt: Adhesive (LT-2)
Mount bolt: 824.0 - 1030.0 Nm (607.7 - 759.6 lbf ft)
Mount bolt: Adhesive (LT-2)
Mount bolt: 490.0 - 608.0 Nm (361.4 - 448.4 lbf ft)
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE CALIPERS
12
PARKING BRAKE CALIPERS DISASSEMBLY 1.
Remove snap ring (1), then pull out adjuster (2).
2.
Remove washers (3) and (4), and seal (5).
3.
Remove bolt, then remove cap (6) and gasket (7).
4.
Remove piston shaft (8) and thrust bearing (9) from piston.
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE CALIPERS
12 5. Remove piston (11) and piston seal (12) from calipers (10).
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE CALIPERS
12 ASSEMBLY 1.
Assemble piston seal (12) in calipers (10), and insert piston (11). Piston, piston seal: Grease (G2-LI)
2.
Screw piston shaft (8) into piston, and install thrust bearing (9). ★ Be careful to install the thrust bearing facing in the correct direction. Thrust bearing: Grease (G2-LI)
3.
Fit gasket (7) and install cap (6). Mount bolt: 177 ± 20 Nm (130.5 ± 14.7 lbf ft)
4.
Install seal (5) and washers (3) and (4). ★ Fit the seal securely in the groove. Seal: Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE CALIPERS
12 5. Assemble adjuster (2) and secure with snap ring (1).
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE PAD
12
PARKING BRAKE PAD REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove disc plate cover (1).
2.
Turn adjustment bolt (2) counterclockwise to increase the clearance between the pad and disc.
3.
Secure calipers (3) with wires.
4.
Remove plate (4).
★ Since 2 dowel pins are installed, raise the calipers a little, then remove the plate. 5.
Remove pad (5).
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Adjust the parking brake pad. For details, see TESTING AND ADJUSTING, PARKING BRAKE.
Mount bolt: Adhesive (LT-2)
Mount bolt: 824.0 - 1030.0 Nm (607.7 - 759.6 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REAR TIRE
12 REAR TIRE
REMOVAL WARNING! Stop the vehicle on level ground and install the safety bar to the frame and put blocks under the wheels to prevent the vehicle from moving.
1.
Set blocks ➀ to both sides of rear axle. ★ These blocks are used to prevent the tire from bouncing when it is removed.
2.
Remove cover (1).
3.
Raise vehicle body with 2 jacks (50 ton) ➁ and set stand ➂ under counterweight.
4.
Sling tire assembly and remove hub nuts (2).
5.
Lift off tire assembly (3). ★ Secure the center of the tire with a noose of the sling. Tire assembly: 2490 kg (5489.5 lb)
INSTALLATION •
Carry out installation in the reverse order to removal.
Hub nut: 736.0 - 912.0 Nm (542.8 - 672.6 lbf ft) ★ Match the holes for the stud bolts by turning the tire on the opposite side.
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DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER COMPRESSOR
12
AIR CONDITIONER COMPRESSOR REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Using tool X1, collect air conditioner refrigerant (R134a).
2.
Disconnect wiring connector (1) (E21).
3.
Disconnect hose (2) between condenser and air conditioner compressor and hose (3) between air conditioner unit and air conditioner compressor.
4.
Loosen mount bolt (4).
5.
Remove adjustment bolt (5) and slant compressor toward engine to remove drive belt (6).
6.
Remove 4 mount bolts (7) to remove air conditioner compressor assembly (8).
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Do not twist the hoses. ★ Do not let dirt, dust, water, etc. in the hoses. ★ Using tool X1, charge the air conditioner circuit with new refrigerant (R134a).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER CONDENSER
12 AIR CONDITIONER CONDENSER
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Using tool X1, collect air conditioner refrigerant (R134a).
2.
Open bulkhead cover (1).
Removal of left air conditioner condenser assembly 1.
Disconnect hose (1) between receiver tank and air conditioner condenser.
â&#x2DC;&#x2026; Since the hose adapter is brittle, be sure to use double spanner to loosen it. 2.
Disconnect hose (2) between right condenser and left condenser.
3.
Disconnect wiring connectors (3) (B10) and (4) (B11).
4.
Remove mount bolts to remove air conditioner condenser assembly (5).
Removal of right air conditioner condenser assembly 1.
Disconnect hose (1) between left condenser and right condenser.
2.
Disconnect hose (2) between air conditioner compressor and right condenser.
3.
Disconnect wiring connectors (3) (B12) and (4) (B13).
4.
Remove mount bolts to remove air conditioner condenser assembly (5).
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DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER CONDENSER
12 INSTALLATION •
Carry out installation in the reverse order to removal.
★ Do not twist the hoses. ★ Do not let dirt, dust, water, etc. in the hoses. ★ Using tool X1, charge the air conditioner circuit with new refrigerant (R134a).
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WA700-3L
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER RECEIVER TANK
12 AIR CONDITIONER RECEIVER TANK
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Open bulkhead cover (1).
2.
Disconnect hose (2) connected to air conditioner unit. ★ Collect air conditioner refrigerant (R134a). For details, see AIR CONDITIONER COMPRESSOR - REMOVAL.
3.
Disconnect hose (3) connected to condenser.
4.
Remove clamp (4) to remove receiver tank assembly (5).
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Do not twist the hoses. ★ Do not let dirt, dust, water, etc. in the hoses. ★ Using tool X1, charge the air conditioner circuit with new refrigerant (R134a).
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DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
12
AIR CONDITIONER UNIT REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove cab assembly. For details, see CAB - REMOVAL.
2.
Disconnect operator’s seat suspension switch wiring connector (1). ★ Installed at the rear of the seat.
3.
Remove operator’s seat assembly (2).
Operator’s seat assembly: 50 kg (110.2 lb)
4.
Remove covers (3) and (4).
5.
Remove console box (5).
6.
Disconnect wiring connectors (6) (A5), (7) (A7), and (8) (A6).
7.
Disconnect wiring connectors (9) (A8B) and (10) (A8A).
8.
Disconnect expansion valve switch connector (11) (A15).
9.
Disconnect tube (12) connected to receiver tank.
10. Disconnect tube (13) connected to air conditioner compressor. ★ Collect air conditioner refrigerant (R134a). For details, see AIR CONDITIONER COMPRESSOR - REMOVAL. ★ Take measure to prevent dirt, water, etc. from entering the system. 11. Disconnect heater hot water inlet hose (14). 12. Disconnect valve of heater hot water outlet hose. ★ Close the valve on the engine side. ★ Plug the disconnected hoses.
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DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
12 13. Remove screws (16). 14. Remove mount bolts (17) to remove air conditioner unit (18). ★ Pull out the unit.
INSTALLATION • •
Carry out installation in the reverse order to removal. Charging air conditioner with gas Using, tool X1, charge the air conditioner circuit with new refrigerant (R134a). ★ If the air conditioner is operated without charging it with refrigerant, its compressor may be broken. Take care.
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DISASSEMBLY AND ASSEMBLY
MAIN MONITOR
12
MAIN MONITOR REMOVAL WARNING! Stop the machine on level ground and install the safety bar to the frame. Lower the work equipment to the ground and stop the engine and apply the parking brake, then put blocks under the wheels to prevent the machine from moving.
WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Removal of surrounding steeling column A. Remove dashboards (1) and (2). B. Remove steering post covers (3) and (4). C. Remove steering post cover (5). D. Remove steering post cover (6) and mount bolt cap (7), then remove the bolt. E. Remove steering post cover (8) and mount bolt cap, then remove mount bolt (9). â&#x2DC;&#x2026; Turn down the steering post cover forward.
2.
Remove bracket (10) on the back side of the main monitor.
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DISASSEMBLY AND ASSEMBLY
MAIN MONITOR
12 3. Remove main monitor (11) and eight mount bolts (12). ★ When removing the main monitor, be careful not to give a large shock to it.
4.
Disconnect connectors (13), (14), (15) and (16) from the main monitor (11), then remove the main monitor.
(13) = CN-LO5 (14) = CN-LO7 (15) = CN-LO6 (16) = CN-LO8
INSTALLATION •
Carry out installation in the reverse order to removal.
★ Apply the locks of the connectors securely.
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DISASSEMBLY AND ASSEMBLY
MAINTENANCE MONITOR
12
MAINTENANCE MONITOR REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Remove armrest (1).
2.
Remove cover (2). ★ Raise the cover and disconnect wiring connector (L40, L41) of power window switches (3).
3.
Remove mount bolts to remove maintenance monitor assembly (4). ★ Disconnect wiring connector of monitor assembly (L18, L19, L21, L22).
INSTALLATION • •
Carry out installation in the reverse order to removal. After installing the maintenance monitor, check its operation.
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DISASSEMBLY AND ASSEMBLY
ENGINE, APS CONTROLLER
12 ENGINE, APS CONTROLLER
REMOVAL WARNING! Stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1.
Open right door of cab and remove console box side cover (1).
Removal of engine controller assembly
1.
Disconnect engine controller wiring connectors (2) (EC1), (3) (ECBA, B), (4) (EC2), and (5) (EC5A, B).
2.
Remove mount bolts to remove engine controller assembly (6).
Removal of APS controller assembly 1.
Disconnect APS controller wiring connectors (7) (L71) and (8) (L72).
2.
Remove mount bolts to remove APS controller assembly (9).
INSTALLATION â&#x20AC;˘
Carry out installation in the reverse order to removal.
â&#x2DC;&#x2026; If the engine controller is being replaced with a new controller, the two rotary adjustment switches must be set correctly to the engine. These settings are referred to as "Q numbers". The Q numbers may be found in one of two places: A. On a sticker on the controller. B. On the engine nameplate.
WA700-3L
30-279 1
DISASSEMBLY AND ASSEMBLY
ENGINE, APS CONTROLLER
12 A. On a sticker (Seal) on the controller.
B. On the engine nameplate.
30-280 1
WA700-3L
DISASSEMBLY AND ASSEMBLY
ENGINE, APS CONTROLLER
12 Procedure to change out a controller 1.
Check the Q number on the controller currently on the engine against the Q number stamped into the engine identification (ID) plate. (They should match, if they do not, use the Q number stamped on the engine ID plate.)
2.
Remove the seal carefully (has to reused) and remove the rubber plugs.
3.
Adjust the new controller to the Q number stamped on the engine ID plate. Use a screw driver to adjust the both rotary switches
4.
Enter the Q number on the seal on the controller and on the seal that you will place over the rubber plugs after they are installed onto the rotary switches. (Write the number with a magic marker or a ball point pen so that it will be permanent.) Remove the paper on the back of the seal and place it onto the controller.
â&#x2DC;&#x2026; After installing the engine and APS controller assembly, check its operation.
WA700-3L
30-281 1
DISASSEMBLY AND ASSEMBLY
ENGINE, APS CONTROLLER
12
MEMORANDUM
30-282 1
WA700-3L
40
MAINTENANCE STANDARD
ENGINE AND TRANSMISSION MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2 . DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 TRANSMISSION CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8 TRANSMISSION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10 TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12 UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12 RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12 LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20 CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26 AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28 CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-33 STEERING DEMAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34 DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-37 STEERING CYLINDER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38 GROUND DRIVEN STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40 BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42 LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42 RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44 SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46 CONTROL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50 MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52 PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54 PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56 HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58 WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60 BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62 BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
WA700-3L
40-1
MAINTENANCE STANDARD
ENGINE AND TRANSMISSION MOUNT
12
ENGINE AND TRANSMISSION MOUNT
40-2
WA700-3L
MAINTENANCE STANDARD
ENGINE AND TRANSMISSION MOUNT
12 Unit: mm No
1
Check item
Clearance between trunnion and torque converter case
Remedy
Criteria Standard size 230
Tolerance Shaft
Hole
Standard clearance
Clearance limit
-0.100 -0.172
+0.072 0
0.100 0.244
---
Replace
2
Clearance between shaft and rubber cushion
63
0 -0.030
+0.035 0
0.00 0.065
---
3
Clearance between rubber cushion and bracket
97
+0.115 +0.080
+0.054 0
-0.115 -0.026
---
4
Thickness of mount shim
---
---
Standard shim thickness: 1.0 mm (parallelism of coupling mating joint of transmission output shaft and center of center pin: Max. 0.10 mm) Torque Nm
lbf ft
5
Bolt
549 ± 59
405.0 ± 43.3
6
Bolt
68.6 ± 9.8
50.6 ± 7.2
7
Bolt
549 ± 59
405.0 ± 43.3
8
Bolt
385 ± 41.7
283.8 ± 30.7
9
Bolt
549 ± 59
405.0 ± 43.3
10
Bolt
176.5 ± 19.6
130.1 ± 14.4
11
Bolt
927 ± 103
683.5 ± 75.9
12
Bolt
927 ± 103
683.5 ± 75.9
WA700-3L
---
40-3
MAINTENANCE STANDARD
DAMPER
12
DAMPER
40-4
WA700-3L
MAINTENANCE STANDARD
DAMPER
12 Unit: mm No
1
Check item
Criteria
Clearance between bearing and shaft
Tolerance
Standard size
Remedy
Shaft
Hole
Standard clearance
Clearance limit
85
+0.015 +0.003
0 -0.020
-0.035 -0.003
0.025
2
Clearance between bearing and housing
150
0 -0.018
-0.008 -0.033
-0.033 0.010
0.018
3
Clearance between body and shaft
85
-0.012 -0.034
+0.110 +0.030
0.042 0.144
0.25
4
inner
Wear of surface in shaft and oil seal
5
Wear of surface in shaft and oil seal
6
Backlash of spline
---
---
Standard size
Tolerance
Repair limit
100
0 -0.087
-0.133
120
0 -0.087
-0.138
0.068 - 0.262 Torque Nm
lbf ft
7
Bolt
12.7 ± 4.9
13.0 ± 3.6
8
Bolt
277 ± 32
204.3 ± 23.5
9
Bolt
66.2 ± 7.35
48.8 ± 5.4
10
Bolt
110.3 ± 12.3
81.3 ± 9.0
11
Bolt
110 ± 12.3
81.3 ± 9.0
WA700-3L
Replace
40-5
MAINTENANCE STANDARD
TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO
40-6
WA700-3L
MAINTENANCE STANDARD
TORQUE CONVERTER AND PTO
12 Unit: mm No
Check item
Tolerance
Repair limit
170
+0.040 0
170.2
75
+0.030 0
75.2
Width
4.25
0 -0.1
3.9
Thickness
6.0
± 0.1
5.85
1
2
Inside diameter of seal ring surface of sleeve
3
Width and thickness of seal ring
Backlash of PTO gear (Drive gear)
---
---
Repair chrome plating or replace
Replace
0.20 - 0.52 Torque Nm
lbf ft
5
Bolt
277 ± 32
206.1 ± 23.5
6
Bolt
54 ± 4.9
39.7 ± 3.6
7
Bolt
613 ± 24.5
452.0 ± 18.0
8
Bolt
66.2 ± 7.4
48.8 ± 5.4
9
Bolt
110 ± 12.3
81.3 ± 9.0
10
Bolt
11.3 ± 1.5
8.3 ± 1.0
11
Bolt
277 ± 32
206.1 ± 23.5
12
Bolt
277 ± 32
206.1 ± 23.5
13
Bolt
24.5 ± 4.9
18.0 ± 3.6
WA700-3L
Remedy
Standard size
Inside diameter of seal ring surface of retainer
4
Criteria
40-7
MAINTENANCE STANDARD
TRANSMISSION CLUTCH
12
TRANSMISSION CLUTCH
Unit: mm No
Check item
Criteria
Remedy
Standard size 1
Reverse clutch springs (12 pieces)
Repair limit
Free length
Installation length
Installation load
Free length
Installation load
91
69.2
192 N 43.1 lbf
85.5
164 N 36.8
91
74.4
146 N 32.8 lbf
85.5
125 N 28.1 lbf
48.9
86.3 N 19.4
2
Forward clutch springs (12 pieces)
3
4th clutch springs (12 pieces)
52
46
101 N 22.7 lbf
4
3rd clutch springs (12 pieces)
52
47
84.3 N 18.9 lbf
48.9
71.6 N 16.0 lbf
5
1st clutch springs (12 pieces)
52
42.8
155 N 34.8
48.9
131 N 29.4 lbf
40-8
Replace
Replace
WA700-3L
MAINTENANCE STANDARD
TRANSMISSION CLUTCH
12 Unit: mm No
6
Check item
Criteria
Thickness of assembled 5 discs and 4 plates for reverse clutch
Remedy
Standard size
Tolerance
Repair limit
50.2
---
48.2
7
Thickness of assembled 6 discs and 5 plates for forward clutch
61.4
---
59.0
8
Thickness of assembled 3 discs and 2 plates for 4th clutch
27.8
---
26.6
9
Thickness of assembled 5 discs and 4 plates for 2nd clutch
45.0
---
43.0
10
Thickness of assembled 3 discs and 2 plates for 3rd clutch
27.8
---
26.6
11
Thickness of assembled 3 discs and 2 plates for 1st clutch
27.8
---
26.6
12
Thickness of 1 disc
Forward, Reverse, 1st, 3rd, 4th
5.4
---
5.0
2nd
5.0
---
4.6
13
Thickness of 1 plate
Forward, Reverse, 1st, 3rd, 4th
5.8
---
5.2
2nd
5.0
---
4.5
14
Outside diameter of input shaft
130
+0.018 -0.007
+0.018 -0.007
15
Outside diameter of input shaft
110
+0.016 -0.006
+0.016 -0.006
16
Outside diameter of output shaft
130
+0.018 -0.007
+0.018 -0.007
17
Outside diameter of output shaft
140
+0.018 -0.007
+0.018 -0.007
Width
3.0
-0.01 -0.03
2.6
Thickness
3.7
± 0.12
3.55
Width
4.5
-0.01 -0.03
3.9
Thickness
5.2
± 0.12
5.05
Width
4.5
-0.01 -0.03
3.9
Thickness
5.4
± 0.12
5.25
Width
6.0
-0.01 -0.03
5.3
Thickness
6.6
± 0.15
5.85
18
19
20
21
Wear of seal ring for input shaft
Wear of seal ring for output shaft
Wear of seal ring for output shaft
Wear of seal ring for 2nd clutch
WA700-3L
Replace
40-9
MAINTENANCE STANDARD
TRANSMISSION GEAR
12
TRANSMISSION GEAR
Unit: mm No
Check item
Criteria
1
Backlash between reverse sun gear and planetary gear
0.13 - 0.32
2
Backlash between reverse planetary gear and ring gear
0.15 - 0.38
3
Backlash between forward sun gear and planetary
0.13 - 0.36
4
Backlash between forward planetary gear and ring gear
0.14 - 0.39
5
Backlash between 4th planetary gear and ring gear
0.14 - 0.39
6
Backlash between 4th sun gear and planetary gear
0.13 - 0.36
7
Backlash between 3rd sun gear and planetary gear
0.13 - 0.36
8
Backlash between 3rd planetary gear and ring gear
0.14 - 0.39
9
Backlash between 1st sun gear and planetary gear
0.13 - 0.36
10
Backlash between 1st planetary gear and ring gear
0.14 - 0.39
40-10
Remedy
Replace
WA700-3L
MAINTENANCE STANDARD
TRANSMISSION GEAR
12
MEMORANDUM
WA700-3L
40-11
MAINTENANCE STANDARD
TRANSMISSION CONTROL VALVE
12
TRANSMISSION CONTROL VALVE UPPER VALVE
RELIEF VALVE
40-12
WA700-3L
MAINTENANCE STANDARD
TRANSMISSION CONTROL VALVE
12
Unit: mm
No
1
Check item
Clearance between valve and body
Criteria
reducing
Standard size
Tolerance
Remedy Standard clearance
Clearance limit
+0.013 0
0.035 - 0.058
0.08
Shaft
Hole
25
-0.035 -0.045
2
Clearance between torque converter relief valve spool and body
25
-0.035 -0.045
+0.013 0
0.035 - 0.058
0.08
3
Clearance between valve spool and body
25
-0.020 -0.041
+0.013 0
0.020 - 0.054
0.08
4
Clearance between quick return valve spool and body
12
-0.035 -0.045
+0.011 0
0.035 - 0.056
0.08
5
Clearance between modulating valve spool and body
25
-0.035 -0.045
+0.013 0
0.035 - 0.058
0.08
6
Clearance between main relief valve spool and body
25
-0.035 -0.045
+0.016 0
0.035 - 0.061
0.08
7
Clearance between quick fill valve spool and body
25
-0.035 -0.045
+0.013 0
0.035 - 0.058
0.08
priority
Standard size 8
Priority valve spring
Replace
Repair limit
Free length
Installation length
Installation load
Free length
Installation load
62
37.74
217 N 48.7 lbf
60.1
206 N 46.3 lbf
9
Torque converter relief valve spring
62
45
152 N 34.1 lbf
60.1
144 N 32.3 lbf
10
Modulating valve spring (Inner)
159
135
300 N 67.4 lbf
154.2
285 N 64.0 lbf
11
Modulating valve spring (Outer)
161
135
328 N 73.7 lbf
156.2
311 N 69.9 lbf
12
Main relief valve spring
128
103
1079 N 242.5 lbf
124.2
1025 N 230.4 lbf
13
Reducing valve spring
75
57
407 N 91.4 lbf
78.2
386 N 86.7 lbf
14
Thickness of shim for reducing valve
3.5 mm (pressure per 1 piece: 0.65 kg/cm2 (9.24 lbf/in2)
15
Thickness of shim for modulating valve
1.0 mm (pressure per 1 piece: 0.36 kg/cm2 (5.12 lbf/in2)
16
Thickness of shim for priority valve
2.0 mm (pressure per 2 piece: 0.26 kg/cm2 (3.69 lbf/in2)
17
Thickness of shim for torque converter relief valve
6.0 mm (pressure per 1 piece: 0.26 kg/cm (3.69 lbf/in )
18
Thickness of shim for main relief valve
2.0 mm (pressure per 1 piece: 0.46 kg/cm2 (6.54 lbf/in2)
19
Thickness of shim for quick fill valve
2.5 mm (pressure per 1 piece: 0.36 kg/cm2 (5.12 lbf/in2)
Adjust
WA700-3L
2
2
40-13
MAINTENANCE STANDARD 12 LOWER
40-14
TRANSMISSION CONTROL VALVE
VALVE
WA700-3L
MAINTENANCE STANDARD
TRANSMISSION CONTROL VALVE
12 Unit: mm No
1
Check item Clearance between FORWARD - REVERSE spool and body
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
2
Clearance between 1st speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
3
Clearance between 2nd speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
4
Clearance between 3rd speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
5
Clearance between 4th speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
6
Clearance between pilot reducing valve spool and body
25
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
7
Clearance between lubrication valve plunger and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
Standard size 8
FORWARD - REVERSE, No. 1, No. 2, No. 3 and No. 4 speed spring
9
Pilot reducing valve spring
10
Lubrication valve spring
11
Thickness of shim for pilot reducing valve
WA700-3L
Replace
Repair limit
Free length
Installation length
Installation load
Free length
Installation load
78
47
107 N 24.0 lbf
75
102 N 22.9 lbf
62
43.7
164 N 36.8 lbf
60.1
156 N 35.0 lbf
39.4
37
60.8 N 13.6 lbf
38.2
57.9 N 13.0 lbf
3 mm (pressure per 1 piece: 0.26 kg/cm2 (3.69 lbf/in2)
Adjust
40-15
MAINTENANCE STANDARD 12 SOLENOID
VALVE
No
40-16
TRANSMISSION CONTROL VALVE
Check item
Torque Nm
lbf in
46.6 ± 2.45
412.4 ± 21.6
Screw
1.62 ± 0.15
14.3 ± 1.3
3
Screw
0.69 ± 0.1
6.1 ± 0.8
4
Screw
0.74 ± 0.05
6.5 ± 0.4
5
Screw
1.62 ± 0.15
14.3 ± 1.3
6
Screw
0.69 ± 0.1
6.1 ± 0.08
1
Screw
2
WA700-3L
MAINTENANCE STANDARD
TRANSMISSION CONTROL VALVE
12
MEMORANDUM
WA700-3L
40-17
MAINTENANCE STANDARD
TRANSFER
12
TRANSFER
40-18
WA700-3L
MAINTENANCE STANDARD
TRANSFER
12
Unit: mm
No
1
Check item
Clearance between input shaft and bearing
Criteria Tolerance
Standard size
Remedy
Shaft
Hole
Standard clearance
Repair limit
140
+0.052 +0.027
0 -0.025
-0.077 -0.027
-0.077 -0.027
2
Clearance between input shaft bearing and case
210
0 -0.030
0 -0.046
-0.046 0.030
-0.046 0.030
3
Clearance between idler shaft and bearing
104.775
+0.070 +0.048
+0.025 0
-0.070 -0.023
-0.070 -0.023
4
Clearance between idler shaft bearing and case
180.975
+0.025 0
+0.025 -0.021
-0.045 0.025
-0.046 0.025
5
Clearance between output shaft and bearing
130
+0.052 +0.027
0 -0.025
-0.077 -0.027
-0.077 -0.027
6
Clearance between output shaft bearing and case
200
0 -0.030
0 -0..046
-0.046 0.030
-0.046 0.030
7
Clearance between output shaft and bearing
100
+0.045 +0.023
0 -0.020
-0.065 -0.023
-0.065 -0.023
8
Clearance between output shaft bearing and case
180
0 -0.025
-0.012 -0.057
-0.057 0.013
-0.057 0.013
9
Oil seal sliding surface of output shaft coupling
10
Oil seal sliding surface of output shaft coupling
11
Clearance between bearing cage and case
Standard size
Tolerance
Repair limit
130
0 -0.100
129.9
150
0 -0.100
149.9
Standard clearance
Replace
Adjust value of bearing preload
2 (shims)
0.05 - 0.1 kgm (4.33 - 8.67 lbf in) Preload, gear as individual part
12
Clearance between bearing out put cover and case
1 (shim)
Max. 0.05 kgm (4.33 lbf in) After inserting shim
13
Clearance between idler cover and case
2 (shims)
0.05 - 0.1 kgm (4.33 - 8.67 lbf in) Preload, gear as individual part
14
Backlash between input gear and idler gear
0.22 - 0.47
15
Backlash between idler gear and idler gear
0.22 - 0.47
16
Backlash between output gear and idler gear
0.22 - 0.47
17
Bolt
WA700-3L
Replace
Adjust
Replace
1324 ± 196 Nm (976.5 ± 144.5 lbf ft)
40-19
MAINTENANCE STANDARD
DRIVE SHAFT
DRIVE SHAFT
No
40-20
Check item
Torque Nm
lbf ft
1
Bolt
176.5 ± 19.6
130.1 ± 14.4
2
Bolt
176.5 ± 19.6
130.1 ± 14.4
3
Bolt
927 ± 103
683.7 ± 75.9
4
Bolt
176.5 ± 19.6
130.1 ± 14.4
5
Bolt
176.5 ± 19.6
130.1 ± 14.4
6
Bolt
176.5 ± 19.6
130.1 ± 14.4
7
Bolt
176.5 ± 19.6
130.1 ± 14.4
8
Bolt
176.5 ± 19.6
130.1 ± 14.4
9
Bolt
214 ± 6.9
157.8 ± 5.0
10
Bolt
214 ± 6.9
157.8 ± 5.0
11
Bolt
214 ± 6.9
157.8 ± 5.0
12
Bolt
214 ± 6.9
157.8 ± 5.0
13
Bolt
214 ± 6.9
157.8 ± 5.0
14
Bolt
214 ± 6.9
157.8 ± 5.0
15
Bolt
214 ± 6.9
157.8 ± 5.0
WA700-3L
MAINTENANCE STANDARD
CENTER SUPPORT
12
CENTER SUPPORT
Unit: mm No
1
Check item
Clearance between and bearing
Criteria
case
case
Tolerance
Remedy
Shaft
Hole
Standard clearance
160
0 -0.025
-0.036 -0.061
-0.061 -0.011
0.008
160
0 -0.025
-0.036 -0.061
-0.061 -0.011
0.008
Standard size
Clearance limit
2
Clearance between and bearing
3
Clearance between coupling shaft and bearing
90
+0.059 +0.037
0 -0.020
-0.079 -0.037
-0.033
4
Clearance between coupling shaft and bearing
90
+0.059 +0.037
0 -0.020
-0.079 -0.037
-0.033
5
Wear of oil seal surface
6
Wear of oil seal surface
7
End play of coupling shaft
Standard size
Tolerance
Repair limit
110
0 -0.087
-0.19
130
0 -0.010
-0.18
0.05 - 0.15
Replace
Repair chrome plating or replace
Replace
Torque 8
9
Bolt
Bolt
WA700-3L
Nm
lbf ft
1716 ± 196
1265.6 ±144.5
66.2 ± 7.4
48.8 ± 5.4
40-21
MAINTENANCE STANDARD
DIFFERENTIAL
12
DIFFERENTIAL
40-22
WA700-3L
MAINTENANCE STANDARD
DIFFERENTIAL Unit: mm
No
1
Check item Clearance of side bearing outer race in differential gear assembly
Criteria Tolerance
Remedy
Shaft
Hole
Standard Clearance
260
0 -0.035
+0.069 +0.017
0.104 0.017
Standard size
2
Clearance of side bearing inner race in differential gear assembly
170
+0.052 +0.027
0 -0.025
-0.027 -0.077
3
Clearance of outer race of pinion
250.825
+0.025 0
+0.020 -0.027
0.020 -0.052
4
Clearance of inner race pinion shaft bearing
101.6
+0.064 +0.038
+0.025 0
-0.013 -0.064
5
Clearance of inner race of pinion shaft bearing
101.6
+0.050 +0.028
+0.025 0
-0.003 -0.064
6
Clearance of outer race of pilot bearing
160
0 -0.025
+0.039 +0.014
-0.064 -0.014
7
Clearance of inner race of pilot bearing
75
+0.061 +0.042
0 -0.015
-0.042 -0.076
8
Clearance between differential carrier and cage
310
-0.020 -0.060
+0.052 +0.010
0.112 0.030
9
Clearance Between spider and differential pinion bushing
50
-0.155 -0.180
+0.03 -0.02
0.210 0.135
10
Thickness of side gear washer
11
Wear of oil seal surface
12
Backlash of bevel gear
0.46 - 0.66
13
Backlash gear
0.25 - 0.33
14
Wear play of pinion gear
15
Free rotating torque of bevel gear
16
Preload of bevel gear
17
Rear face runout of bevel gear
of
Clearance limit
---
0.35
Standard size
Tolerance
Repair limit
4.0
± 0.05
3.5
160
0 -0.100
---
differential
Replace
0 - 0.266
Remedy
Replace
15.2 Nm (11.2 lbf ft) 1000 - 2000 kgf (2204.6 - 4409.2 lbf) 0.1 Torque
18
Bolt
Nm
lbf ft
549 ± 59
404.9 ± 43.5
19
Bolt
110.3 ± 12.3
81.3 ± 9.0
20
Bolt
392 ± 49
289.1 ± 36.1
WA700-3L
40-23
MAINTENANCE STANDARD
DIFFERENTIAL Torque
21
Bolt
Nm
lbf lb
549 ± 59
404.9 ± 43.5
22
Bolt
1716 ± 196
1265.6 ± 144.5
23
Bolt
549 ± 59
404.9 ± 43.5
24
Bolt
549 ± 59
404.9 ± 43.5
25
Bolt
927 ± 103
683.7 ± 75.9
26
Bolt
549 ± 59
404.9 ± 43.5
40-24
WA700-3L
MAINTENANCE STANDARD
DIFFERENTIAL
12
MEMORANDUM
WA700-3L
40-25
MAINTENANCE STANDARD
FINAL DRIVE
12
FINAL DRIVE
Unit: mm No
1
Check item
Clearance between planetary shaft and bearing
Criteria Tolerance
Remedy
Shaft
Hole
Standard Clearance
90
+0.018 0
0 -0.020
0-0.038
Standard size
2
Clearance between planet gear and bearing
155
0 -0.025
-0.035 -0.075
-0.010 -0.075
3
Clearance between ring gear hub and bearing
300.038
+0.066 +0.034
+0.025 0
-0.009 -0.066
4
Clearance between wheel hub and bearing
422.275
+0.051 0
-0.0017 -0.080
-0.017 -0.131
5
Clearance between case and bearing
266.7
-0.017 -0.049
+0.025 0
0.074 0.017
6
Clearance between wheel hub and bearing
355.6
+0.051 0
-0.016 -0.073
-0.016 -0.124
40-26
Clearance limit
Replace ---
WA700-3L
MAINTENANCE STANDARD No
FINAL DRIVE
Check item
7
Thickness of retainer at ring gear hub mount
8
Backlash between planetary gear and sun gear
9
backlash between planetary gear and ring gear
10
Thickness of standard shim for wheel hub
Criteria
Remedy
Standard size
Tolerance
Repair limit
25
± 0.1
24.6
Standard clearance
Clearance limit
0.22 - 0.53
---
0.26 - 0.72
---
Remedy
Replace
2.1 Torque
11
Bolt
Nm
lbf ft
66.2 ± 7.4
48.8 ± 5.4
12
Bolt
66.2 ± 7.4
48.8 ± 5.4
13
Bolt
824 ± 89
607.7 ± 65.6
14
Bolt
594 ± 59
438.1 ± 43.5
15
Bolt
110.3 ± 12.3
81.3 ± 9.0
16
Bolt
68.7 ± 9.8
50.6 ± 7.2
WA700-3L
40-27
MAINTENANCE STANDARD
AXLE MOUNT
12
AXLE MOUNT
40-28
WA700-3L
MAINTENANCE STANDARD
AXLE MOUNT 12 Unit: mm
No
1
Check item
Criteria
Clearance of shaft and hole (Front support side) (Before press-fit bushing)
Tolerance
Standard size
Remedy Standard Clearance
Clearance limit
Shaft
Hole
470.2
+4.800 +0.800
+0.155 0
---
---
Bushing is stuck to housing
2
Clearance of shaft and hole (Front support side) (Before press-fit bushing)
460.0
-0.068 -0.165
+0.555 0
0.068 0.720
1.6
Replace
3
Clearance of shaft and hole (Rear support side) (Before press-fit bushing)
470.2
+4.800 +0.800
+0.155 0
---
---
Bushing is stuck to housing
4
Clearance of shaft and hole (Rear support side) (Before press-fit bushing)
460.0
-0.068 -0.165
+0.555 0
0.068 0.720
1.6
5
Thickness washer
of
thrust
Standard size
Tolerance
Repair limit
8
± 0.2
---
6
Thickness of thrust plate
33
-0.21 -0.35
---
7
Thickness of rear bushing
5
± 0.1
---
8
Thickness of front bushing
5
± 0.1
---
Replace
Torque 9
Bolt
Nm
lbf ft
3521 ± 353
2596.9 ± 260.3
10
Bolt
3521 ± 353
2596.9 ± 260.3
11
Bolt
549 ± 59
404.9 ± 43.5
12
Bolt
549 ± 59
404.9 ± 43.5
WA700-3L
40-29
MAINTENANCE STANDARD
CENTER HINGE PIN
12
CENTER HINGE PIN
40-30
WA700-3L
MAINTENANCE STANDARD
CENTER HINGE PIN
12
Unit: mm
No
1
Check item Clearance between lower hinge pin and upper bushing
Criteria Tolerance
Standard size
Remedy
Shaft
Hole
Standard Clearance
Clearance limit
139.725
-0.043 -0.068
+0.063 0
0.043 0.131
1.0
2
Clearance between lower hinge pin and bearing
139.725
-0.043 -0.068
0 -0.025
0.018 0.068
---
3
Clearance between lower hinge pin and lower bushing
139.725
-0.043 -0.068
+0.063 0
0.043 0.131
1.0
4
Clearance between lower bushing and frame (bottom) at lower hinge
180.0
-0.043 -0.106
+0.063 0
0.043 0.169
---
5
Clearance between front frame and lower hinge bearing
254.025
0 -0.025
-0.074 -0.126
-0.049 -0.126
---
6
Clearance at press-fit part of seal of lower hinge pin
200
+0.260 +0.160
+0.072 0
-0.088 -0.260
---
7
Clearance between upper hinge pin and rear frame
127
-0.018 -0.043
+0.063 0
0.018 0.106
---
8
Clearance between rear frame and bushing at upper hinge
170
-0.043 -0.068
+0.063 0
0.043 0.131
---
9
Clearance between front frame and upper hinge bearing
215.925
0 -0.025
-0.063 -0.109
-0.109 -0.038
---
10
Clearance at press-fitted part of seal of upper hinge pin
146.05
-0.043 -0.068
+0.063 0
0.043 0.131
---
11
Shim thickness for upper hinge and retainer
12
Height of top bushing at lower hinge
13
1.8
Replace
Adjust
Standard size
Tolerance
Repair limit
55
± 0.1
---
Height of lower bushing at lower hinge
113.3
± 0.1
---
14
Thickness for lower hinge retainer
32
± 0.8
---
15
Shim thickness for lower hinge and retainer
3.65
16
Shim thickness for lower hinge and retainer
1.7
Replace
Adjust
Torque 17
Bolt
WA700-3L
Nm
lbf ft
78.5 ± 7.9
57.8 ± 5.8
40-31
MAINTENANCE STANDARD
CENTER HINGE PIN Torque
18
Bolt
Nm
lbf ft
549 ± 59
404.9 ± 43.5
19
Bolt
549 ± 59
404.9 ± 43.5
20
Bolt
147.1 ± 14.7
108.4 ± 10.8
21
Bolt
549 ± 59
404.9 ± 43.5
22
Bolt
549 ± 59
404.9 ± 43.5
23
Bolt
927 ± 10.5
683.7 ± 7.7
40-32
WA700-3L
MAINTENANCE STANDARD
STEERING COLUMN
12
STEERING COLUMN
Unit: mm No
1
Check item Clearance between steering shaft and column bushing
Criteria Standard size 19
Tolerance
Remedy
Shaft
Hole
Standard Clearance
0 -0.08
+0.15 -0.05
0.05 0.23
Clearance limit 0.4
Replace
Torque 2
Bolt
Nm
lbf ft
29.4 ± 2.9
21.6 ± 2.1
3
Bolt
53.9 ± 4.9
39.7 ± 3.6
4
Bolt
57.9 ± 4.9
42.7 ± 3.6
5
Bolt
34.3 ± 4.9
25.2 ± 3.6
6
Bolt
34.3 ± 4.9
25.2 ± 3.6
WA700-3L
40-33
MAINTENANCE STANDARD
STEERING DEMAND VALVE
12
STEERING DEMAND VALVE
40-34
WA700-3L
MAINTENANCE STANDARD
STEERING DEMAND VALVE
12
WA700-3L
40-35
MAINTENANCE STANDARD
STEERING DEMAND VALVE
12U Unit: mm No
Check item
Criteria
Remedy
Standard size 1
Steering spool return spring
Repair limit
Free length
Installation length
Installation load
Free length
Load limit
41.8
38.0
74.5 N (16.7 lbf)
---
58.8 N (13.2 lbf)
2
Load check valve spring
20.9
3.2
8.8 N (1.9 lbf)
---
7.0 N (1.5 lbf)
3
Demand spool return spring
90.8
83.0
410 N (92.1 lbf)
---
328 N (73.7 lbf)
4
Surge cut relief valve spring
24.0
22.19
182.4 N (41.0 lbf)
---
145.1 N (32.6 lbf)
5
Main relief valve spring
24.0
22.19
182.4 N (41.0 lbf)
---
145.1 N (32.6 lbf)
6
Overload relief valve spring
39.5
35.7
590 N (132.6 lbf)
---
471 N (105.8 lbf)
7
Check valve return spring
20.9
13.2
8.8 N (1.9 lbf)
---
7.0 N (1.5 lbf)
40-36
Replace
WA700-3L
MAINTENANCE STANDARD
DIVERTER VALVE
12
DIVERTER VALVE
Unit: mm No
1
Check item
Clearance between body and spool
Criteria Standard size 40
Tolerance
Remedy
Shaft
Hole
Standard Clearance
-0.013 -0.015
+0.015 +0.007
0.020 0.030
Standard size 2
Spool return spring
Clearance limit --Repair limit
Free length
Installation length
Installation load
Free length
Load limit
122.6
84
216.7 N (48.5 lbf)
120.7
205.9 N (46.2 lbf)
3
Check valve spring
79.2
54.5
5.6 N (1.2 lbf)
77.9
5.3 N (1.1 lbf)
4
Check valve spring
79.2
57.5
4.9 N (1.1 lbf)
77.9
4.6 N (1.0 lbf)
WA700-3L
Replace
Replace
40-37
MAINTENANCE STANDARD
STEERING CYLINDER MOUNT
12
STEERING CYLINDER MOUNT
40-38
WA700-3L
MAINTENANCE STANDARD
STEERING CYLINDER MOUNT
12 Unit: mm No
1
Check item Clearance between mount pin and bushing connecection of steering cylinder rod and frame
2
Clearance between mount pin and bushing at connection of steering cylinder bottom and frame
3
Connection of steering cylinder and front frame
4
Connection of steering cylinder rod and rear frame
5
Width of spacer
WA700-3L
Criteria Tolerance
Standard size 110
110
Remedy
Shaft
Hole
Standard Clearance
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1.0
-0.036 -0.090
+0.020 0
0.036 0.110
1.0
Width of boss 0 88 -0.2
Width of hinge 96+1 0
Clearance limit
Replace
Standard clearance (Clearance a + b) 1.2 - 3.2
90+0.8
96 Âą 1.5
After adjusting with shim: Less than 1.0
Standard size
Tolerance
Repair limit
3.2
Âą 0.2
---
0
Replace
40-39
MAINTENANCE STANDARD
GROUND DRIVEN STEERING PUMP
12
GROUND DRIVEN STEERING PUMP (SAM3-125)
Unit: mm No
Check item
1
Side clearance
2
Clearance between inside diameter of plain bearing and outside diameter of gear shaft
3
Insertion depth of pin
4
Rotating torque of spline shaft
---
Discharge: Oil: SAE10W Temperature: 50 to 80°C 122 to 176°F
Criteria
Remedy
Standard clearance
Clearance limit
0.10 - 0.15
019
0.020 - 0.043
0.075 Replace
Standard size
Tolerance
Repair limit
14
0 -0.5
---
6.86 - 11.8 Nm (5.0 - 8.7 lbf ft) Revolution (rpm)
Pressure kg/cm2 (lbf/in2)
Standard discharge L/min (gal/min)
Repair limit discharge L/min (gal/min)
2500
20.6 (293.0)
276 (72.9)
244 (64.4)
---
Torque 5
40-40
Bolt
Nm
lbf ft
277 ± 32
204.3 ± 23.6
WA700-3L
MAINTENANCE STANDARD
GROUND DRIVEN STEERING PUMP
12
MEMORANDUM
WA700-3L
40-41
MAINTENANCE STANDARD
BRAKE VALVE
12
BRAKE VALVE LEFT
Unit: mm No
1
2
3
40-42
Check item Clearance between pedal mount hole and bracket hole Clearance between roller and pin
Outside diameter of roller
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard Clearance
Clearance limit
10
-0.025 -0.075
+0.1 0
0.175 0.025
0.25
10
-0.025 -0.075
+0.1 0
0.175 0.025
0.25
Standard size
Tolerance
Repair limit
30
0 -0.5
29.2
Replace
Replace
WA700-3L
MAINTENANCE STANDARD
BRAKE VALVE
12 No
Check item
Criteria Standard size
4
Control spring
Remedy Repair limit
Free length
Installation length
Installation load
Free length
Test load
34
33.5
3.82 N (0.85 lbf)
33
--Replace
5
Control spring
46.3
46.0
11.8 N (2.65 lbf)
45.3
---
6
Return spring
86.2
58
60.8 N (13.66 lbf)
78
---
7
Return spring
31.5
19.5
16.7 N (3.75 lbf)
28
---
Torque
8
Bolt
Nm
lbf ft
66.2 ± 7.3
48.8 ± 5.3
9
Bolt
7.8 ± 2
5.7 ± 1.4
10
Bolt
152 ± 24.5
112.1 ± 18.0
11
Bolt
66.2 ±7.3
48.8 ± 5.3
WA700-3L
40-43
MAINTENANCE STANDARD
BRAKE VALVE
12 RIGHT
Unit: mm No
1
2
40-44
Check item Clearance between pedal mount hole and bracket hole
Clearance between roller and pin
Criteria Tolerance
Remedy
Shaft
Hole
Standard Clearance
10
-0.025 -0.075
+0.1 0
0.175 0.025
0.25
10
-0.025 -0.075
+0.1 0
0.175 0.025
0.25
Standard size
Clearance limit
Replace
WA700-3L
MAINTENANCE STANDARD
BRAKE VALVE
12 No
3
Check item
Outside diameter of roller
Criteria
Remedy
Standard size
Tolerance
Repair limit
30
0 -0.5
29.2
Standard size 4
Control spring
Replace
Repair limit
Free length
Installation length
Installation load
Free length
Test load
34
33.5
3.82 N (0.85 lbf)
33
---
5
Control spring
46.3
46.0
11.8 N (2.65 lbf)
45.3
---
6
Return spring
86.2
58
60.8 N (13.66 lbf)
78
---
7
Spring
17
16.5
17.7 N (3.97 lbf)
16.2
---
8
Return spring
31.5
19.5
16.7 N (3.75 lbf)
28
---
Replace
Torque
9
Bolt
Nm
lbf ft
66.2 ± 7.3
48.8 ± 5.3
10
Bolt
7.8 ± 2
5.7 ± 1.4
11
Bolt
66.2 ±7.3
48.8 ± 5.3
12
Bolt
152 ± 24.5
112.1 ± 18.0
WA700-3L
40-45
MAINTENANCE STANDARD
SLACK ADJUSTER
12
SLACK ADJUSTER
Unit: mm No
1
Check item
Clearance between body and piston
Criteria Tolerance
Standard size 80
Remedy
Shaft
Hole
Standard Clearance
-0.030 -0.076
+0.074 0
0.030 0.150
Clearance limit 0.250
Standard size 2
3
Spring
Spring
Replace
Repair limit
Free length
Installation length
Installation load
Free length
Installation load
230
88
118 N (26.5 lbf)
---
---
45.4
38
66.7 N (14.9 lbf)
---
---
Replace
Torque
4
5
40-46
Bolt
Bolt
Nm
lbf ft
55.9 ± 6.9
41.2 ± 5.0
171.6 ± 14.7
126.5 ± 10.8
WA700-3L
MAINTENANCE STANDARD
CONTROL PUMP
12
CONTROL PUMP BAR025
Unit: mm No 1
Check item
Top clearance
Criteria
Remedy
Standard size
Repair limit
0.090 - 0.130
0.145
2
Side clearance of gear
0.055 - 0.075
0.105
3
Clearance between gear shaft and bushing
0.045 - 0.076
0.13
---
Discharge: Oil: EO10-CD Temperature: 45 to 55°C 113 to 131°F
---
Tightening torque for housing case mount bolt
WA700-3L
Replace
Revolution (rpm)
Pressure kg/cm2 (lbf/in2)
Standard discharge L/min (gal/min)
Repair limit discharge L/min (gal/min)
3200
2.9 (426.7)
72 (19.0)
68 (17.9)
110.3 ± 12.3 Nm (81.1 ± 9.0 lbf ft)
---
Tighten
40-47
MAINTENANCE STANDARD
BRAKE
12
BRAKE
Unit: mm No
Check item
Criteria Standard size
1
Return spring
Free length 114.8
40-48
Remedy Repair limit
Installation length
Installation load
Free length
Installation load
95.0
1010 N (227.0 lbf)
113.1
924 N (207.7 lbf)
Replace
WA700-3L
MAINTENANCE STANDARD
BRAKE
12 No
Check item
Remedy
Standard size
Repair limit
3.1
2.8
Thickness of disc
6.7
6.2
Total thickness of plates and disc
61.9
56.8
2
Thickness of plate
3 4
5
Criteria
Wear of contact surface of seal
Standard size
Tolerance
Repair limit
580
0 -0.175
---
6
Wear of surface in contact with piston seal
585
+0.110 0
---
7
Wear of surface in contact with piston seal
655
+0.125 0
---
8
Deformation of friction surface of plate and disc
9
Backlash between outer gear and plate
0.211 - 0.638
10
Backlash between inner gear and disc
0.222 - 0.662
Standard
Repair limit
Max. 0.4
0.70
Replace
Torque 11
Bolt
Nm
lbf ft
549 ± 59
404.9 ± 43.5
12
Bolt
549 ± 59
404.9 ± 43.5
13
Bolt
1716 ± 196
1265.6 ± 144.5
14
Bolt
927 ± 103
683.7 ± 75.9
15
Bolt
39.2 ± 4.9
28.9 ± 3.6
WA700-3L
40-49
MAINTENANCE STANDARD
PARKING BRAKE
12
PARKING BRAKE
40-50
WA700-3L
MAINTENANCE STANDARD
PARKING BRAKE
12 Unit: mm No
1
Check item
Wear rod
of
Remaining thickness of friction material Including backing plate
Criteria
Remedy
Standard size
Tolerance
Repair limit
22.2
---
3.7 Replace
31.7
---
12.7
2
Face runout of disc
0.6
---
1.2
3
Wear of rod connecting pin
12.7
-0.10 -0.17
---
4
Wear of disc (Thickness of disc plate)
25
± 0.7
Rebuild Thickness of plate must be under 23 mm Less than 23 mm
5
6
Clearance between pad and disc (Total of both sides)
1.06
± 0.18
Replace
2.1 Adjust
Clearance between brake body and plate
0.36 - 1.0 Torque
7
Bolt
WA700-3L
Nm
lbf ft
927 ± 103
683.7 ± 75.9
40-51
MAINTENANCE STANDARD
MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
Unit: mm No
Check item
Criteria
Remedy
Standard size 1
Spool return spring
Repair limit
Free length
Installation length
Installation load N (lbf)
Free length
Installation load N (lbf)
69.9
63.0
431(96.8)
---
345 (77.5)
2
Spool return spring
77.0
77.0
0 (0)
---
---
3
Spool return spring
79.7
78.5
61.6 (13.8)
---
49 (11.0)
4
Main valve spring
52.4
38.0
86.319.4)
---
69 (15.5)
5
Check valve spring
78.2
52.0
18.8 (4.2)
---
14.7 (3.3)
6
Suction valve spring of safety valve
27.9
18.0
6.86 (1.5)
---
5.88 (1.32)
40-52
Replace
WA700-3L
MAINTENANCE STANDARD
MAIN CONTROL VALVE
12 No
Check item
Criteria
Remedy
Standard size 7
Suction valve spring
Repair limit
Free length
Installation length
Installation load N (lbf)
Free length
Installation load N (lbf)
27.9
18.0
6.86 (1.5)
---
5.88 (1.32)
8
Float selector valve spring
53.0
42.1
137 (30.7)
---
440 (24.7)
9
Unloader valve spring
82.7
47.0
49.0 (11.0)
---
39.2 (8.8)
10
Relief spring
30.7
26.9
320 (71.9)
---
256 (57.5)
valve
poppet
Replace
Torque
11
Bolt
Nm
lbf ft
321.2 ± 54.6
236.9 ± 40.2
12
Bolt
152.0 ± 24.5
112.1 ± 18.0
13
Bolt
88.3 ± 9.8
61.4 ± 7.2
14
Bolt
225.6 ± 9.8
166.3 ± 7.2
15
Bolt
68.7 ± 9.8
50.6 ± 7.2
16
Bolt
22.1 ± 2.5
15.5 ± 1.8
17
Bolt
225.6 ± 9.8
166.3 ± 7.2
WA700-3L
40-53
MAINTENANCE STANDARD
PPC VALVE
12
PPC VALVE
40-54
WA700-3L
MAINTENANCE STANDARD
PPC VALVE
12 Unit: mm No
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Installation length
Installation load N (lbf)
Free length
Installation load N (lbf)
39.9
34.5
5.4 (1.2)
---
---
2
Centering spring bucket tilt, boom raise
56.7
34.5
21.1 (4.7)
---
---
3
Metering spring
33.5
29.4
33.3 (7.4)
---
---
4
Return spring
28.2
17.5
14.7 (3.3)
---
---
1
Centering spring bucket dump, boom raise
Replace
Torque
5
Bolt
Nm
lbf ft
44.1 ± 4.9
32.5 ± 3.6
6
Bolt
17.7 ± 3.9
13.0 ± 2.8
7
Bolt
30.9 ± 3.4
22.7 ± 2.5
WA700-3L
40-55
MAINTENANCE STANDARD
PPC RELIEF VALVE
12
PPC RELIEF VALVE
Unit: mm No
Check item
Criteria
Remedy
Standard size 1
2
40-56
Main valve spring
Poppet spring
Repair limit
Free length
Installation length
Installation load N (lbf)
Free length
Installation load N (lbf)
47
26
20.6 (4.6)
---
15.7 (3.5)
33.6
29.7
73.5 (16.5)
---
47.1 (10.5)
Replace
WA700-3L
MAINTENANCE STANDARD
PPC RELIEF VALVE
12
MEMORANDUM
WA700-3L
40-57
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
Unit: mm No
1
2
3
40-58
Check item
Clearance between piston rod and bushing
Clearance between piston rod mount pin and bushing
Clearance between cylinder bottom mount pin and bushing
Criteria Name of cylinder
Standard size
Steering
Tolerance
Remedy Standard clearance
Clearance limit
Shaft
Hole
85
-0.036 -0.090
+0.257 +0.047
0.083 0.347
0.597
Bucket
170
-0.043 -0.106
+0.255 +0.038
0.081 0.361
0.661
Boom
140
-0.043 -0.106
+0.256 +0.039
0.082 0.362
0.662
Steering
100
---
+0.207 +0.120
---
---
Bucket
180
---
+0.395 +0.295
---
1.0
Boom
160
---
+0.3 +.02
---
1.0
Steering
100
---
+0.020 0
---
---
Bucket
180
---
+0.395 +0.295
---
1.0
Boom
160
---
+0.395 +0.295
---
1.0
Replace bushing
WA700-3L
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
12 No
4
Check item
Criteria
Remedy
Name of cylinder
Standard size
Tolerance
Repair limit
Steering
130
+0.15 0
---
Bucket
280
+0.2 0
---
Boom
225
+0.2 0
---
Cylinder bore
Replace
Torque
5
Bolt
Nm
lbf ft
228 ± 81
168.1 ± 59.7
6
Bolt
2450 ± 245
1807.0 ± 180.7
7
Bolt
1180 ± 294
870.3 ± 216.8
8
Bolt
110 ± 12.3
81.1 ± 9.0
9
Bolt
277 ± 31.9
204.3 ± 23.5
10
Bolt
177 ± 19.6
130.5 ± 14.4
WA700-3L
40-59
MAINTENANCE STANDARD
WORK EQUIPMENT LINKAGE
12
WORK EQUIPMENT LINKAGE
40-60
WA700-3L
MAINTENANCE STANDARD
WORK EQUIPMENT LINKAGE
12
Unit: mm
No
1
Check item
Clearance between pin and bushing of bucket link
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
160
-0.043 -0.106
+0.434 +0.347
0.391 0.540
1.0
Standard size
Clearance limit
2
Clearance between pin and bushing of bucket link
160
-0.043 -0.106
+0.395 +0.295
0.338 0.501
1.0
3
Clearance between pin and bushing at joint of boom and bucket
160
-0.043 -0.106
+0.434 +0.347
0.390 0.540
1.0
4
Clearance between pin and bushing at joint of boom and frame
200
-0.050 -0.122
+0.435 +0.320
0.370 0.557
1.0
5
Clearance between pin and bushing at joint of bucket cylinder bottom and frame
180
-0.043 -0.106
+0.395 +0.295
0.358 0.501
1.0
6
Clearance between pin and bushing at joint of bucket cylinder rod and bellcrank
180
-0.043 -0.106
+0.395 +0.295
0.358 0.501
1.0
7
Clearance between pin and bushing at joint of bellcrank and boom
200
-0.050 -0.122
+0.435 +0.320
0.370 0.557
1.0
8
Clearance between pin and bushing and frame
160
-0.043 -0.106
+0.395 +0.295
0.338 0.501
1.0
9
Clearance between pin and bushing at joint of boom cylinder rod and boom
160
-0.043 -0.106
+0.395 +0.295
0.338 0.501
1.0
10
Joint of bucket cylinder and frame
Std. clearance (Clearance a + b)
Width between bosses
Width of hinge
213 ± 0.8
210+0.8
1.4 - 3.8
0
11
Joint of boom and frame
214 ± 0.8
210 ± 2.1
1.1 - 6.9
12
Joint of boom and bucket
259 +1.5 0
254 ± 4 After installing flange
1.0 - 10.5
13
Joint of bucket link and bucket
259 +1.5 0
14
Joint of bellcrank and bucket link
203+1.5 0
200+1 -3
2.0 - 7.5
15
Joint of boom cylinder and frame
229 ± 0.8
225+0.8 0
2.4 - 4.8
16
Joint of bellcrank and boom
358 ± 0.5
355 ± 0.5
2.0 - 4.0
17
Joint of bellcrank and bucket cylinder
213+1.5 0
210+0.8 0
2.2 - 4.5
18
Joint of boom cylinder and boom
184 ± 1.5
180 ± 2.1
0.4 - 7.6
WA700-3L
254+3 -5 After installing flange
2.0 - 11.5
Replace, also if other parts are biting into pin replace them
No. 12 and 13 only. Insert shims so that clearance is 1.5 mm on both left and right. No. 10, 11 & 15 only. Insert shims on both sides so that clearance on both left and right is less than 1.5 mm.
40-61
MAINTENANCE STANDARD
BUCKET POSITIONER
12
BUCKET POSITIONER BOOM KICK-OUT
Unit: mm No
Check item
Criteria
1
Clearance of bucket position switch
3-5
2
Clearance of boom kick-out switch
3-5
3
Clearance between bucket positioner protector and tip of switch
40-62
Remedy
Adjust
0.5 - 1.0
WA700-3L
MAINTENANCE STANDARD
BOOM KICK-OUT Torque
4
Bolt
Nm
lbf ft
17.2 ± 2.5
12.6 ± 1.8
5
Bolt
17.2 ± 2.5
12.6 ± 1.8
6
Bolt
88.3 ± 34.3
65.1 ± 25.2
WA700-3L
40-63
MAINTENANCE STANDARD
BOOM KICK-OUT
12
MEMORANDUM
40-64
WA700-3L
90 12
OTHERS SHOP MANUAL FOLDOUTS
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 DIAGRAM ONE (1/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 DIAGRAM ONE (2/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5 DIAGRAM ONE (3/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7 DIAGRAM ONE (4/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9 DIAGRAM ONE (5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11 DIAGRAM ONE (6/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 DIAGRAM TWO (1/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15 DIAGRAM TWO (2/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17 DIAGRAM TWO (3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19 DIAGRAM TWO (4/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21 CONNECTOR PIN ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 CONNECTOR PIN DIAGRAM (1/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 CONNECTOR PIN DIAGRAM (2/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25 CONNECTOR PIN DIAGRAM (3/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27 CONNECTOR PIN DIAGRAM (4/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29 CONNECTOR PIN DIAGRAM (5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31 CONNECTOR PIN DIAGRAM (6/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 90-35
WA700-3L
90-1 1
OTHER
MEMORANDUM
12
MEMORANDUM
90-2
WA700-3L
SHOP MANUAL FOLDOUTS
FOLDOUT 10-189
12
DIAGRAM ONE (1 SHEET OF 6 SHEETS) ELECTRICAL CIRCUIT
90-3
OTHER
MEMORANDUM
MEMORANDUM
90-4
SHOP MANUAL FOLDOUTS
FOLDOUT 10-191
12
DIAGRAM ONE (2 SHEET OF 6 SHEETS) ELECTRICAL CIRCUIT
90-5
OTHER
MEMORANDUM
MEMORANDUM
90-6
OTHERS
FOLDOUT 10-193
12
DIAGRAM ONE (3 SHEET OF 6 SHEETS) ELECTRICAL CIRCUIT
90-7
OTHER
MEMORANDUM
MEMORANDUM
90-8
OTHERS
FOLDOUT 10-195
12
DIAGRAM ONE (4 SHEET OF 6 SHEETS) ELECTRICAL CIRCUIT
90-9
OTHER
MEMORANDUM
MEMORANDUM
90-10
OTHERS
FOLDOUT 10-197
12
DIAGRAM ONE (5 SHEET OF 6 SHEETS) ELECTRICAL CIRCUIT
90-11
OTHER
MEMORANDUM
MEMORANDUM
90-12
OTHERS
FOLDOUT 10-199
12
DIAGRAM ONE (6 SHEET OF 6 SHEETS) ELECTRICAL CIRCUIT
90-13
OTHER
MEMORANDUM
MEMORANDUM
90-14
OTHERS
FOLDOUT 10-201
12
DIAGRAM TWO (1 SHEET OF 4 SHEETS) ELECTRICAL CIRCUIT
90-15
OTHER
MEMORANDUM
MEMORANDUM
90-16
OTHERS
FOLDOUT 10-203
12
DIAGRAM TWO (2 SHEET OF 4 SHEETS) ELECTRICAL CIRCUIT
90-17
OTHER
MEMORANDUM
MEMORANDUM
90-18
OTHERS
FOLDOUT 10-205
12
DIAGRAM TWO (3 SHEET OF 4 SHEETS) ELECTRICAL CIRCUIT
90-19
OTHER
MEMORANDUM
MEMORANDUM
90-20
OTHERS
FOLDOUT 10-207
12
DIAGRAM TWO (4 SHEET OF 4 SHEETS) ELECTRICAL CIRCUIT
90-21
OTHER
MEMORANDUM
MEMORANDUM
90-22
OTHERS
FOLDOUT 20-206-1
12
CONNECTOR PIN ARRANGEMENT CONNECTOR PIN DIAGRAM (1/6)
WA700-3L
90-23 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
12
MEMORANDUM
90-24 1
WA700-3L
OTHERS
FOLDOUT 20-206-2
12
CONNECTOR PIN DIAGRAM (2/6)
WA700-3L
90-25 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
MEMORANDUM
90-26 1
WA700-3L
OTHERS
FOLDOUT 20-206-3
12
CONNECTOR PIN DIAGRAM (3/6)
WA700-3L
90-27 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
MEMORANDUM
90-28 1
WA700-3L
OTHERS
FOLDOUT 20-206-4
12
CONNECTOR PIN DIAGRAM (4/6)
WA700-3L
90-29 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
MEMORANDUM
90-30 1
WA700-3L
OTHERS
FOLDOUT 20-206-5
12
CONNECTOR PIN DIAGRAM (5/6)
WA700-3L
90-31 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
MEMORANDUM
90-32 1
WA700-3L
OTHERS
FOLDOUT 20-206-5
12
CONNECTOR PIN DIAGRAM (6/6)
WA700-3L
90-33 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
MEMORANDUM
90-34 1
WA700-3L
OTHERS
FOLDOUT 20-608
12
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM
WA700-3L
90-35 â&#x17E;&#x20AC;
OTHERS
MEMORANDUM
MEMORANDUM
90-36 1
WA700-3L
DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186
PROPOSAL FOR MANUAL OR CSS REVISION
DATE:
FOR INTERNAL USE ONLY -- No. PMR
P NAME OF COMPANY: R O P O DEPARTMENT: S E NAME: R
CITY: STATE OR PROVINCE:: COUNTRY: FAX NO:
MANUAL DESCRIPTION:
CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO:
CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE:
CSS BOOK PUBLISHER:
BOOK DESCRIPTION MACHINE MODEL & S/N: MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS: PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet. FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PROPFREV.WPD 012100
DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186
PROPOSAL FOR MANUAL OR CSS REVISION
DATE:
FOR INTERNAL USE ONLY -- No. PMR
P NAME OF COMPANY: R O P O DEPARTMENT: S E NAME: R
CITY: STATE OR PROVINCE:: COUNTRY: FAX NO:
MANUAL DESCRIPTION:
CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO:
CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE:
CSS BOOK PUBLISHER:
BOOK DESCRIPTION MACHINE MODEL & S/N: MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS: PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet. FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PROPFREV.WPD 012100