SEBM018209
1
WA1200-3 MACHINE MODEL
SERIAL NO.
WA1200-3
50001 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
WA1200-3 mount the Cummins QSK60 engine.
© 2004 1 All Rights Reserved Printed in Japan 10-04(01)
00-1 (9)
CONTENTS No. of page
01
GENERAL ........................................................................
01-1
10
STRUCTURE AND FUNCTION ......................................
10-1
20
TESTING AND ADJUSTING ..........................................
20-1
30
DISASSEMBLY AND ASSEMBLY .................................
30-1
40
MAINTENANCE STANDARD .........................................
40-1
90
OTHERS...........................................................................
90-1
00-2 5
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20-872
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20-913
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30-039
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30-074
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20-873
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30-001
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20-884
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20-885
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WA1200-3
00-2-5 (9)
LIST OF REVISED PAGES
Mark
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Time of revision
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Time of revision
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Time of revision
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Page
Time of revision
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WA1200-3
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is 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.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts 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. 20.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. 21.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. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.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.
FOREWORD
GENERAL
FOREWORD 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 chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING 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" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
k
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water must be drained, and quantity to be drained.
a
4
3 2
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING k 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 4 •
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
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 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k 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.
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 kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list. Category
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
• Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Polyethylene container
• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
• Used as heat-resisting sealant for repairing engine.
50 g
Polyethylene container
• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of metals, rubbers, plastics and woods.
Adhesives
Three bond 1735
790-129-9140
• Used as adhesive or sealant for metal, glass and plastic.
Aron-alpha 201
790-129-9130
2g
Polyethylene container
• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.
LG-1
790-129-9010
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
LG-5
790-129-9080
1 kg
Can
• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.
LG-6
790-129-9020
200 g
Gasket sealant LG-7
790-129-9070
1 kg
Tube
• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Three bond 1211
790-129-9090
100 g
Tube
• Used as heat-resisting sealant for repairing engine.
Tube
• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case
Three bond 1207B
00-10
• Used as sealant for machined holes.
419-15-18131
100 g
FOREWORD
Molybdenum disulphide lubricant
Grease
Primer
Adhesive
Caulking material
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding portion (to prevent from squeaking).
Tube
• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
200 g
• General purpose type Various
Various
Various
Various
• Used for normal temperature, light load bearing at places in contact with water or steam.
• Used for heavy load portion
Molybdenum disulphide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White Grease G2-T G0-T (*) *: For use in cold district
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
400 g 16 kg
• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.
Biogrease G2B G2-BT (*) *: For high temperature and large load
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400 g 16 kg
Bellows type Can
SUNSTAR PAINT PRIMER 580 SUPER
20 ml
Glass container
SUNSTAR GLASS PRIMER 580 SUPER
20 ml
Glass container
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can
417-926-3910
SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
320 ml
Polyethylene container
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass
Category
COATING MATERIALS
• "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque (Nm {kgm})
Norminal No.
02 03, 04 05, 06 10, 12 14
Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010
{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
mm
mm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
Tightening torque (Nm {kgm})
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5
{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
10 0 2 24 0 4 43 0 6 77 0 12
6 8 10 12
1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
802 10 0 2 12 0 2 24 0 4 36 0 5
6 8 10 12 14
0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9
1 / 16 1/8 1/4 3/8 1/2 3/4 1
0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference)
Range
Target
34 – 54 {3.5 – 5.5}
44 {4.5}
–
9 — – 18UN 16
14.3
34 – 63 {3.5 – 6.5}
44 {4.5}
14
–
–
22
54 – 93 {5.5 – 9.5}
74 {7.5}
–
11 — – 16UN 16
17.5
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
–
–
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
13 — – 16UN 16
20.6
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
1 – 14UNS
25.4
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
3 1 — – 12UN 16
30.2
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
–
–
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
–
–
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
–
–
02
03
00-14
19
FOREWORD
ELECTRIC WIRE CODE
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: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
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
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
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
2 Color White & Red
—
Code
—
WB
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
3
4
Auxiliary
Color White & Black
—
Code
—
WL
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
Color White & Blue
—
Code
—
—
Color White & Green
—
—
Code
—
—
—
Color
—
—
—
WG
RY
Black & Red Red & Yellow RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
5 Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
6 Red & Blue Yellow & White Green & Blue
n n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE 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. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740
6
7
8
9
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
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
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
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
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
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
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
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
7.969
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
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 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
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/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
1934
1949
1963
1977
140
1991
2005
2020
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
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice 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. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–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 0
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
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {
}.
Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
10-04
01
GENERAL
General assembly drawing . .. . . . .. . . . . . . .. . . . . . . . .. . . 01-2 Specifications . . .. . .. . . . . . .. . . . . .. .. . . . .. . .. .. . . . . . . .. . . . . .. . . .. 01-3 Weight table . . . . . . .. . . . .. . . . . . .. . . . . . . .. .. . . . . . . . . . .. . . . . . .. . . 01-6 List of lubricant and water .. . . . . . . .. .. . . . . . . .. . . .. . . 01-8
WA1 200-3
01-l
GENERAL
GENERAL ASSEMBLY
GENERAL ASSEMBLY DRAWING
DRAWING Dimensions in ( 1 are for vehicles equipped with 65/65-57-62PR tires. Dimensions marked with % are for vehicles for handling rocks and those marked with *X are for vehicles for handling lime.
SJWO4720
01-2
WA1 200-3
SPECIFICATIONS
GENERAL
Machine model
WA1 200-3
Serial No.
50001 and up
Operating weight
kg
205,200 [210,4001
Distribution (front)
kg
122,220 [ 124,840l
Distribution (rear)
kg
82,950 I85,5601
Bucket capacity (piled)
m3
20.0
Rated load
kg
36,000
FORWARD 1st
km/h
6.3 i6.51
FORWARD 2nd
km/h
11.5 [Il.91
FORWARD 3rd
km/h
19.8 120.41
REVERSE 1st
km/h
7.4 17.71
REVERSE 2nd
km/h
13.4 113.91
REVERSE 3rd
km/h
22.6 i23.21
Max. rimpull
kN {kg)
1,127 {115,000~ [1,088 ~lll,OOO~l
Gradeability
deg
25
Center of outside wheel
mm
12,000
Outside portion of chassis
mm
14,300
Overall length
mm
18,210
Overall width (chassis)
mm
5,7 10 [5,9701
Bucket width
mm
6,400 (Cutting edge) 6,550 (Tire guard)
(top of ROPS cab)
mm
6,865 !6,9301
(Bucket raised)
mm
11,865 [I I,9301
Wheelbase
mm
7,100
Tread
mm
4,300
Min. ground clearance
mm
650 [7151
Height of bucket hinge pin
mm
8,830 [8,8951
Dumping clearance (tip of edge)
mm
6,735 [6,8001
Dumping reach (tip of edge)
mm
2,665
Bucket dump angle
deg
49.5 (Max. height)
Bucket tilt angle (SAE carrying position)
deg
50
Digging depth (IO” dump) (tip of edge)
mm
590 [5251
Travel speed
Min. turning radius
I
Overall height
I I: with 65/65-57-62PR tires WA1 200-3
01-3
SPECIFICATIONS
GENERAL
Machine model
WA1 200-3
Serial No.
50001 and up
Model
Cummins QSK60
Type
4-cycle, water-cooled, V type, 16-cylinder direct injection, with turbocharger, after-cooler
No. of cylinders - bore x stroke
16-159x190
e {cc)
60 (60,360)
Wrpm IHP/rpml
1,I 60/l ,900 {I ,558/l ,900)
lmlrpm Ikgmlrpml
7,830/l ,500 {798/l ,500)
g/kW-h {g/HP-h}
214 {ISO} (at rated output, gross)
High idling speed
wm
2,050
Low idling speed
wm
650
Piston displacement
Fuel consumption i
mm
ratio
24 V 9.0 kW x 2
Starting motor
24V140A
Alternator
12 V 200 Ah x 6
Battery Torque converter
3-element,
Planetary gear, multiple-disc, hylraulically actuated, modulation type
Transmission
Spiral bevel gear
Reduction gear Differential
Straight bevel gear
Final drive
Planetary gear, 2 reduction, oil bath Front/rear-wheel
Drive type
Fixed-frame, full-floating
Rear axle
Center pin support type, full-floating
Wheel rim Inflation pressure Main brake
1 ? a
drive
Front axle
55.5/80-57-68PR(L-5) [65/65-57-62PR(L-511
Tire
-
l-stage, single-phase (TCA51-3)
kPa {kg/cm21
44.00 x 57i6.0 [52.00 x 57i6.01 588 (6.01 Front/rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated
Parking brake
Drive shaft (Transmission output shaft) braking, multiple wet disc, hydraulically release spring apply
r I: ’with 65/65-57-62PR tires
01-4
WA1 200-3
SPECIFICATIONS
GENERAL
Machine model
WA1 200-3
Serial No.
50001 and up Articulated type
Type
Fully hydraulically power steering
Structure
Hydraulic pump Delivery
Control valve Set pressure
Cylinder
Torque converter, transmission pump
Umin
Steering pump
Umin
630 (Fixed capacity piston pump: HPF160+160)
Switch pump
Umin
630 Variable + fixed capacity piston pump: HPV160+HPF160)
PPC pump
4Ymin
95 (Gear type: SAR(2)50)
Brake pump
Urnin
54 (Gear type: SAR(2)28)
Work equipment pump (I)
Urnin
630 (Variable capacity piston pump: HPV160+160)
Work equipment pump (2)
l?/min
383 (Variable capacity piston pump: H PV95+95)
Transmission valve
MPa {kg/cm?
2.65 127) (Spool type, electric control)
Steering valve
VlPa {kg/cm21
31.4 {320} (Spool type)
PPC valve
VlPa {kg/cm?
3.7 08) (2-lever type)
Main control valve
VlPa {kg/cm’)
31.4 (320) (2-spool type)
Steering cylinder No. - bore x stroke
mm
Reciprocating piston 2 - 225 x 660
3oom cylinder No. - bore x stroke
mm
Reciprocating piston 2-360x 1,835
3ucket cylinder No. - bore x stroke
mm
Reciprocating piston 2-300x 1,025
-ink type 3ucket edge type
WA1 200-3
817 (Gear type: SAR(4)200+SAR(4)200)
Double Z bar link Spade nose bucket with teeth
01-5
WEIGHT TABLE
GENERAL
WEIGHT TABLE A
This weight table is a guide for use when transporting or handling components. Unit: kg Machine model
I
WA1 200-3 50001 and up
Serial No. Engine
7,250
Radiator (including hydraulic oil cooler)
2,750
Torque converter
I
1,404
Torque converter oil cooler
I
285 338
Fuel cooler
3,690
Transmission Damper
I
359
Upper drive shaft
112
Center drive shaft
184
Front drive shaft
209
Rear drive shaft
215
Center support
I
154
Front axle
I
16,500 16,500
Rear axle Front differential assembly
1,570
Rear differential assembly
1,800
Planetary carrier assembly (each) Planetary hub assembly (each)
880 I
710 6251960
Axle pivot (Rear axle) (front/rear) Wheel (55.5 tire/65 tire) (each)
1,913/2,051
Tire (55.5 tire/65 tire) (each)
5,930/7,150 68
Steering valve Steering cylinder (each)
I
589 1,366 ( 1,230)
Hydraulic tank (tank unit)
193/I 66
Work equipment pump (No.VNo.2) Torque converter charging + PPC pump
70.3
Switch pump
189
Steering pump
191
Fender (one side) PPC valve
01-6
I
140 4
WA1 200-3
WEIGHT TABLE
GENERAL
Unit: kg Machine model
WA1 200-3
Serial No.
50001 and up 95
Main control valve (each) Boom cylinder (each)
2,943
Bucket cylinder
1,380
Radiator guard
905
Front frame
I
15,160
Rear frame Bucket link (including bushing) (each) Bellcrank (including bushing) (each) Boom (including bushing)
646
r
2,440 18,430
Bucket (with teeth)
I
23,840
Rear bumper (including fuel tank)
I
6,470
Fuel tank (side x 2, center x 1)
side: 520 x 2, center: 609
Battery (each)
59
Cab assembly
539
Air conditioner unit
I
55
I
3,238
Operator’s seat Floor plate ROPS support assembly
WA1 200-3
01-7
LIST OF LUBRICANT AND WATER
GENERAL
LIST OF LUBRICANT AND WATER RESERVOIR
AMBIENT TEMPERATURE -40 -22 -4 14 32 50 88 88 104 -40 -30 -20 -10
0
10
20
30
40
CAPACITY 122°F 50°C
Specified
Refill
260 Q
Engine oil pan
Transmission case
380 k!
350 Q
Engine oil Hydraulic system
Brake tank
1,200 e
Brake Cooling
Axle (Front and rear) (each)
See Note 1
Auto-grease
Grease
Work equipment pir
Gear oil
Fuel tank
Gear
60 Q
45 Q
280 Q
270 Q
670 Q
670 Q
5,100 Q -
Cooling system
Water
Add antifreeze
510 Q
% ASTM 0975 No.1 Note 1: For axle oil, use only recommended oil as follows. DONAX TT or TD SHELL: RPM TRACTOR HYDRAULIC FLUID CALTEX: TRACTOR HYDRAULIC FLUID CHEVRON: TDH OIL TEXACO: MOBILAND SUPER UNIVERSAL MOBIL: It is possible to substitute engine oil CLASS-CD SAE30 for axle oil. If noise comes from the brake, it is no problem of durability.
01-8
*
In cold areas when the hydraulic oil temperature is low, if the steering wheel is turned and the machine is stopped in that position, there may be a time lag before the machine turns and stops. If this happens, turn the steering wheel slowly to the left and right (repeat for about 10 minutes) and the oil inside the steering valve will be warmed up. [xl]: When working in particularly severe conditions, use a multi-purpose grease containing 3 - 5% molybdenum. b+21: For machines equipped with an autogrease system, if the machine is operated in temperatures below -2O”C, use lithiumbased grease No. 0 for the grease.
WA1 200-3
LIST OF LUBRICANT AND WATER
GENERAL
REMARK 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
0.5 to 1.0% Above
Change interval of oil in engine oil pan
content
1.0%
I
l/2 of regular
interval
l/4 of regular
interval
When starting the engine in an atmospheric temperature of lower than O”C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W40, 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, reduce the engine oil change interval to half. There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-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:
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
WA1 200-3
01-9
10
STRUCTURE AND FUNCTION
Outline ......................................................... 10- 2 Radiator and hydraulic oil cooler ............. 10- 4 Damper ........................................................ 10- 5 Torque converter and transmission piping ............................. 10- 6 Torque converter ........................................ 10- 8 Main relief valve and torque converter relief valve ............................................ 10- 17 Torque converter regulator valve ............. 10- 20 ECMV ........................................................... 10- 22 Transmission .............................................. 10- 28 Transmission control valve ....................... 10- 38 Lubricating oil relief valve ......................... 10- 49 Transfer ....................................................... 10- 50 Torque converter oil cooler ...................... 10- 52 Center support ............................................ 10- 53 Axle .............................................................. 10- 54 Final drive ................................................... 10- 59 Axle mount ................................................. 10- 60 Center hinge pin ......................................... 10- 62 Arrangement of steering equipment ........ 10- 63 AJSS (Advanced Joystick Steering System) ................................................. 10- 64 Steering pump ............................................ 10- 65 Switch pump .............................................. 10- 68 Servo valve ................................................. 10- 71 Steering demand valve ............................. 10- 75 Rotary valve ................................................ 10- 86 EPC valve .................................................... 10- 89 Diverter valve ............................................. 10- 90 Arrangement of brake equipment ............ 10- 94 Brake valve ................................................. 10- 96 Charge valve ............................................... 10-101 Accumulator (for brake) ............................ 10-105 Slack adjuster ............................................. 10-106
WA1200-3
Brake ............................................................ 10-109 Parking brake .............................................. 10-110 Arrangement of hydraulic equipment ...... 10-112 Work equipment lever linkage .................. 10-114 Hydraulic tank ............................................. 10-115 Work equipment pump No. 1 ................... 10-118 Work equipment pump No. 2 ................... 10-131 PPC valve .................................................... 10-148 PPC relief valve .......................................... 10-152 Accumulator (for PPC valve) ..................... 10-153 Main control valve ..................................... 10-154 Work equipment linkage ........................... 10-168 Operation of proximity switch .................. 10-170 Air conditioner ............................................ 10-172 Machine monitor system........................... 10-175 Main monitor .............................................. 10-177 CGC monitor ............................................... 10-181 All-range electronic control automatic transmission (ATM) system ................ 10-218 Modulated clutch (MOD/C) control system ..................................... 10-233 Work equipment and joystick steering control system ..................................... 10-237 Work equipment and joystick steering controller .............................................. 10-243 Engine starting circuit ................................ 10-244 Engine stopping circuit .............................. 10-248 Ether injection circuit ................................. 10-249 Electric parking brake control ................... 10-250 Parking brake solenoid valve .................... 10-260 Emergency parking brake reset solenoid valve ............................ 10-261 Kick-down switch and auto shift/ manual shift selector switch ............... 10-262
10-1 (7)
STRUCTURE
AND FUNCTION
OUTLINE
OUTLINE
SWWO4721
OUTLINE The power of engine (16) is transmitted through the engine flywheel to damper (15). The damper output shaft is connected to modulated clutch (13) through upper drive shaft (14). The output of the modulated clutch is connected to the pump of torque converter (11). The turbine of the torque converter is connected to input shaft of transmission (IO). The transmission has five hydraulically operated clutches and generates three gear speeds each in forward and reverse directions which are selected with an electric control switch. The transmission output shaft is connected to the gear of transfer (91, then the power is transmitted to the transfer output shaft. Then, the power is transmitted from the transfer output shaft through center drive shaft (71, center support (321, front drive shaft (61, and rear drive shaft (31) to front axle (5) and rear axle (281, then transmitted through the wheels to the tires.
1
o-2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Front differential Front brake Front final drive Front tire Front axle Front drive shaft Center drive shaft Emergency steering pump Transfer (Output) Transmission Torque converter Transfer (Input) Modulated clutch Upper drive shaft Damper Engine Work equipment pump No. 1 Work equipment pump No. 2 Switching pump Steering pump Control pump PPC pump
WA1 200-3
STRUCTURE
23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
AND
FUNCTION
Torque converter, transmission Brake cooling pump Brake pump Rear final drive Rear tire Rear axle Rear differential Rear brake Rear drive shaft Center support Parking brake
WA1 200-3
OUTLINE
pump
SWW04722
1o-3
STRUCTURE AND FUNCTION
RADIATOR
AND HYDRAULIC
RADIATOR AND HYDRAULIC OIL COOLER
OIL COOLER ,______----I
2
3
Y SJW04723
1. Fan guard 2. Water level sensor 3. Radiator cap 4. Sub-tank 5. Upper tank 6. Hydraulic oil cooler 7. Radiator (LTC) 8. Radiator (HTC) 9. Lower tank
1o-4
Specification LTC Core type Total heat dissipating
m* area I I Cross-sectional area of water tubes /cm ‘1
I
HTC
1
Modular core Modular core
I
I
211.6 59,042
414.8 1
88,690
I
/ I
WA1 200-3
DAMPER
STRUCTURE AND FUNCTION
DAMPER
3
4
5
6
SJW04724
1. Shaft
2. 3. 4. 5. 6.
Breather Rubber cushion Inner body Rubber cushion Outer body
FUNCTION . The damper reduces the caused by changes in the acts to protect the units beyond the engine from sional vibration.
torsional vibration engine torque, and of the power train the effects of tor-
OPERATION . The power of the engine is transmitted from the flywheel to outer body (6). The torsional vibration of the engine is absorbed by rubber cushions (3) and (51, passes through inner body (4) and shaft (I), and is transmitted to the upper drive shaft between the torque converter.
WA1 200-3
1o-5
STRUCTURE AND FUNCTION
TORQUE CONVERTER
TORQUE CONVERTER AND TRANSMISSION
AND TRANSMISSION
PIPING
PIPING
SWW04725
1. 2. 3. 4. 5. 6. 7. 8. 9.
Transmission Transmission control valve Transfer (input) Torque converter oil cooler Torque converter charging pump Torque converter Torque converter oil filter Transmission oil level gauge Transfer (output)
10-6
WA1 200-3
TORQUE CONVERTER
STRUCTURE AND FUNCTION
TORQUE CONVERTER (INPUT
TRANSFER,
PTO, MODULATED CLUTCH, TORQUE CONVERTER)
lZ
W 7
9JA00061
1O-8
WA1 200-3
STRUCTURE AND FUNCTION
TORQUE CONVERTER
G
!
H
.\... F
J
v
IO
9JBOOO62
A: Torque converter outlet port B: Outlet oil pressure pick-up port of torque converter c: Torque converter inlet port D: Lubrication port for PTO, input transfer, and modulated clutch E: Interconnection port F: Torque converter inlet port G: Inlet oil pressure pick-up port of torque converter H: Main oil pressure pick-up port J: Torque converter relief port K: Drain port
WA1 200-3
1. Mounting port for steering pump, control pump, and PPC pump 2. Mounting port for switch pump 3. Mounting port for transmission charging pump, torque converter charging pump, brake cooling pump, and brake pump 4. Regulator valve of torque converter outlet 5. Mounting port for work equipment pump 6. Mounting port for work equipment pump 7. Output rotation sensor of modulated clutch 8. ECMV for modulated clutch 9. Torque converter valve 10. Input rotation sensor of input transfer
1o-9
STRUCTURE AND FUNCTION
TORQUE CONVERTER
14
A-A
9JB00063
10-10
WA1 200-3
STRUCTURE
AND
FUNCTION
TORQUE
CONVERTER
9JBOOO64
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Coupling Drive gear (Number of teeth: 74) PTO gear (Number of teeth: 68) PTO gear (Number of teeth: 68) Idler gear (Number of teeth: 68) Modulated clutch output shaft Modulated clutch piston Modulated clutch outer drum Modulated clutch inner drum Coupling
WA1 200-3
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Torque converter input shaft Drive case Turbine Stator Pump Torque converter case Transmission input shaft Driven gear (Number of teeth: 58) Modulated clutch disc Modulated clutch plate
10-11
STRUCTURE AND FUNCTION
TORQUE CONVERTER
Specifications Model: 42C-13-11002 Type: 3-elemet, single stage, single phase Stall torque ratio: 2.23 (T3/Tl) 2.84 (T3/T2)
T3
10-12
WA1 200-3
STRUCTURE
AND
FUNCTION
TORQUE
CONVERTER
Operation Power
transmission
route
9JBOOO66
l
The torque converter is installed between the damper and transmission. The power from the damper is transmitted through the upper drive shaft to coupling (II). The speed of the rotation is heightened with drive gear (121, idler gear (151, and driven gear (28) of the input transfer, then transmitted to modulated clutch inner drum (19). If oil pressure is applied to the back of modulated clutch piston (171, modulated clutch piston (171 presses modulated clutch disc (29) against modulated clutch plate (30) to transfer the power to modulated clutch outer drum (18).
10-14 0
l
The power transmitted to modulated clutch outer drum (18) is further transmitted through modulated clutch output shaft (16) and coupling (20) to torque converter input shaft (21). Since torque converter input shaft (211, drive case (22). and pump (25) are secured with bolts, they are rotated with the power from the modulated clutch. The power of pump (25) rotates turbine (23) to drive transmission input shaft (271, using the oil as medium. The power of coupling (11) is used to drive the pump, too, through drive gear (121, PTO gear (131, or idler gear (15).
WA1 200-3
STRUCTURE AND FUNCTION
TORQUE CONVERTER
Flow of oil
9JBOOO67
l
The oil flows through the main relief valve and its pressure is regulated below the set pressure by the torque converter relief valve, then it flows in inlet port A and merges with the oil sent from the torque converter charging pump through torque converter case (26), then the merged oil flows in pump (25). Set pressure: 1.05 MPa (IO.7 kg/cm*} The oil is given centrifugal force by pump (251, then it flows in turbine (23) and gives its energy to turbine (23).
WA1 200-3
The oil from turbine (23) flows to stator (24) and flows in pump (25) again. At this time, a part of the oil flows through stator (24) and outlet port B to the torque converter outlet regulator valve. The oil that flows in the torque converter outlet regulator valve flows further through the oil cooler to cool itself, then it is used to lubricate the transmission.
10-M
STRUCTURE AND FUNCTION
TORQUE CONVERTER
Outline The modulated clutch is installed between the input transfer and torque converter. The clutch can be engaged or slipped by adjusting the clutch oil pressure with ECMV. The power transmitted to the torque converter can be reduced by slipping the clutch. l
l
l
Operation When clutch is engaged The oil sent from ECMV (1) for the modulated clutch flows through the oil passage of modulated clutch case (2) to piston (3) and moves piston (3) to the right. If piston (3) moves and the clutch oil pressure rises, the pressure of piston (3) increases and presses disc (4) against plate (5) to engage inner drum (6) with outer drum (7). Accordingly, all of the power transmitted from inner drum (6) is transmitted to outer drum (7). l
When clutch is slipped . If the controller outputs the signal to lower the clutch oil pressure, ECMV (I) for the modulated clutch lowers the clutch oil pressure. If the clutch oil pressure lowers, the pressure of piston (3) lowers and disc (4) slips on plate (51, then outer drum (7) rotates slower than inner drum (6). As a result, the transmitted power is reduced. l
9JBOOO68
The transmitted power depends on the slip ratio of the clutch and the speed ratio of the torque converter. Slip ratio = (I - Output rpm/lnput rpm) x 100 (%)
10-16
WA1 200-3
STRUCTURE AND FUNCTION
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE I
E
23
D
7
A-A P4
\
A4
Pi 9JB00069
A: B: C: D: E: F: G: PI:
From pump To torque converter To transmission lubricating circuit Drain Drain Drain Drain Inlet oil pressure pick-up port of torque converter P4: Main oil pressure pick-up port
Outline . Main relief valve The main relief valve keeps the transmission oil pressure at the set level. Set pressure: 2.65 MPa (27 kg/cm21 (At the rated engine speed) Torque converter relief valve The torque converter relief valve is installed l
WA1 200-3
1. 2. 3. 4. 5. 6. 7. 8. 9. IO.
Valve body Valve spring (Small) Valve spring (Large) Main relief valve spool Piston spring Piston Valve spring Torque converter relief valve spool Piston spring Piston
to the torque converter inlet circuit, and it keeps the oil pressure at the torque converter inlet circuit below the set pressure to protect the torque converter from abnormally high pressure. Set pressure: 1.05 MPa 110.7 kg/cm*) (Cracking pressure)
10-17
Operation Operation of main relief valve l
From
The oil from the torque converter charging pump flows through the filter into port A of spool (41, then flows through orifice a into port B. If the circuit is filled with the oil from the pump, the oil pressure starts rising.
To torque converter
Pump
To transmission lubrication
SXW04736
l
As the oil pressure in the circuit rises, the oil in chamber B presses piston (6) and its reaction force compresses springs (2) and (3) to move spool (4) to the left to open ports A and C. Then, the oil from the pump flows through port A and port C into the torque converter. At this time, the oil pressure at port A is 2.65 MPa 127 kg/cm21 (at the rated engine speed).
To torque converter
To transmission lubrication
sxwo4737
lo-18
WA 1200-3
STRUCTURE AND FUNCTION
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
Operation of torque converter relief valve The oil from the main relief valve flows through port C into the torque converter. It also flows through orifice b of spool (8) into chamber D. If the torque converter is filled with the oil, the oil pressure starts rising. As the oil pressure in the torque converter rises, the oil in chamber D presses piston (10) and its reaction force compresses valve spring (7) to move spool (8) to the right to open ports C and E. Then, the oil in port C flows through port E into the transmission lubricating circuit. At this time, the oil pressure at port C is 1.05 MPa 110.7 kg/cm? (cracking pressure).
l
l
To toraue converter
To transmission lubrication
sxwo473a
WA1 200-3
10-19
TORQUE CONVERTER REGULATOR VALVE
STRUCTURE AND FUNCTION
TORQUE CONVERTER REGULATOR VALVE
9JBOOO73
A: From torque converter B: To oil cooler 1. 2. 3. 4. 5. 6.
Valve body Valve spring (Small) Valve spring (Large) Spool Piston spring Piston
1O-20 0
Outline The torque converter regulator valve is installed to the torque converter outlet circuit to extract the full performance of the torque converter by keeping the oil pressure in the torque converter at the set level. Set pressure: 0.88 2 0.10 MPa 19 -c 1 kg/cm? l
WA1 200-3
STRUCTURE AND FUNCTION
TORQUE CONVERTER REGULATOR VALVE
Operation The oil from the torque converter flows through port A and orifice a into chamber B. Since the oil pressure in chamber B is lower than the tension of valve springs (2) and (31, spool (4) does not move.
l
8
From torque converter
.
sxwo4739
If oil pressure in chamber B rises above the tension of valve springs (2) and (31, the oil in chamber B presses piston (6) and its reaction force compresses valve springs (2) and (3) to move spool (4) to the left to open ports A and C.
/ A
WA1 200-3
ii From torque converter
sxwo4740
1o-21
STRUCTURE AND FUNCTION
ECMV
ECMV (For modulated clutch)
9JBOOO76
A: B: C: P:
To clutch Drain From pump Clutch oil pressure pick-up port
1o-22
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connector Spring Flow sensor valve spool Spring Fill switch Proportional solenoid Pressure control valve spool Load piston Spring
WA1 200-3
STRUCTURE AND FUNCTION
ECMV
Outline Outline of ECMV ECMV (Electronic Control Modulated Valve) consists of one pressure control valve and one flow sensor valve. . Pressure control valve This valve receives the current sent from the controller with a proportional solenoid, then converts it into oil pressure.
A
l
l
Flow sensor valve This valve operates according to the trigger signals sent from the pressure control valve and has the following functions. 1) Keeps open untilthe clutch is filled with oil to shorten the time to fill the clutch with oil (filling time). 2) Closes and outputs a signal (a filling signal) to the controller to notify that filling is completed when the clutch is filled with oil. 3) Keeps outputting signals (filling signals) to the controller to notify that oil pressure is applied or not while oil pressure is applied to the clutch. Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
ECMV and proportional solenoid . For each ECMV, one proportional solenoid is installed. The proportional solenoid generates propulsion force according to the command current from the controller as shown in the figure at right. The propulsion force generated by the proportional solenoid is applied to the pressure control valve spool to generate the oil pressure shown in the figure at right. Accordingly, the propulsion force is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil.
0’
MPa!_ to/cm’) _
,
E
,
I
I
D
’
_
w3ec
Time
t .-c al zz .-al
/-
‘,;I
;
t-l o 1
OFF
)
1
*Set
Time
1
ON
*Set
Time
sxwo474
1
Characteristics of ProPortional solenoid current-propulsion force N (ka)
0
’
(A) -
MPa( kg/cm’)
Current
Characteristics of solenoid propulsion-oil
proportional Pressure
ECMV and fill switch For each ECMV, one fill switch is installed. If the clutch is filled, the flow sensor valve
l
turns on the fill switch. When this signal output, oil pressure starts building up.
is
N(kel -
Propulsion
force
SXW04742
WA1 200-3
1 O-23
STRUCTURE AND FUNCTION
ECMV
Operation Operation of ECMV ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship among the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown at right. l
Set
Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
L
4
i;;
,Sec Time
t-l 1
OFF
1
ON Time
esec
sxwo474
1.
1
Before shifting gear (when draining) (Range A in chart) While any current is not flowing in proportional solenoid (6). proportional solenoid (6) is pushed back by the reaction force of pressure control valve spring (9) through pressure control valve spool (7). Accordingly, pressure control valve spool (7) drains the oil from clutch port C through drain port E. At this time, since any oil pressure is not applied to flow sensor valve spool (3), flow sensor valve spool (3) is separated from fill switch (5) by the reaction force of fill switch spring (4) and stopped at a position where fill switch spring (4) is balanced with flow sensor valve return spring (2).
9JEOOO77
1O-24
WA1 200-3
STRUCTURE AND FUNCTION
2.
ECMV
When fill starts (During trigger) (Range B in chart) 1) If a trigger current (the maximum current) is given to proportional solenoid (6) while there is not oil in the clutch, proportional solenoid (6) moves through its stroke and pressure control valve spool (7) moves to the left. As a result, pump port A and pressure control valve output port B open, then the oil starts flowing into the clutch through orifice a of flow sensor valve spool (3).
9JBOOO78
2)
At this time, differential pressure is generated between the upstream side and downstream side of orifice a of flow sensor valve spool (3). Because of this differential pressure, flow sensor valve spool (3) compresses flow sensor valve return spring (2) and moves to the left. Then, flow sensor valve spool (3) opens pump port D and oil flows through orifice a into clutch port C.
9JBOOO79
WA1 200-3
1o-25
STRUCTURE
3.
AND FUNCTION
When fill is completed (When pressure trol valve is set to initial pressure) (Range C in chart) I)
ECMV
con-
If pump port D of the flow sensor valve opens and oil starts flowing, differential between the uppressure is generated side of oristream side and downstream fice a of flow sensor valve spool (31, and this pressure keeps pressing flow sensor valve spool (3) to the left. At this time, if the current flowing in proportional solenoid (61 is lowered to the alinitial pressure level for a moment, most all the pump pressure is applied to load piston (8) and pressure control valve spool (7) is pushed back to the right, then a little oil flows from pressure control valve output port B to drain port E. Since the quantity of this oil is not much, almost all the oil from the pump flows into the clutch and flow sensor valve spool (3) is kept pressed to the left. 9JBOOO80
2)
If the clutch is filled with oil, the oil from pressure control valve port B does not flow into clutch port C. The pressure receiving area of the left side of flow sensor valve spool (3) is larger than that of if the same the right side. Accordingly, oil pressure is applied to both sides, flow sensor valve spool (3) is moved by the oil pressure to the right. As a result, pump port D and clutch port C are closed. At this time, flow sensor valve spool (3) is pushed to the right further by the difboth sides and ferential area between the tension of flow sensor valve return spring (21, and it compresses fill switch spring (4). Then, flow sensor valve spool (3) touches fill switch (5) and notifies the controller of completion of filling. At this time, a current of the initial pressure level solenoid (6) and flows in proportional pressure control valve (71 is set to the initial pressure.
9JROOORl
1O-26
WA1 200-3
STRUCTURE AND FUNCTION
4.
ECMV
Pressure adjustment (Range D in chart) If a current flows in proportional solenoid (61, the solenoid generates a propulsion force in proportion to the current. This propulsion force of the solenoid is balanced with the sum of the propulsion force of load piston (8) generated by the oil pressure in clutch port C and the reaction force of pressure control valve spring (91, then the pressure is settled. Flow sensor valve spool (3) is pressed to the right by the differential oil pressure between both sides of itself and it continues outputting the fill signal to the controller.
9JBOOO82
WA1 200-3
lo-27
TRANSMISSION
STRUCTURE AND FUNCTION
TRANSMISSION (Transmission, transfer, and parking brake)
9JB00083
1. Transmission valve 2. Transmission input shaft 3. Transmission 4. Transfer 5. Output coupling (Front side) 6. Drain plug
1O-28
7. 8. 9. 10. 11.
Parking brake Output coupling (Rear side) Travel speed sensor adapter Oil filler adapter Strainer
WA1 200-3
STRUCTURE AND FUNCTK)N
TRANSMISSION
9JBOO
From oil filter From oil cooler Lubricating oil pressure pick-up port To parking brake valve To modulated clutch ECMV To main relief valve and torque converter relief valve G: Drain port H: From torque converter case J: To transmission charging pump and torque converter charging pump
A: B: c: D: E: F:
WA1 200-3
004
K: From torque converter case L: To modulated clutch (Lubrication) and input transfer (Lubrication) M: To parking brake piston N: To transmission lubricating circuit P: To transmission lubricating circuit Q: To 1st speed clutch R: To 2nd speed clutch S: To 3rd speed clutch T: To forward clutch U: To reverse clutch
1O-29
TRANSMISSION
STRUCTURE AND FUNCTION
+
6
44
x-x
+ SJBOOOB5
1O-30
WA1 200-3
TRANSMISSION
STRUCTURE AND FUNCTION
’I. 2. 3. 4. 5.
+
9JROOO86
WA1 200-3
Transmission inout shaft Pinion shaft ’ Clutch disc Clutch plate Planetary pinion No. 1 (for reverse) (Number of teeth: 31) 6. Clutch No. 1 housing (for reverse) 7. Ring gear No. 1 (for reverse) (Number of teeth: 88) 8. Clutch No. 2 housing (for forward) 9. Ring gear No. 2 (for forward) (Number of teeth: 165, 94) 10. Planetary pinion No. 2 (for forward) (Number of teeth: 28) 11. Pinion shaft 12. Planetary pinion No. 3 (for 3rd speed) (Number of teeth: 28) 13. Ring gear No. 3 (for 3rd speed) (Number of teeth: 165, 94) 14. Clutch No. 3 housing (for 3rd speed) 15. Pinion shaft 16. Planetary pinion No. 4 (for 2nd speed) (Number of teeth: 22) 17. Clutch No. 4 housing (for 2nd speed) 18. Ring gear No. 4 (for 2nd speed) (Number of teeth 165, 94) 19. Piston No. 5 return spring (for 1st speed) 20. Clutch No. 5 piston (for 1st speed) 21. Rear housing 22. Transmission output shaft 23. Clutch No. 5 housing (for 1st speed) 24. Carrier No. 4 (for 2nd speed) (Number of teeth: 94) Clutch No. 5 drum (for 1st speed) (Number of teeth: 164) 25. Clutch No. 5 hub (for 1st speed) 26. Sun gear No. 4 (for 2nd speed) (Number of teeth: 50) 27. Clutch No. 4 piston (for 2nd speed) .28. Piston No.4 return spring (for 2nd speed) 29. Sun gear No. 3 (for 3rd speed) (Number of teeth: 38) 30. Clutch No. 3 piston (for 3rd speed) Piston No. 3 return spring (for 3rd speed) 3”:: Carrier No. 2, 3 (for forward, 3rd speed) (Number of teeth: 88) 33. Clutch No. 2 piston (for forward) 34. Sun gear No. 2 (for forward) (Number of teeth: 38) 35. Piston No. 2 return spring (for forward) 36. Clutch No. 1 piston (for reverse) 37. Sun gear No. 1 (for reverse) (Number of teeth: 26) 38. Ring gear No. 1 (for reverse) (Number of teeth: 165, 94) 39. Carrier No. 1 (for reverse) (Number of teeth: 94) 40. Piston No. 1 return spring (for reverse) 41. Pin 42. Washer spring 43. Tie bolt 44. Front housing
1o-31
TRANSMISSION
STRUCTURE AND FUNCTION
Outline The transmission system consists of a forward 3-gear speed and reverse 3-gear speed+ transmission consisting of planetary gear mechanisms and disc clutches, transfer, parking brake, and transmission control valve. Among the five sets of a planetary gear mechanism and a disc clutch, 2 clutches are operated with a control valve and fixed hydraulically to select one rotation direction and one rpm. Clutch No. 1 is fixed for reverse travel, clutch No. 2 for forward travel, clutch No. 3 for travel at 3rd speed, clutch No. 4 for travel at 2nd speed, and clutch No. 5 for travel at 1st speed. l
l
l
Gear speeds and operated clutches Gear speed Forward Forward Forward Reverse Reverse Reverse
Operated (Engaged) clutch No.2 No.2 No.2 No.1 No.1 No.1
1st speed 2nd speed 3rd speed 1st speed 2nd speed 3rd speed
. . . . .
No.5 No.4 No.3 No.5 No.4 No.3
Number of plates and discs used Clutch No. Clutch Clutch Clutch Clutch Clutch
No. No. No. No. No.
lo-32
1 2 3 4 5
Number of plates Number of discs 7 8 4 3 8
8 9 5 4 9
WA1 200-3
STRUCTURE AND FUNCTION
TRANSMISSION
Operation Operation of clutch The clutch consists of piston (361, plate (41, disc (3), pin (411, piston return spring (401, washer spring (421, etc. to secure ring gear (38). The inside teeth of disc (3) are engaged with the outside teeth of ring gear (38). The cut part of the outside of plate (4) is engaged with pin (41) fixed to clutch housing (6). l
l
l
9J800087
Clutch “ON” (Fixed) The oil sent from the transmission valve flows through the oil passage in the transmission to the back side of piston (36) to move piston (36) to the left. Piston (36) presses plate (4) against disc (3) to stop rotation of disc (3) with friction force and fixes ring gear (38) engaged with the inside teeth.
l
l
9J800088 Clutch ‘OFF” (Released) . If the oil sent from the transmission valve is shut off, piston (36) is returned by piston return spring (401, then the friction force between plate (4) and disc (3) is released and ring gear (38) is set in neutral. Washer spring (42) installed between plates (4) at the pin section returns piston (36) quickly and separates plate (4) from disc (3) sharply to prevent drag turning when the clutch is disengaged.
l
95800089
WA1 200-3
1o-33
TRANSMISSION
STRUCTURE AND FUNCTION
Power train Forward 1st speed
9J 800090
l
l
When the transmission is set in the forward 1st speed, clutches No. 2 and No. 5 are connected and ring gear No. 2 (9) is fixed and clutch No. 5 hub (25) is directly coupled with output shaft (22) to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 2 (34) to planetary pinion No. 2 (10). Since ring gear No. 2 (9) is fixed, planetary pinion No. 2 (10) rotates and revolves along ring gear No. 2 (9) around sun gear No. 2 (34) simultaneously.
1o-34
l
l
l
At this time, rotation of carriers No. 2 and No. 3 (32) is transmitted as rotary power in the rotation direction of sun gear No. 2 (34). Since clutch No. 5 is engaged, ring gear No. 3 (13), carrier No. 4, clutch No. 5 drum (24), and clutch No. 5 hub (25) are fixed as one unit. Since carriers No. 2 and No. 3 (32) rotate under this condition, the whole unit of ring gear No. 3 (13), carrier No. 4, clutch No. 5 drum (24), and clutch No. 5 hub (25) rotates, and the rotary power is output through output shaft (22) in the rotation direction of sun gear No. (2) (34).
WA1 200-3
STRUCTURE AND FUNCTION
TRANSMISSION
Forward 2nd speed
9JB00091
When the transmission is set in the forward 2nd speed, clutches No. 2 and No. 4 are connected and ring gears (9) and (18) are fixed to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 2 (34) to planetary pinion No. 2 (IO). Since ring gear No. 2 (9) is fixed, planetary pinion No. 2 (IO) rotates and revolves along ring gear No. 2 (9) around sun gear No. 2 (34) simultaneously. At this time, rotation of carriers No. 2 and No. 3 (32) is transmitted as rotary power in the rotation direction of sun gear No. 2 (34).
WA1 200-3
l
.
Since clutch No. 4 is engaged, ring gear No. 4 (18) is fixed. Since carriers No. 2 and No. 3 (32) rotate under this condition, the power is transmitted from ring gear No. 3 (13) through carrier No. 5 to clutch No. 5 drum (24). Planetary pinion No. 4 (16) rotates and revolves along ring gear No. 4 (18) around sun gear No. 4 (261, and its rotary power is output to output shaft (22) in the rotation direction of sun gear No. 2 (34).
1o-35
TRANSMISSION
STRUCTURE AND FUNCTION
Forward 3rd speed
QJBOOO!32
l
l
l
When the transmission is set in the forward 3rd speed, clutches No. 2 and No. 3 are connected and ring gears No. 2 (9) and No. 3 (13) are fixed to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 2 (34) to planetary pinion No. 2 (IO). Since ring gear No. 2 (9) is fixed, planetary pinion No. 2 (10) rotates and revolves along ring gear No. 2 (9) around sun gear No. 2 (34) simultaneously.
1O-36
.
l
l
At this time, rotation of carriers No. 2 and No. 3 (32) is transmitted as rotary power in the rotation direction of sun gear No. 2 (34). Since ring gear No. 3 (13) is fixed, as carriers No. 2 and No. 3 (32) rotate, planetary pinion No. 3 (12) rotates along ring gear No. 3 (13) and revolves around sun gear No. 3 (291. Under this condition, the rotary power of carriers No. 2 and No. 3 (32) rotates sun gear No. 3 (29) and is output to output shaft (22) in the rotation direction of sun gear No. 2 (34).
WA1 200-3
STRUCTURE AND FUNCTION
TRANSMISSION
Reverse 1st speed
9JEOOO93
l
l
l
When the transmission is set in the reverse 1st speed, clutches No. 1 and No. 5 are con-
nected and ring gear No. 1 (38) is fixed and clutch No. 5 hub (25) is directly coupled with output shaft (22) to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 1 (36) and planetary pinion No. 1 (5) to ring gear No. 1 (7). Since ring gear No. 1 (38) is fixed, planetary pinion No. 1 (5) rotates and revolves around sun gear No. 1 (36) simultaneously.
WA1 200-3
l
.
At this time, since clutch No. 1 fixes carrier No. 1 (391, the rotary power of planetary pinion No. 1 (5) is transmitted to carriers No. 2 and No. 3 (32) to rotate ring gear No. 1 (7) in the opposite direction to sun gear No. 1 (36). As a result, the power in the reverse direction is transmitted to output shaft (22). The power train after this point in the reverse lst, 2nd, or 3rd speed is similar to that in the forward Ist, 2nd, or 3rd speed described before.
1o-37
STRUCTURE AND FUNCTION
TRANSMISSION
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
9JBOOO94
1O-38
WA1 200-3
STRUCTURE AND FUNCTION
A: B: c: D: E: F: G: H:
TRANSMISSION
CONTROL VALVE
Reverse clutch oil pressure pick-up port Forward clutch oil pressure pick-up port 3rd speed clutch oil pressure pick-up port 2nd speed clutch oil pressure pick-up port Lubricating oil pressure pick-up port 1st speed clutch oil pressure pick-up port To parking brake valve To modulated clutch ECMV
1. By-pass fill valve and by-pass drain valve (for reverse clutch) 2. ECMV (for reverse clutch) 3. By-pass fill valve (for forward clutch) 4. ECMV (for forward clutch) 5. Lubricating oil relief valve 6. By-pass fill valve (for 1st speed clutch) 7. ECMV (for 1st speed clutch) 8. ECMV (for 2nd speed clutch) 9. ECMV (for 3rd speed clutch) 10. Pilot filter
ECMV operations table
%
When the transmission is set in neutral in the manual operation mode, the clutch of the gear speed in which the gear shift lever is set is turned “ON”.
WA1 200-3
1o-39
STRUCTURE AND FUNCTION
TRANSMISSION
CONTROL VALVE
By-pass fill valve Outline When the piston volume of a clutch is large, if only ECMV is used, it takes long time to fill the clutch, that is, the fill time is lengthened and the operator feels time lag in gear shifting operation. To solve this problem, by-pass valves are installed, which are operated simultaneously with ECMV to fill the large-piston volume clutches with oil quickly. The by-pass fill valves are installed to the reverse clutch, forward clutch, and 1st speed clutch circuits.
Relationship between by-pass fill valve and ECMV Each bv-oass fill valve is controlled with the , . command current from the transmission controller. The relationship between ECMV and operation of this valve is shown at right.
F
l
Range A: Before shifting gear (when draining) Range B: Fill starts (both by-pass fill valve and ECMV are opened simultaneously and oil is filled at large flow rate) Range C: During filling (only ECMV is opened and oil is filled at medium flow rate) Range D: Fill completed (only ECMV is opened and filling is completed at low flow rate) Range E: Pressure adjustment by ECMV Range F: During filling
1O-40
Time
Set)
WA1 200-3
TRANSMISSION
STRUCTURE AND FUNCTION
CONTROL VALVE
Operation When solenoid valve is “Da-energized” l
Since spool (2) in solenoid valve (11 is pressed to the right by return spring (31, chamber A and port T are opened and no oil pressure is applied to chamber A. Accordingly, spool (4) of the by-pass fill valve is pressed to the right by return spring (5) and ports P and C are closed.
5
When solenoid valve is “Energized” . If a current flows in solenoid valve (I), spool
(2) is pressed to the left and port P and chamber A are opened and pressurized oil is supplied to chamber A. Accordingly, spool (4) is moved to the left by the pressurized oil to open ports P and C, then the oil is supplied to the clutch.
C4PA
I
T32
I 9JEIOOO96
ECMV
9JB00097
WA1 200-3
10-41
TRANSMISSION
STRUCTURE AND FUNCTION
CONTROL VALVE
By-pass drain valve Outline l
%
When a clutch is “disengaged”, the oil in the clutch piston is drained through ECMV into the transmission case. When the piston volume of the clutch is large, if only ECMV is operated as past, it takes long time to discharge the oil. If the next gear shifting operation starts before the all oil is discharged, a shock may be generated. To prevent this, a by-pass drain valve is installed to discharge the oil quickly from a large-piston volume clutch without through ECMV. The by-pass drain valve reverse clutch circuit.
is installed
to the
Operation When solenoid valve is “De-energized” (When normal) l
Since spool (2) in solenoid valve (1) is pressed to the right by return spring (3), chamber A and port T are opened and no oil pressure is applied to chamber A. Accordingly, spool (4) of the by-pass fill valve is pressed to the right by return spring (5) and ports C and T are closed. 9JBOOO98
When solenoid valve is “Energized” (When clutch oil is discharged) . If a current flows in solenoid valve (I), spool (2) is pressed to the left and port P and chamber A are opened and pressurized oil is supplied to chamber A. Accordingly, spool (4) is moved to the left by the pressurized oil to open ports C and T, then the oil from the clutch is drained. c!r Z
This valve is operated for a set time just after the clutch is “disengaged”. Accordingly, it does not operate under the normal condition (while the clutch oil pressure is being adjusted or the clutch is being filled with oil or after a set time has passed after the clutch is “disengaged”).
1o-42
A
P2
1 9JBOOO99
WA1 200-3
STRUCTURE
TRANSMISSION
AND FUNCTION
CONTROL
VALVE
ECMV (For transmission)
SJBOOlOO
A: B: C: P:
To clutch Drain From pump Clutch oil pressure
WA1 200-3
pick-up port
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connector Spring Flow sensor valve spool Spring Fill switch Proportional solenoid Pressure control valve spool Load piston Spring
1o-43
TRANSMISSION
STRUCTURE AND FUNCTION
Outline Outline of ECMV ECMV (Electronic Control Modulated Valve) consists of one pressure control valve and one flow sensor valve. . Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, then converts it into oil pressure. . Flow sensor valve This valve operates according to the trigger sinnals sent from the pressure control valve and has the following functions. I) Closes and outputs a signal (a filling signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2) Keeps outputting signals (filling signals) to the controller to notify that oil pressure is applied or not while oil pressure is applied to the clutch. Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
CONTROL VALVE
l
ECMV and proportional solenoid For each ECMV, one proportional solenoid is installed. The proportional solenoid generates propulsion force according to the command current from the transmission controller as shown in the figure at right.
-L !k=i z-a LC zg z 5s: a. u-
Time
Characteristics of proportional solenoid current-propulsion
l
The propulsion force generated by the proportional solenoid is applied to the pressure control valve spool to generate the oil pressure shown in the figure at right. Accordingly, the propulsion force is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil.
(Set)
force
N (ke)
(A)
0' -
MPa ( ks/cm’l
Current
Characteristics of solenoid propulsion-oil
proportional pressure
ECMV and fill switch . For each ECMV, one fill switch is installed. If the clutch is filled, the flow sensor valve turns on the fill switch. When this signal is output, oil pressure starts building up.
Niksl __c
Propulsion
force
sxwo4742
1o-44
WA1 200-3
STRUCTURE AND FUNCTION
TRANSMISSION
CONTROL VALVE
Operation Operation of ECMV . ECMV is controlled with the command current sent from the transmission controller to the proportional solenoid and the fill switch output signal. The relationship among the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown at right. Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
Tine (Sec)
1.
Before shifting gear (when draining) (Range A in chart) While any current is not flowing in proportional solenoid (61, proportional solenoid (6) is pushed back by the reaction force of pressure control valve spring (9) through pressure control valve spool (7). Accordingly, pressure control valve spool (7) drains the oil from clutch port C through drain port E. At this time, since any oil pressure is not applied to flow sensor valve spool (31, flow sensor valve spool (3) is separated from fill switch (5) by the reaction force of fill switch spring (4) and stopped at a position where fill switch spring (4) is balanced with flow sensor valve return spring (2).
9JBOOlOl
WA1 200-3
1o-45
STRUCTURE AND FUNCTION
2.
When fill starts (During trigger) (Range B in chart) If a trigger current (the maximum current) is given to proportional solenoid (6) while there is not oil in the clutch, proportional solenoid (6) moves through its stroke and pressure control valve spool (7) moves to the left. As a result, pump port A and pressure control valve output port B open, then the oil starts flowing into the clutch through orifice a of flow sensor valve spool (3).
TRANSMISSION
CONTROL VALVE
a
0
A
7 9JBOOlO2
1O-46
WA1 200-3
STRUCTURE AND FUNCTION
3.
When fill is completed (When pressure control valve is set to initial pressure) (Range C in chart) 1) After the set time, the current in proportional solenoid (6) is lowered to the initial pressure level to move pressure control valve spool (7) to the right to throttle the passage between pump port A and pressure control valve output port B. As a result, the oil flow rate into the clutch is lowered. By this operation, generation of peak pressure in clutch port C at the end of oil filling process is prevented and the gear speed is changed smoothly.
TRANSMISSION
CONTROL VALVE
C
9JBOO103
2)
If the clutch is filled with oil, the oil from pressure control valve port B does not flow into clutch port C. The pressure receiving area of the left side of flow sensor valve spool (3) is larger than that of the right side. Accordingly, if the same oil pressure is applied to both sides, flow sensor valve spool (3) is moved by the oil pressure to the right. At this time, flow sensor valve spool (3) is pushed to the right further by the differential area between both sides and the tension of flow sensor valve return spring (21, and it compresses fill switch spring (4). Then, flow sensor valve spool (3) touches fill switch (5) and notifies the controller of completion of filling. At this time, a current of the initial pressure level flows in proportional solenoid (6) and pressure control valve (7) is set to the initial pressure.
95800104
WA1 200-3
1o-47
STRUCTURE AND FUNCTION
4.
TRANSMISSION
CONTROL VALVE
Pressure adjustment (Range D in chart) If a current flows in proportional solenoid (61, the solenoid generates a propulsion force in proportion to the current. This propulsion force of the solenoid is balanced with the sum of the propulsion force of load piston (8) generated by the oil pressure in clutch port C and the reaction force of pressure control valve spring (91, then the pressure is settled. Flow sensor valve spool (3) is pressed to the right by the differential oil pressure between both sides of itself and it continues outputting the fill signal to the controller.
9JB00105
lo-48
WA1 200-3
STRUCTURE AND FUNCTION
LUBRICATING
LUBRICATING OIL RELIEF VALVE
OIL RELIEF VALVE
A-A 9JBOO106
P: Lubricating
oil pressure
pick-up port
1. Spool 2. Valve body
Function l
This valve is installed to the transmission valve and prevents the pressure of the transmission lubricating oil from rising abnormally. Set pressure: 0.26 MPa 12.7 kg/cm*) (Cracking pressure)
WA1 200-3
1o-49
STRUCTURE AND FUNCTION
TRANSFER
TRANSFER
9JBOO107
1. Transmission
2. 3. 4. 5. 6. 7. 8.
output shaft Transfer input shaft (Number of teeth: 38) Transfer idler gear (Number of teeth: 57) Transfer output gear (Number of teeth: 40) Output shaft Front coupling Rear coupling Parking brake
Outline The transfer is installed on the output side of the transmission and secured to the transmission case with bolts. l
1O-50
WA1 200-3
STRUCTURE AND FUNCTION
TRANSFER
Operation Power train Since transmission output shaft (I) and transfer input gear (2) are fixed with the spline, the power is transmitted through transfer idler gear (3) to transfer output gear (41, then transmitted to output shaft (5). One part of the power transmitted to output shaft (5) is further transmitted through the center drive shaft and front drive shaft to the front axle. The other part of the power is transmitted through the rear drive shaft to the rear axle.
l
9JEIOOlO8
WA1 200-3
10-51
STRUCTURE AND FUNCTION
TORQUE CONVERTER
TORQUE CONVERTER OIL COOLER
OIL COOLER
1. Torque converter oil cooler A. Oil inlet port (From torque converter regulator valve) B. Oil outlet port (To transmission lubricating) C. Water inlet port (From water pump) D. Water outlet port (To engine block)
1O-52
OUTLINE . The oil which comes out from the torque converter outlet port is at a high temperature because of the energy used in transmitting the motive force. This torque converter oil passes through oil cooler port A and enters the oil cooler. Here it is cooled by the engine cooling water. The oil then flows out from oil outlet port B, lubricates the transmission and returns to the transfer case.
WA1 200-3
STRUCTURE AND FUNCTION
CENTER SUPPORT
CENTER SUPPORT
1. 2. 3. 4.
Front coupling Case Grease nipple Rear coupling
FUNCTION The center support is installed to the front frame between the center drive shaft and the front drive shaft. With the articulating frame, this part is constantly twisting from side to side, so there is liable to be large stress on the drive shaft. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and in this way improve the durability of the drive shafts.
l
l
WA1 200-3
1o-53
STRUCTURE AND FUNCTION
AXLE
AXLE FRONT AXLE
SJW04727
1. 2. 3. 4. 5.
Front axle Final drive Brake Front differential Drain plug
1o-54
WA1 200-3
AXLE
STRUCTURE AND FUNCTION
FRONT DIFFERENTIAL
SJWO4728
1. 2. 3. 4.
Housing Bevel gear (Teeth 39) Differential side gear (Teeth 28) Differential pinion gear (Teeth 22)
WA1 200-3
5. 6. 7.
Shaft Bevel pinion (Teeth Coupling
IO)
1o-55
STRUCTURE AND FUNCTION
AXLE
REAR AXLE
lZ \
b---=-t 5
SJWO4729
1. 2. 3. 4. 5.
Rear axle Rear differential Brake Final drive Drain plug
lo-56
WA1 200-3
STRUCTURE AND FUNCTION
AXLE
REAR DIFFERENTIAL
SJWO4730
1. 2. 3. 4. 5. 6. 7.
Bevel pinion (Teeth IO) Bevel gear (Teeth 39) Shaft Differential pinion gear (Teeth 22) Differential side gear (Teeth 28) Differential housing Coupling
WA1 200-3
1o-57
STRUCTURE AND FUNCTION
AXLE
Outline The power of the engine is transmitted through the damper, upper drive shaft, modulated clutch, torque converter, transmission, and drive shaft to the front and rear axles. In the axle, the rotation is transmitted from pinion gear (I) to bevel gear (5) and its direction is changed by 90 degrees and its speed is reduced, then it is transmitted through differential (4) to axle shaft (2). The rotation speed of the axle shaft is further reduced by the final drive of planetary gear type, then transmitted to the wheels.
sEwooo77
When driving straight forward When the machine is driven straight forward, the rotating speed of the left and right wheels is the same, so pinion gear (4) inside carrier (6) is sent through pinion gear (4) and side gear (3) and is transmitted equally to the left and right axle shafts (2). l
SEW00078
When turning When turning, the rotating speed of the left and right wheels is different, so pinion gear (4) and side gear (3) inside the differential assembly rotate in accordance with the difference between the rotating speed of the left and right wheels. The motive force of carrier (6) is then transmitted to axle shafts (2). l
lo-58
WA1 200-3
STRUCTURE AND FUNCTION
FINAL DRIVE
FINAL DRIVE
SJW04731
1.
Axle shaft
2. Brake 3. 4. 5. 6. 7. 8. 9. 10. 11.
Ring gear (Number of teeth: 81) Ring gear (Number of teeth: 76) Sun gear (Number of teeth: 21) Sun gear (Number of teeth: 28) Drain plug Planetary gear (Number of teeth: 23) Planetary gear (Number of teeth: 29) Housing Wheel
WA1 200-3
Outline l
l
The final drive reduces the rotation speed to obtain a large drive force by using a planetary gear mechanism and transmits the obtained drive force to the tires. The power is transmitted from the differential through axle shaft (I) to sun gear (5) of the first stage, then transmitted to planetary gear (9). The planetary gear rotates inside fixed ring gear (3) to transmit the power to sun gear (6) of the second stage. Then, the reduced rotation is transmitted to the planetary carrier as in the first stage, then further transmitted to wheels (II) installed to the carrier.
1o-59
AXLE MOUNT
STRUCTURE AND FUNCTION
AXlE MOUNT
2
I
Z
c
A-A
B-B
SJWO4732
1O-60
WA1 200-3
STRUCTURE AND FUNCTION
AXLE MOUNT
SJWO4733
1. 2. 3. 4. 5.
Front frame Rear frame Rear axle Front axle ROPS support
Front axle . Front axle (4) receives the force directly during operations, so it is fixed directly to front frame (I) by axle mounting bolts. Rear axle . Rear axle (3) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the ground when traveling over soft ground.
WA1 200-3
lo-61
STRUCTURE
AND
CENTER
FUNCTION
HINGE
PIN
CENTER HINGE PIN
B-0
A-A
1. 2. 3. 4. 5. 6.
Front frame Rear frame Rear axle Front axle Upper hinge pin Lower hinge pin
OUTLINE The front frame and rear frame are joined by the center hinge pin through a bearing. The steering cylinders adjust the angle of curvature to the left and right of the front and rear frame (in other words, they adjust l
the turning
1O-62
SJW04734
radius).
WA1 200-3
STRUCTURE AND FUNCTION
ARRANGEMENT
ARRANGEMENT
OF STEERING
OF STEERING EQUIPMENT
EQUIPMENT
3 \
1. Steering demand valve 2. Rotary valve 3. Hydraulic tank 4. Steering pump 5. EPC valve 6. Steering cylinder
WA1 200-3
1O-63
STRUCTURE AND FUNCTION
AJSS (ADVANCED
1. 2. 3. 4. 5. 6.
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
JOYSTICK
Steering lever Potentiometer (Lever operating angle) Joint Joint Joint Joint
1O-64
STEERING SYSTEM)
7. 8. 9. 10. 11. 12.
Rotary valve Potentiometer (Frame angle) Front frame Bracket Joint Lever
WA1 200-3
STEERING PUMP
STRUCTURE AND FUNCTION
STEERING
PUMP
Model: HPV160+ 160 l
This pump consists of 2 fixed-displacement swash plate piston pumps, 2 gear pumps and 1 impeller pump between them.
For the operation of this pump, see the section of work equipment pump.
PGSl
PS
PD12
PA1
PA2
PD22
PAD1
PGSP
PAD2
9JYOO227
PAI: PA2: PADI: PAD2: PDII: PD12: PD21: PD22:
Front pump discharge Rear pump discharge Gear pump discharge Gear pump discharge Drain port Drain port Drain port Drain port
WA1 200-3
port port port port
PGSI : Gear pump suction Port PGSS: Gear pump suction Port PS: Pump suction port 1. 2. 3. 4.
Front pump Rear pump Gear pump Gear pump
1O-65
STEERING PUMP
STRUCTURE AND FUNCTION
STEERING PUMP
c-c 2
3
4
B-0
I!
9JYOO228
1O-66
WA1 200-3
STEERING PUMP
STRUCTURE AND FUNCTION
1. Front shaft 2. Front cradle 3. Front case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate
WA1 200-3
8. 9. 10. 11. 12. 13. 14.
Front end cap Impeller Coupling Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
Rocker cam Rear case Rear cradle Rear shaft Servo piston
lo-67
STRUCTURE AND FUNCTION
SWITCH PUMP
SWITCH PUMP Model HPV160+ HPF160 l
This pump consists of 1 variable-displacement swash plate piston pump, 1 fixed-displacement swash plate piston pump, and 1 impeller pump built in between the front
pump and rear pump. For the operation of this pump, see the section of work equipment pump.
PIN
PDl
1
PD12
PSV
PA1
PD21
PA2
PD22
9JYOO229
PAI: PA2: PDll: PD12: PD21: PD22: PIN:
Front pump discharge port Rear pump discharge port Drain port Drain port Drain port Drain port Main pump pressure input port
1O-68
PS: Pump suction port PSV: Servo main pressure supply port 1. 2. 3. 4.
Front pump Front servo valve Front CO + NC valves Rear pump
WA1 200-3
STRUCTURE AND FUNCTION
SWITCH PUMP
SWITCH PUMP
PSVl
B
PSI’1
PSVlA
X
PSVPA
PSVP
PSV2B
Y 9JYOO230
PSVI : PSVIA: PSVlB:
Servo valve main pressure port Servo valve output port Servo valve output port
WA1 200-3
PSVP: Servo valve main pressure port PSV2A: Servo valve output port PSVSB: Servo valve output port
1O-69
STRUCTURE AND FUNCTION
SWITCH PUMP
SWITCH PUMP
A-A
Cd
18
c-c 9JYOO231
1. Front shaft 2. Front cradle 3. Front case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate
1O-70
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
Rocker cam Rear case Rear cradle Rear shaft Servo piston
WA1 200-3
SERVO VALVE
STRUCTURE AND FUNCTION
SERVO VALVE 1.
Servo valve assembly (For front of switch)
PA ,c2
‘AC1
Pl
P2
\ PECN 9JYOO232
Main pump pressure IN pot-t Main pump pressure IN port PACl: Servo actuator port PACS: Servo actuator port PDR: Servo drain OUT port PECN: CO + NC valves output pressure
PIN: Main pump pressure input port PPO: Servo main pressure IN port
PI:
P2:
WA1 200-3
OUT port
1. 2. 3.
CO + NC valves Servo valve Plate
1o-71
SERVO VALVE
STRUCTURE AND FUNCTION
2.
Servo valve
(For front of switch)
Pl
P2 I
I
CN
A-A
D-D
E-E
F-F
G-G
H-H
K-K
J-J
9JYOO233
Pll: PlO: P21: P20:
Main Main Main Main
lo-72
pump pressure pump pressure pump pressure pump pressure
IN port OUT port IN port OUT port
PDR:
CO + NC valves drain IN pot-t
PPO:
Servo
main pressure
OUT port
PECN: CO + NC valves output pressure
IN port
WA1 200-3
SERVO VALVE
STRUCTURE AND FUNCTION
CO + NC valves
(For front
of switch)
PECN
PPO
PDR
P2
Pl
9JYOO234
Main pump pressure front IN port Pl: P2: Main pump pressure rear IN port PDR: CO + NC valves drain OUT port
WA1 200-3
PPO: Servo main pressure IN port PECN: CO + NC valves output pressure OUT port
1o-73
SERVO VALVE
STRUCTURE AND FUNCTION
PEO
,PDR
A-A
SJYOO235
PI: P2: PDR: PEO: PPO:
Main pump pressure rear OUT port Main pump pressure rear OUT port TVC valve drain IN port Servo main pressure IN port Servo main pressure OUT port
1o-74
CO 1. 2. 3. 4. 5. 6. 7.
valve Cover Sleeve Piston Spool Spring Seat Plug
NC 8. 9. 10. 11. 12. 13.
valve Cover Sleeve Piston Spool Spring Cover
WA1 200-3
STRUCTURE AND FUNCTION
STEERING DEMAND VALVE
STEERING DEMAND VALVE
PB
PI
PI
1. 2. 3. 4. 5.
Overload relief valve Surge cut relief valve Steering spool Demand spool Main relief valve
A. To steering cylinder 6. To steering cylinder PI. From steering pump P2. From switch pump PB. To main control valve T. To hydraulic tank (through hydraulic oil cooler)
5’
i A-A
WA1 2003
SEW01395
1o-75
STEERING DEMAND VALVE
STRUCTURE AND FUNCTION
OVERLOAD RELIEF VALVE
1. 2. 3. 4. 5.
i
i
i
‘5
Poppet Relief valve poppet Check valve poppet Pilot poppet Spring
SDW01396
FUNCTION l
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 at the cylinder negative pressure is generated 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 l
oil passes through the hole in poppet (1) and dl and d2. acts on the area of diameters Checkvalve poppet (3) and relief valve poppet (2) are securely seated.
d
SDW01397
l
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.
A
1O-76
SDW0139S
WA1 200-3
STEERING DEMAND VALVE
STRUCTURE AND FUNCTION
.
When pilot poppet (4) opens, the pressure at the rear of poppet (I) drops, poppet (1) moves to the right, and it is seated with pilot poppet (4).
A
.
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.
A
2.
SDW01399
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 (31,and the oil flows from port B to port A to prevent a vacuum from forming in the circuit.
B
SDW01400
3
l
d
A
WA1 200-3
e
SDWO1401
1o-77
STRUCTURE AND FUNCTION
STEERING DEMAND VALVE
MAIN RELIEF VALVE 1. Adjustment screw 2. Spring 3. Plug 4. Pilot poppet 5. Valve seat
FUNCTION l
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.
1 O-78
WA1 200-3
STRUCTURE AND FUNCTION
STEERING DEMAND VALVE
OPERATION OF STEERING RELIEF VALVE
To main control
valve
sxwo4904
l
l
When the pressure in the circuit rises and reaches the pressure set by spring (2) and adjustment screw (I), pilot poppet (3) opens and drains the oil. When this happens, the balance of the pressure in pressure receiving chamber (I) and pressure receiving chamber (II) is lost, and demand spool (4) moves to the left.
WA1 200-3
l
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.
1o-79
STRUCTURE
AND
FUNCTION
STEERING
DEMAND
VALVE
OPERATION OF DEMAND VALVE When
steering
spool is at neutral
From switch
sxwo4905
l
*
.
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 (I) to the left.
1 O-80
l
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.
WA1 200-3
STEERING DEMAND VALVE
STRUCTURE AND FUNCTION
WHEN STEERING SPOOL IS OPERATED Engine running at low speed
From switch
SXWO4906
.
When the steering is operated, oil flows from the rotary valve 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 (I) moves to the right until notch h 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.
WA1 200-3
l
.
The merged oil passes through notches c and d, pushes load check valve (51, 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 (I) 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).
lo-81
STEERING DEMAND VALVE
STRUCTURE AND FUNCTION
Engine running at high speed
%
To main control
valve
% From Porno
steering sxwo4907
l
l
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.)
1O-82
.
.
The oil from the steering pump passes through notches c and d, pushes load check valve (51, 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.
WA1 200-3
STRUCTURE AND FUNCTION
STEERING DEMAND VALVE
OPERATION OF STEERING VALVE Neutral
SXWO4908
l
l
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.
WA1 200-3
l
When the pressure at ports A and B rises, demand spool (I) 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.
lo-83
STRUCTURE AND FUNCTION
STEERING DEMAND VALVE
Turning to right
From
From
ro
steerin sxwo4909
.
If the steering lever is moved to the right, the rotary valve operates and the steering spool (2) moves to the left. The oil from the steering pump flows in port A, then flows through flow control spool (I) to steering spool (2) and pushes load check valve (6) of the spool open to supply oil to the bottom side of the left cylinder and rod
1O-84
side of the right cylinder to turn the machine to the right. The oil from both cylinders is drained through load check valve (5) of the steering spool. The oil from the switch pump flows in port 6, then flows through flow control spool (I) to push check valve (4) open and merges with the steering pump oil.
WA1 200-3
STEERING DEMAND VALVE
STRUCTURE AND FUNCTION
Turning to left
From valve
rotary
control
valve
sxw04910
.
If the steering lever is moved to the left, the rotary valve operates and the steering spool (2) moves to the right. The oil from the steering pump flows in port A, then flows through flow control spool (1) to steering spool (2) and pushes load check valve (5) of the spool open to supply oil to the rod side of the left cylinder and bottom
WA1 200-3
side of the right cylinder to turn the machine to the left. The oil from both cylinders is drained through load check valve (6) of the steering spool. The oil from the switch pump flows in port B, then flows through flow control spool (I) to push check valve (41 open and merges with the steering pump oil.
lo-85
STRUCTURE
AND
FUNCTION
ROTARY
VALVE
.b
swwa94
1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11.
Neutral position spring Valve body Check valve Spool Sleeve Feedback spool Feedback sleeve Loose spring Drive shaft Center pin Body
1O-86
a. b. c. d.
To hydraulic tank To port Pb of steering To pot-t Pa of steering From PPC pump
demand demand
valve valve
WA1 200-3
ROTARYVALVE
STRUCTURE AND FUNCTION
Outline The steering lever is connected to the top of the rotary valve. The direction of the oil sent from the PPC pump through the EPC valve to this valve is changed with the steering lever to move the spool of the steering demand valve. As a result, the steering cylinder is operated to set the steering direction of the machine. The link installed to the front frame is connected to the bottom of the rotary valve to feed back the steering angle of the machine. Accordingly, the position of the steering lever is matched to the steering angle of the machine. l
l
Structure Spool (4) is connected through pin (IO) (which is not in contact with the spool while the steering lever is in “neutral”) and neutral position spring (II to sleeve (5). The top and bottom of drive shaft (9) are engaged with pin (IO) and assembled into one unit together with sleeve (5) and feedback sleeve (7). . Feedback spool (6) is connected through pin (IO) (which is not in contact with the spool while the steering lever is in “neutral”) and loose spring (8) to feedback sleeve (7). Valve body (2) has four ports, which are connected to the pump circuit, tank circuit, and pilot circuit of the steering demand valve respectively. l
lever
Steerina
t
l
l
4
Link
WA1 200-3
lo-87
STRUCTURE AND FUNCTION
ROTARY VALVE
Operation . If the steering
.
lever is operated, spool (4) rotates along sleeve (5), against neutral position spring (I). By this rotation, the port of spool (4) is matched to that of sleeve (5) to form an oil passage, then the oil flows in the steering demand valve. If the steering lever is operated more than the allowable displacement of neutral position spring (I), loose spring (8) absorbs the displacement through drive shaft (9). If the oil flows in the steering cylinder and steering operation starts, the link installed to the front frame turns sleeve (5) through feedback spool (6) and drive shaft (9) so that the deviation of sleeve (5) from spool (4) will be offset. If the machine is steered to the position matched to the operating distance of the steering lever, deviation of spool (4) from sleeve (5) is eliminated and the oil passage is closed.
1O-88
WA1 200-3
EPC VALVE
STRUCTURE AND FUNCTION
EPC VALVE
e r---------7
I
,_+_______AD I
c
_I
T
L
(
i
i:--_.____i
11 T
P2
Ii
Pl
T
SJWO4896
1. 2.
Min. pressure assurance pressure reducing valve Electromagnetic proportional valve
Pl. P2. C. D.
From PPC pump From diverter valve To rotary valve TO hydraulic tank
Outline The EPC valve controls the oil flow to the rotary valve with the electromagnetic proportional valve controlled with the command current from the work equipment and joystick controller. l
WA1 200-3
l
Even if the electromagnetic proportional valve does not work because of a controller trouble, the minimum pressure assurance pressure reducing valve supplies the minimum oil pressure to the rotary valve.
1O-89
STRUCTURE AND FUNCTION
DIVERTER VALVE
DIVERTER VALVE
1. Check valve 2. Check valve 3. Check valve 4. Check valve 5. Spool 6. Valve body
1O-90
A. 6. C. D. E. F.
To emergency pump Sensor mounting port To hydraulic oil tank To steering valve From hydraulic tank 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 emergency pump to the tank. If no pilot pressure from the steering pump reaches the diverter valve, the oil from the emergency pump is switched to the steering circuit and flows to enable the machine to be steered.
l
WA1 200-3
DIVERTER
STRUCTURE AND FUNCTION
VALVE
EMERGENCY STEERING RELIEF VALVE
m
1. 2. 3. 4. 5.
Kzr
Main valve Valve seat Pilot poppet Spring Adjustment screw
SDW01420
FUNCTION Compared to the steering valve relief pressure of 31.4 MPa 1320 kg/cm*}, the rated pressure of the emergency steering pump and diverter valve are both 20.6 MPa (210 kg/cm*). Therefore, to protect the emergency steering pump and diverter valve, there is a relief valve in the piping from the diverter valve to the steering valve. When the emergency steering is being operated, and the hydraulic pressure generated by the steering exceeds 20.6 MPa (210 kg/cm*}, 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 (I) and fills port B. Pilot poppet (3) is in contact with valve seat (2).
I l
l
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 (I) generates a difference in pressure between port A and port B. Main valve (I) is opened by the pressure at port A and the oil at port A is relieved.
WA1 200-3
A
I
B
10-91
STRUCTURE AND FUNCTION
HYDRAULIC
CIRCUIT
SCHEMATICS
DIVERTER VALVE
FOR EMERGENCY
Pump, engine working normally
STEERING To steering cylinder
From CY I
steering inder
6
When the steering pump and engine are working normally, the main pump, 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 emergency 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.
1 O-92
WA1 200-3
STRUCTURE AND FUNCTION
l
DIVERTER VALVE
When pump or engine has trouble while machine is traveling
To steering cylinder
From CYI
6
6
If the pump or engine has a trouble while the machine is traveling, the rotation of the tires is transmitted through the transmission to the emergency pump. Since the steering pump is not rotating, any pressure is not generated in port D. Accordingly, spool (3) is pressed to the right by spring (4). The oil from the emergency pump flows through port A and port 6 to the rotary valve, and the machine can be steered. %
The emergency pump can rotated in either forward or reverse direction.
WA1 200-3
steering inder
n
Emergency steering
n
ourno
1o-93
STRUCTURE AND FUNCTION
ARRANGEMENT
OF BRAKE EQUIPMENT
OF BRAKE EQUIPMENT
1. Front brake (right) 2. Brake valve (right) 3. Parking brake switch 4. Rear brake (right) 5. Slack adjuster (rear) 6. Torque converter + transmission, brake cooling, brake pump 7. Rear brake (left) 8. Brake oil tank
1o-94
ARRANGEMENT
9. IO. 11. 12. 13. 14. 15. 16.
Parking brake (Built in transmission) Accumulators Brake valve (left) Front brake (left) Slack adjuster (front) Charge valve Strainer Parking brake solenoid valve
WA1 200-3
BRAKE VLAVE
STRUCTURE AND FUNCTION
BRAKE VALVE BRAKE VALVE (RIGHT)
swwo4aa5
1. Brake pedal (left, right brake) 2. Rod (right brake) 3. Pilot piston (right brake) 4. Spool (right brake) 5. Upper cylinder (right brake) 6. Spool (right brake) 7. Lower cylinder (right brake) 8. Rod (left brake)
1O-96
9. Spool (left brake) 10. Cylinder (left brake) A. B. C. D. E.
Pilot port (right brake) To rear brake (right brake) To front brake (right brake) Drain (left, right brake) To pilot port (left brake)
WA1 200-3
STRUCTURE AND FUNCTION
BRAKE VLAVE
BRAKE VALVE (LEFT)
II\_J
U
SDWOO108
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. l
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.
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WA1 200-3
1o-97
STRUCTURE AND FUNCTION
BRAKE VLAVE
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. l
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.
l
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.
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Left brake valv
l
To front brake
1O-98
WA1 200-3
STRUCTURE
AND
BRAKE VLAVE
FUNCTION
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 (I) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails (right brake valve) l Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.
When actuation is balanced Upper portion l 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. l 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.
From pump M
From pump -&
l
WA1 200-3
From
pump
From
pump
To front brake
1o-99
STRUCTURE AND FUNCTION
BRAKE VLAVE
Brake released (right brake valve) Upper portion When pedal (I) 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. l
Lower portion When the pedal is released, spool (3) in the upper portion moves up. At tlie 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. l
10-100
From pump
From pump
From rear brake
rom front brake SEW00113
WA1 200-3
STRUCTURE AND FUNCTION
CHARGE VALVE
CHARGE VALVE
PP
ACC
_-_-_~-_---_--‘--_-,
I
I ACC
PP
i_
-__--__________~I
T
SXWO4764
ACC. Plug PP. To brake valve P. From pump T. To brake oil tank
Function 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.
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WA1 200-3
10-101
STRUCTURE AND FUNCTION
CHARGE VALVE
A-A
1. Main relief valve (R3)
2. 3. 4. 5. 6.
Valve body Relief valve (RI) Relief valve (HI) Filter Filter
10-102
WA1 200-3
STRUCTURE AND FUNCTION
CHARGE VALVE
Operation 1. When no oil is being supplied to accumulator (cut-out condition) l
l
The pressure at port B is higher than the set pressure of the relief valve (RI), so piston (8) is forcibly pushed up by the oil pressure at port B. 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 (RI), 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). It also passes through orifices (171, (181, and (16), and flows to the brake oil tank.
2.
When oil is supplied to accumulator
I)
Cut-in condition When the pressure at port B is lower than the set pressure of the relief valve (RI), 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.
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l
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WA1 200-3
Front pi
lot
accumulator ~rasaura
rant accumulator i lot oresaura
10403
STRUCTURE AND FUNCTION
2) When cut-out pressure is reached When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (RI), 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 18) 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 (Rl), 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 6 is stopped.
3. .
CHARGEVALVE
rant accumulator ilot
~reawre
Main 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.
10-104
WA1 200-3
ACCUMULATOR
STRUCTURE AND FUNCTION
(FOR BRAKE)
ACCUMULATOR (FOR BRAKE)
1. Valve
2. 3. 4.
Top cover Cylinder Piston
sxwo4770
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 (41, 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.
l
WA1 200-3
Specifications Gas used: Nitrogen gas Charge amount: 20 e Charging pressure: 11.8 f 0.49 MPa 020 * 5 kg/cm21
10-105
STRUCTURE AND FUNCTION
SLACK ADJUSTER
SLACK ADJUSTER
sxwo4771
1. 2. 3. 4. 5.
Bleeder Cylinder Check valve Piston Spring
A. Inlet port B. Outlet port
SPECIFICATIONS Piston operating oil pressure: O.O1’~oo’MPa {O.l’~“’ kg/cm*) Check valve cracking pressure: 17.4 r 0.05 MPa (17.8 -c 0.5 kg/cm*}) Check valve closing pressure: 1.09 + 0.05 MPa (11.1 + 0.5 kg/cm9 FUNCTION The slack adjuster is installed in the brake oil line from the brake valve 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.
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10-106
WA1 200-3
SLACK ADJUSTER
STRUCTURE AND FUNCTION
OPERATION 1. When brake pedal is depressed . Before the brake is depressed, piston (4) is returned by the distance of stoke 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 (21, where it moves piston (4) by stroke S to the left and right.
l
Right brake c To bra
From brake valve
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 and disc is to 0, the greater the braking force becomes.
From brake valve
.
SEW00122
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.
Right brake
From brake valve
WA1 200-3
SEW00123
SEW00124
10407
SLACK ADJUSTER
STRUCTURE AND FUNCTION
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.
lo-108
4
0
7
I)
Fro lef bra
SEW00125
WA 1200-3
STRUCTURE AND FUNCTION
BRAKE
BRAKE
I
2
3
VT) I ’ JJ.-J II i \:-
;:7,
I
/
_~_____________ ----
---_s; 9
\1 i
SXW04772
1. 2. 3. 4. 5. 6.
Guide pin Brake piston Return spring Floating seal Disc Plate
FUNCTION The brakes are wet-type multiple disc brakes, and are fitted to all four wheels. l
WA1 200-3
Operation When the brake pedal is depressed, moves brake piston (2) to the right, and presses disc (5) and plate (6) together to hold them in position. Disc (5) is rotating together with the wheel, so when it is held in position, the rotation stops, the brake is actuated, and the machine is stopped. When the brake pedal is released, the pressure at the rear face of piston (2) is released, and the piston is moved to the left by the force of return spring (3) to release the brake. l
10409
PARKING BRAKE
STRUCTURE AND FUNCTION
PARKING BRAKE
9JEIOO109
A: Piston chamber
Outline The parking brake is a multiple-wet disc brake, which is operated mechanically with spring (3) to brake output shaft (2). The tension of spring (3) presses discs (5) and plates (6) with piston (4) to lock output shaft (2). This brake is released by supplying pressurized oil to piston chamber A to move piston (4) against the tension of spring (3) to set discs (5) and plates (6) free. l
1. 2. 3. 4. 5. 6. 7.
Rear coupling Output shaft Spring Piston Disc Plate Front coupling
10-l10
l
l
WA1 200-3
STRUCTURE AND FUNCTION
ARRANGEMENT
OF HYDRAULIC
ARRANGEMENT OF HYDRAULICEQUIPMENT
EQUIPMENT
-/ swwo4773
10-l 12
WA1 200-3
ARRANGEMENT
STRUCTURE AND FUNCTION
1. Bucket cylinder
2. 3.
4. 5. 6. 7.
8. 9. 10.
PPC valve Main pump 3A. No.1 main pump 3B. No.2 main pump Switch pump Accumulator Hydraulic oil cooler 4th gear pump (Torque converter + transmission + brake cooling + brake) Transmission Boom cylinder Main control valve (x 3)
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l
.
.
WA1 200-3
OF HYDRAULIC EQUIPMENT
The work equipment system consists of the hydraulic circuit and steering circuit. The hydraulic circuit controls the operation of the bucket and attachment. The oil from hydraulic tank is sent from main pumps (3A) and (381, and switch pump (4) through the steering valve to two main control valves (IO). If the bucket and boom spools of the main control valve are both in neutral, the oil passes through the drain circuit of the main control valve, is filtered by the filter inside the hydraulic tank, and returns to the tank. The bucket or boom spool in PPC valve is activated by operating the work equipment control lever, causing each spool in the work equipment valve to be hydraulically activated. Thereby, the oil is allowed to flow from the work equipment valve to boom cylinder (9) or bucket cylinder (I), thus operating the boom or the bucket. The maximum pressure of the hydraulic circuit is regulated by the relief valve inside the main control valve. There are two safety valves (with suction valve) and an unloader valve in the bucket cylinder circuit to protect the circuit. Even when engine is at rest, the boom can be lowered to the ground because accumulator (5) is provided in the circuit. Hydraulic tank is a pressurized, sealed type and has a breather with a relief valve. This acts to pressurize the tank and at the same time prevents negative pressure. This protects the pump from cavitation. A port is made on the hydraulic tank to pressurize the hydraulic tank with air to bleed air from the piston pump after removing and installing the piston pump and its piping.
10-113
STRUCTURE AND FUNCTION
HYDRAULIC
HYDRAULIC TANK
TANK
A-A
SJWO4782
1. 2. 3. 4. 5. 6. 7.
Strainer Oil filler Oil filler strainer Filter bypass valve Filter Breather Drain valve
A. B. C. D. E. F.
Steering return port Loader return port Emergency steering return port Main suction port Emergency steering suction port PPC, control suction port
OUTLINE Oil is sent from the hydraulic tank through the work equipment valve to each cylinder. Then, it merges with the oil from various parts in the return circuit, and a part of it is cooled by the oil cooler and filtrated by the oil filter, then returned to the hydraulic tank. The oil filter filtrates the all oil in the return circuit from the work equipment valve. If this filter is clogged, the bypass valve operates to let the oil return to the tank directly for prevention of breakage of the filter. The bypass valve also operates when negative pressure is generated in the circuit. Strainer (I 1 is installed to the suction port of the hydraulic tank. l
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WA1 200-3
10-l 15
HYDRAULIC TANK
STRUCTURE AND FUNCTION
OPERATION VALVE
OF OIL FILTER BYPASS
When the filter is clogged. Bypass valve (1) opens and the oil returns directly to the tank without passing through the filter. Bypass valve set pressure: 125 kPa (1.27 kg/cm21 From
To hvdrailic
main
control
SDW02312
tank
When negative pressure is formed in the return circuit. Valve (2) moves up and acts a check valve. Check valve set pressure: 25.5 kPa IO.26 kg/cm21
To main
@
From
10-116
hydraulic
tank
control
SDW02313
WA1 200-3
STRUCTURE
AND
HYDRAULIC
FUNCTION
TANK
BREATHER
1. 2. 3. 4.
Body Filter element Poppet Sleeve
SEW00141
FUNCTION Preventing
negative
pressure
inside the tank
The tank is pressurized, sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure opens poppet (31, and air from the outside is let into the tank to prevent negative pressure. Preventing
rise in pressure
inside the tank
When the hydraulic cylinder are being used, the oil level in the hydraulic circuit changes and the temperature rises. If the hydraulic pressure rises above the set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.
WA1 200-3
10417
STRUCTURE AND FUNCTION
WORK EQUIPMENT
PUMP No. 1
WORK EQUIPMENT PUMP No. 1 Model: HPV160+ 160 PA1
PDl
1
PA2
PESl
PSV
PS
PESP
?
PD21
?
CZ 9JYOO236
P: PAI: PA2: PDII: PD21: PESI: PESS: PS: PSV:
Main pump pressure IN port Front pump discharge port Rear pump discharge port Drain port Drain port ES valve output pressure IN port ES valve output pressure IN port Pump suction port Servo main pressure supply port
lo-118
1. 2. 3. 4. 5.
Front pump Front servo valve Rear servo valve Rear CO + NC valves Rear pump
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT
PUMP No. 1
Work equipment pump No. 1
f A
PSVlA
PSVl
PSVlB
X
PSVPB
PSVP
PSVPA
Y 9JYOO237
PSVI: Servo valve main pressure port PSVIA: Servo valve output port PSVIB: Servo valve output port
WA1 200-3
PSV2: Servo valve main pressure PSVPA: Servo valve output port PSVPB: Servo valve output port
port
10419
STRUCTURE AND FUNCTION
WORK EQUIPMENT PUMP No. 1
c-l
A-A
I8
c-c
1. 2. 3. 4. 5. 6. 7.
Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate
10-120
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
9JYOO238
15. 16. 17. 18. 19.
Rocker cam Rear case Rear cradle Rear shaft Servo piston
WA1 200-3
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
PUMP No. 1
Servo valve 1.
Servo valve (For front No. 1)
PACl
PPO
P2
PACP
PDR
A-A
D-D
E-E
G-G
F-F
H-H
9JYOO239
P2: Main pump pressure PACI: Servo actuator port PAC2: PDR:
PESI: PPO:
IN port
1. Servo valve
Servo actuator port Servo valve drain OUT port ES valve output pressure IN port Servo valve main pressure IN port
WA1 200-3
10421
WORK EQUIPMENT PUMP No. 1
STRUCTURE AND FUNCTION
2.
Servo valve assembly (For rear No. 1)
PPO
PAC
1
PEbN
PES
p: PACI: PAC2: PDF?: PECN: PES: PESP: PPO:
Main pump pressure IN port Servo actuator port Servo actuator port Servo valve drain OUT port CO + NC valves output pressure OUT port ES valve output pressure pick-up pot-t ES valve output pressure IN port Servo main pressure IN port
10422
1. CO + NC valves
2. 3.
Servo valve Plate
WA1 200-3
WORK EQUIPMENT
STRUCTURE AND FUNCTION
3.
PUMP No. 1
Servo valve (For rear No. I)
D-D
E-E
F-F
G-G
H-H
J-J
K-K
9JYOO241
PII: PIO: PZI: P20:
Main Main Main Main
WA1 200-3
pump pump pump pump
pressure pressure pressure pressure
IN port OUT port IN port OUT port
PDR: CO + NC valves drain IN port PPO: Servo main pressure OUT port PECN: CO + NC valves output pressure IN port
lo-123
WORK EQUIPMENT PUMP No. 1
STRUCTURE AND FUNCTION
Structure
9JYOO242
1. 2. 3. 4. 5. 6.
Locknut Cover Plug Spring Valve body Arm
7. 8. 9. IO. 11. 12.
13. 14. 15. 16. 17. 18.
Pin Piston Locknut Plug Locknut Cover
Function Discharge amounts Ql and 02 of main pumps Pl and P2 are controlled individually by the respective servo valves. The relationship between pump discharge amount 0 and input signal PECN to the servo valve is as shown in the graph on the right. 0 varies in proportion to PECN.
Sleeve Piston Spring Plug Cover Locknut
(cc/rev1
a z= E
(MPa(kdcm’l) CWNC
lo-124
valve
output
pressure
PECN
SWP06953
WA1 200-3
STRUCTURE
1)
Operation
AND FUNCTION
in direction
of increase
WORK
of pump
discharge
amount
EQUIPMENT
PUMP
No. 1
(max. angle)
J SWPO6954
Operation
The control, pump pressure PPO is taken to port a. \ Signal pressure PECN from the NC valve is taken from port b to chamber c. When signal pressure PECN rises, piston (8) is pushed to the right by the pressure in chamber c, and stops at a point where it balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the right in the same way as piston (8). This moves guide spool (13) to the right. When guide spool (13) moves, port a and port d are closed and port d is connected to drain chamber e. As a result, servo piston chamber f is also interconnected with drain chamber e through port g and port d.
WA1 200-3
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At the same time, port a is interconnected with port h, so the pressure oil flows through port i to servo piston chamber j, pushes servo piston (19) to the right, increases the swash plate angle in the main piston pump and increases the pump discharge amount. When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin (7) and moves guide spool (13) to the left. Port a, port d and port h close, so the discharge increases by an amount that matches signal pressure PECN.
10-125
STRUCTURE
21
Operation
AND
WORK EQUIPMENT
FUNCTION
in direction
of decrease
of pump
discharge
amount
PUMP
No. 1
(min. angle)
1 NCvalve 1
TVC valve
SWPO6955
Operation l
l
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When signal pressure PECN goes down, piston (8) moves to the left and stops at a point where the pressure in chamber c balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the left in the same way as piston (81. This moves guide spool (13) to the left. When guide spool (13) moves, port a and port h are closed and port h is connected to drain chamber e. As a result, servo piston chamber j is also interconnected with drain chamber e through port i and port h.
10-126
.
l
At the same time, port a is interconnected with port d, so the oil flows through port g to servo piston chamber f, pushes servo piston (19) to the left, decreases the swash plate angle in the main piston pump and decreases the pump discharge amount. When servo piston (19) moves, arm (6) rotates clockwise with its center at pin (7). Guide spool (13) is moved to the right and closes port a, port d and port h, so the discharge decreases by an amount that matches signal pressure PECN.
WA1 200-3
STRUCTURE AND FUNCTION
CO + NC valves
WORK EQUIPMENT PUMP No. 1
(For rear No. 1)
PECti
PDR
P2
9JYOO243
P2: Main pump pressure IN port PDR: CO + NC valves drain OUT port PECN: CO + NC valves output pressure OUT port
WA1 200-3
lo-127
WORK EQUIPMENT PUMP No. 1
STRUCTURE AND FUNCTION
9JYOO244
CO valve 1. Cover
2. 3. 4. 5. 6. 7.
Sleeve Piston Spool Spring Seat Plug
lo-128
NC valve 8. 9. 10. 11. 12. 13.
Cover Sleeve Piston Spool Spring Cover
WA1 200-3
WORK EQUIPMENT
STRUCTURE AND FUNCTION
1.
CO valve
Function When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss.
l
I)
PUMP No. 1
The CO valve is controlled by balancing the spring with the total of main pump discharge pressure P and CO valve output pressure PEC.
When main pump discharge pressure is lower than relief pressure
w Servo
Sma I I
Piston
r)
Large
Operation . Spool (4) is being pushed down fully by spring (3). As a result, port a and port b are fully open and TVC valve output pressure PE and CO valve output pressure PEC are equal. In this way, CO valve output pressure PEC becomes the maximum and the main pump discharge amount also becomes the maximum.
WA1 200-3
1O-l 29
STRUCTURE AND FUNCTION
2)
WORK EQUIPMENT PUMP No. 1
When main pump discharge pressure becomes close to relief pressure
Smal
@
Servo
valve
Servo
Piston
I+
Large
sxwo4747
Operation . If the load increases and main pump discharge pressure P comes close to the relief pressure, main pump discharge pressure P pushes piston (5). At the same time, CO valve output pressure PEC pushes piston (51, and spool (4) moves up.
10-130
l
As a result, the flow of oil from port a to port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. In this way, CO valve output pressure PEC goes down, and the pump discharge amount becomes the minimum.
WA1 200-3
WORK EQUIPMENT PUMP No. 2
STRUCTURE AND FUNCTION
WORK EQUIPMENT Model:
HPV95
PUMP No. 2
+ 95
3 L
J
Pyl
1
PA2
I
PA1 PL)21
PE,S I
PS’V
\
PSG
PS
9JYOO247
P: PI: P2: PAl: PA2: PAG: PDII: PD21: PESI: PESO: PS: PSG: PSV:
Main pump input pressure IN port Orifice upstream pressure IN port Orifice downstream pressure IN port Front pump discharge port Rear pump discharge port Gear pump discharge port Drain port Drain port ES valve output pressure IN port ES valve output pressure OUT port Pump suction port Gear pump suction port Servo main pressure supply port
WA1 200-3
1. 2. 3. 4. 5. 6. 7. 8. 9.
Front pump Rear pump Fan driving gear pump Rear servo valve Plate ES valve (Engine sensing) CO + NC valves Plate Servo valve
10431
STRUCTURE AND FUNCTION
Work equipment
WORK EQUIPMENT
PUMP No. 2
pump No. 2
PSVlB
PSVl
PSVlA
PSVPA
PSVP
PSVPB
9JYOO248
PSVI: Servo valve main pressure port PSVIA: Servo valve output port PSVIB: Servo valve output port
1O-l 32
PSV2: Servo valve main pressure port PSV2A: Servo valve output port PSVSB: Servo valve output port
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT
PUMP No. 2
A-A
9JYO0’249
1. Front shaft 2. Front cradle 3. Front case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate
WA1 200-3
8. Front end cap 9. IO. 11. 12.
Coupling Impeller Rear end cap
Valve plate 13. Cylinder block 14. Piston
15. 16. 17. 18. 19.
Rear case Rocker cam Rear cradle Rear shaft Servo piston
m-133
STRUCTURE AND FUNCTION
WORK EQUIPMENT PUMP No. 2
Servo valve 1.
Servo valve assembly (For front No. 21
PEiN
PDR P2 PPO
PACl PAC2 Z 9JYOO250
P: P2: PACI: PAC2: PDR: PECN: PES: PPO:
Main pump pressure IN port Main pump pressure IN port Servo actuator port Servo actuator port Servo valve drain OUT port CO + NC valve output pressure OUT port ES valve output pressure IN port Servo main pressure IN port
10-134
1. CO + NC valves
2. 3.
Servo valve Plate
WA1 200-3
STRUCTURE AND FUNCTION
2.
WORK EQUIPMENT
PUMP No. 2
Servo valve (For front No. 21
PECN
PDR
pDP2
R
@ isiik! H
CZ
QO
0
0
Y
A-A k-E
D-D
E-E
F-F
G-G
H-H
9JYOO251
P2: Main pump pressure OUT port PDR: CO + NC valve drain IN port PECN: CO + NC valve output pressure IN port
WA1 200-3
10-135
WORK EQUIPMENT PUMP No. 2
STRUCTURE AND FUNCTION
3.
Servo valve assembly (For rear No. 2)
POkl
PCiRP
PES
PECN’
P2
PDR
Pl PACl
PPO
PAC2 9JYOO252
Pl: P2: PACI: PAC2: PDR: PES: PECN: PPO: PORI: POR2:
Main pump pressure IN port Main pump pressure IN port Servo actuator port Servo actuator port Servo valve drain OUT port ES valve output pressure OUT port CO + NC valve output pressure IN port Servo main pressure IN port Orifice upstream pressure IN port Orifice downstream pressure IN port
lo-136
1. ES valve
2. 3.
Servo valve Plate
WA1 200-3
WORK EQUIPMENT
STRUCTURE AND FUNCTION
4.
PUMP No. 2
Servo valve (For rear No. 2)
I--D
H4
M-0 + Y
E-E
D-D
F-F
G-G
H-H
J-J
K-K
9JYOO253
PI: Main pump pressure OUT port P2: Main pump pressure OUT port PDR: ES valve drain IN port
WA1 200-3
PPO: Servo main pressure OUT port PECN: CO + NC valve output pressure IN port
10-137
STRUCTURE AND FUNCTION
WORK EQUIPMENT PUMP No. 2
Structure (For rear No. 21
9JYOO254
1. Locknut 2. Cover 3. Plug 4. Spring 5. Valve body 6. Arm
7. 8. 9. 10. 11. 12.
Pin Piston Locknut Plug Locknut Cover
13. 14. 15. 16. 17. 18.
Sleeve Piston Spring Plug Cover Locknut
Function Discharge amounts Ql and Q2 of main pumps PI and P2 are controlled individually by the respective servo valves. The relationship between pump discharge amount 0 and input signal PECN to the servo valve is as shown in the graph on the right. Q varies in proportion to PECN.
(MPa{ktdcm'l) CO+NC valve output oressure PECN SUP06953
10438
WA1 200-3
STRUCTURE AND FUNCTION
I)
WORK EQUIPMENT
PUMP No. 2
Operation to increase pump discharge (increase swash plate angle)
Control pump
Main
Pump SXWO4748
Operation Signal pressure PI acts on chamber E of the control piston through port D. Control pump pressure PC is led in port B. If PI rises, the oil pressure applied to chamber E rises and control piston (9) moves to the right until the oil pressure force in chamber E is balanced with the force of spring (IO). At the same time, arm (4) rocks to the right, using servo piston (11) as a fulcrum, and moves guide spool (12) to the right. As guide spool (12) moves, port B is connected to port A, then control pump pressure PC is applied to chamber F of servo piston (I 1) to push servo piston (II) to the right. As a result, the swash plate angle of the main piston is increased to increase the discharge.
WA1 200-3
l
Consequently, arm (4) turns counterclockwise around pin (13) to move guide spool (12) to the left. Since ports B, A, and C are closed, the discharge is increased by the quantity corresponding to signal pressure PI.
10-139
STRUCTURE AND FUNCTION
2)
WORK EQUIPMENT PUMP No. 2
Operation to decrease pump discharge (reduce swash plate angle)
From servo valve
rear @
PI-
Control Pump
Main
Pump sxwo4749
Operation . If PI lowers, piston (9) moves to the left until the oil pressure force in chamber E is balanced with the force of spring (IO). At the same time, arm (4) rocks to the left, similarly to piston (9) and using servo piston (I I) as a fulcrum, and moves guide spool (12) to the left. As guide spool (12) moves, port B is disconnected from port A, the port A is connected to drain chamber T. Accordingly, servo piston chamber F is connected through port A to drain chamber T.
.
l
l
10-140
l
At this time, port B is connected to port C and the pressurized oil flows in servo piston chamber H and pushes servo piston (11) to the left, together with the force of spring (14). As a result, the swash plate angle of the main pump is reduced to decrease the pump discharge. As servo piston (11) moves, arm (4) turns clockwise around pin (13) to move guide spool (12) to the right. Since ports B, C, and A are closed, the discharge is decreased by the quantity corresponding to signal pressure PI.
WA1 200-3
STRUCTURE
AND
CO + NC valves
FUNCTION
(For front
WORK EQUIPMENT
PUMP
No. 2
No. 2)
0/
0
0
Z l--A
9JYOO257
P: Main pump pressure IN port PDR: CO + NC valve drain OUT port PECN: CO + NC valve output pressure
WA1 200-3
OUT port
10-141
WORK EQUIPMENT PUMP No. 2
STRUCTURE AND FUNCTION
A-A
9JYOO258
CO 1. 2. 3. 4. 5. 6. 7.
valve
Cover Sleeve Piston Spool Spring Seat Plug
lo-142
NC 8. 9. IO. 11. 12. 13.
valve Cover Sleeve Piston Spool Spring Cover
WA1 200-3
WORK EQUIPMENT
STRUCTURE AND FUNCTION
1.
PUMP No. 2
CO valve
Function When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss.
l
*
The CO valve is controlled by balancing the spring with the total of main pump discharge pressure P and CO valve output pressure PEC.
1) When main pump discharge pressure is lower than relief pressure
Servo
piston
Operation Spool (4) is being pushed down fully by spring (3). As a result, port a and port b are fully open and TVC valve output pressure PE and CO valve output pressure PEC are equal. In this way, CO valve output pressure PEC becomes the maximum and the main pump discharge amount also becomes the maximum. l
WA1 200-3
10-143
WORK EQUIPMENT PUMP No. 2
STRUCTURE AND FUNCTION
2)
When main pump discharge pressure becomes close to relief pressure
a
b
Servo
1 ‘“I
fl
IPPoy
Piston
,I ’ f ’ , ,,‘,,,‘/ I I I I , YI I, , , , , , , , , , , ,‘
sxwo4751
Operation . If the load increases and main pump discharge pressure P comes close to the relief pressure, main pump discharge pressure P pushes piston (5). At the same time, CO valve output pressure PEC pushes piston (51, and spool (4) moves up.
10-144
l
As a result, the flow of oil from port a to port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. In this way, CO valve output pressure PEC goes down, and the pump discharge amount becomes the minimum.
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT
PUMP No. 2
ES valve (For rear No. 2)
PES
PPO
POR
9JYOO261
PDR: ES valve drain OUT port PE: NC valve output pressure front-rear connecting port
WA1 200-3
PES: ES valve output pressure OUT port PPO: Servo main pressure IN port
10-145
WORK EQUIPMENT PUMP No. 2
STRUCTURE AND FUNCTION
1,1 0
G
D-D
7 f
G
E-E
F-F
G-G
H-H
9JYOO262
1. Cover 2. Plug 3. Rod 4. Plug 5. Nut 6. Screw
lo-146
7. Cover 8. Sleeve 9. Piston 10. Spool 11. Cover
WA 1200-3
STRUCTURE AND FUNCTION
FUNCTION A variable displacement piston pump is used for the hydraulic pump to save energy by reducing the consumption of hydraulic pressure when the engine is running at low speed. At the same time, it is also used to increase the engine acceleration from low speed. For this reason, a pressure difference valve is used to detect the engine speed by using a pressure difference system. The delivery (delivery per rotation) is then adjusted to match the engine speed.
WORK EQUIPMENT PUMP No. 2
l
OPERATION Oil from the PPC pump passes through pressure difference valve (I) and is sent to the PPC valve. Pilot pressure from the inlet and outlet ports (ports A and B) of the pressure differential valve is supplied to the ES valve (2). The difference in pilot pressure becomes larger as the flow from the PPC pump increases (in other words, as the engine speed increases). When the pilot pressure difference reaches point a (0.14 MPa 11.44 kg/cm*}), the ES valve starts to operate, and actuates the servo valve and servo cylinder to change the swash plate angle of the pump. When the swash plate angle is changed, the piston stroke also changes to change the delivery of the pump (delivery per rotation). Until the difference in pilot pressure reaches 0.37 MPa (3.8 kg/cm*}, the pump delivery (delivery per rotation) increases in proportion with the increase in the difference in pilot pressure (in other words, the increase in the engine speed). When the difference in pressure reaches 0.37 MPa (3.8 kg/cm*}, the pump delivery (delivery per rotation) reaches the maximum.
;
a
o.l4*oD1 {IA4*0.11
Approx.800
O-37*0.02 Pilot pressure (3.8*0.21difference
A~~t0~.1100
Ensine speed(rpm)
sxwo4752
When the pilot pressure difference is below point a
SDW01720
When the pilot pressure difference is above point b
SDW01721
WA1 200-3
10-147
PPC VALVE
STRUCTURE AND FUNCTION
PPC VALVE (Proportional
Pressure Valve)
C
C
P2
P3
A
P4
P T PI P2 P3 P4
: From pump : To tank (drain) : To boom cylinder : To bucket cylinder : To boom cylinder : To bucket cylinder
(Raise) (Dump) (Lower) (Tilt)
SEW01483
lo-148
WA1 200-3
PPC VALVE
STRUCTURE AND FUNCTION
A-A
D-D
1. Bolt
2. 3. 4. 5. 6. 7. 8. 9.
Piston Plate Collar Retainer Center spring Metering spring Valve Body
WA1 200-3
c-c
SWWO3476
10-149
PPC VALVE
STRUCTURE AND FUNCTION
OPERATION 1.
Control lever at “neutral” (Fig. 1): Ports PA,, P2, Pe, 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 (21, retainer (7) is pushed. Valve (IO) 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 (IO) 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 (IO) 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 PA, (same as pressure at port P2) and the force of the return spring of the control valve are balanced.
PA1
10-150
(Fig. 2)
PBl
SDW01466
WA1 200-3
STRUCTURE
3.
AND
PPC VALVE
FUNCTION
Control lever moved back from slightly erated position to neutral (Fine control) (Fig. 3):
op-
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 (IO) is connected to drain chamber D, so the oil at port P2 escapes. If the pressure at port P2 drops too far, valve (IO) 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 PB,.
4.
Control lever operated (Fig. 4):
to end of travel
Plate (2) pushes piston (4) down, and piston (4) forcibly pushes in valve (IO). 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 Pe, through fine control hole (f’) to drain chamber D.
PA1
WA1 200-3
(Fig. 4)
PBl
SDWOl 488
PPC RELIEF VALVE
STRUCTURE AND FUNCTION
PPC RELIEF VALVE Pump control circuit relief valve 1. 2. 3. 4. 5.
9JYOO264
Function 1. PPC relief valve The PPC relief valve is installed between the PPC pump and PPC valve. While the PPC valve is not operating or when abnormally high pressure is generated, this valve relieves oil sent from the pump to prevent breakage of the pump and circuit. (It sets the maximum pressure in the circuit.)
l
Main valve Valve seat Pilot poppet Spring Adjustment screw
Set pressure: For PPC: 3.73 MPa 138.0 kg/cm*} For pump control circuit: 2.94 MPa (30.0 kg/cm*)
2. l
Pump control circuit relief valve The pump control circuit relief valve is installed between the main pump control pump and main pump. The oil sent from the control pump is relieved through this valve to keep the pressure in the main pump control circuit constant.
Operation . Ports A and C are connected to the pump circuit and drain circuit respectively. The oil is filled in port B through the orifice of main valve (I). Pilot poppet (3) is in contact with valve seat (2).
9JYOO265
.
If the pressure in ports A and B reaches the set pressure of the poppet spring, pilot poppet (3) opens to let the oil flow from port B through port D to port C, then pressure in port B lowers.
.
If the pressure in port B lowers, discharge pressure is generated between ports A and B because of the orifice of main valve (I), then main valve (I) is opened by the pressure of port A and the oil flows out of port A.
I
9JYOO266
9JYOO267
lo-152
WA1 200-3
ACCUMULATOR
STRUCTURE AND FUNCTION
ACCUMULATOR
(FOR PPC VALVE)
1. 2. 3.
Cap Nut Body
4. 5. 6.
Bladder Oil port Nut
Specifications Type of gas: Nitrogen gas Gas amount: 3,000 cc Max. actuation pressure: 2.9 MPa (30 kg/cm*) Min. actuation pressure: 1.6 MPa (16 kg/cm*)
FUNCTION The accumulator is installed between the hydraulic pump and PPC valve. An inflatable bladder is filled with nitrogen gas, and the compressibility is used to store the pressure of the oil. As a result, the boom and bucket can be lowered under their own weight even after the engine has been stopped.
l
‘4
SEW0
OPERATION After the engine stops, when the PPC valve is a NEUTRAL, chamber A (volume of nitrogen gas: 3000 cc) inside the bladder is compressed by chamber B.
Before operation
After operation
l
l
When the PPC valve is operated, the pressure in chamber B drops below 2.9 MPa (30 kg/cm*) and the pressure of the nitrogen gas in chamber A makes the bladder expand. The actuating pressure is 1.6 to 2.9 MPa (16 to 30 kg/cm*}.
t From PPC
pump SEW0 1494
WA1 200-3
+ To PPC valve SE
10-153
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
Pl
PA2
.PB2
PA1 ‘PBl
Al
P
61
9JYOO268
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Main relief valve Bucket spool return spring Boom spool return spring Boom spool Bucket spool Body Suction valve Unloader valve Float selector valve Safety valve (with suction)
1o-1 54
PA1 : PA2 : PBI : PB2 : Al : A2 : Bl : 82 : : P PI : : T
From PA1 of PPC valve From PA2 of PPC valve From PBI of PPC valve From PB2 of PPC valve To bucket cylinder bottom side To boom cylinder bottom side To bucket cylinder rod side To boom cylinder rod side Pump port From PA2 of PPC valve Drain port (to hydraulic tank)
WA1 200-3
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
7 A-A
D-D
E-E
B-B 9JYOO269
FUNCTION The three main control valves control the actuation of the attachments and the bucket in the hydraulic system. It has a tandem circuit which gives priority to the bucket circuit. The oil from the pump enters port P. The maximum pressure is set by main relief valve (I). The oil passes through the bypass circuit of bucket spool (5) and boom spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to the tank. If the bucket and boom spools are actuated, the oil flows to the bucket and boom cylinders. However, the circuit gives priority to the bucket, so when the bucket spool is being operated, even if the boom spool is operated, the boom will not move.
l
l
WA1 200-3
l
There are two safety valves (with suction valves) (IO) to protect the circuit if abnormal pressure is generated in the bucket circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up any lack of oil.
10-155
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
RELIEF VALVE I
2
3
45
6 1. Main valve
2. 3. 4. 5. 6.
Valve seat Pilot poppet Pilot poppet spring Adjustment screw Lock nut
Set pressure: 31.4 MPa 1320 kg/cm21
FUNCTION The relief valve is installed at the inlet of the main control valve. When the oil goes above the set pressure, the relief valve drains the oil to the tank. In this way, it sets the maximum pressure in the hydraulic circuit and protects the circuit.
l
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 (I) and flows to port B. Pilot poppet (3) is in close contact with valve seat (2). When the hydraulic pressure in the circuit inside port A and port B reaches the set pressure of pilot poppet spring (41, pilot poppet (3) opens, and the pressurized oil from port B flows from port D to port C, so the pressure at port B drops. When the pressure at port B drops, the orifice effect of main valve (I) generates a difference in pressure between port A and port B. The main valve is pushed open and the oil from port A passes through port C and flows to the drain circuit to release the abnormal pressure.
SDW01500
SDWOlSOl
10456
WA1 200-3
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
SAFETY-SUCTION
VALVE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 9JYOO270
Suction valve Main valve Piston Piston spring Poppet Poppet spring Suction valve spring Sleeve Adjustment screw Locknut
Set pressure: 36.8 MPa 1375 kg/cm21
FUNCTION . If any impact is applied to the cylinder and abnormally high pressure is generated, that pressure is relieved through the safety-suction valve to protect the cylinder and other hydraulic devices. . If any negative pressure is generated in the cylinder circuit, the safety-suction valve functions as a suction valve. Operation as safety valve . Ports A and B are connected to the cylinder circuit and drain circuit respectively. The oil pressure in port A is led through the hole of piston (3) into port C. Main valve (2) is in contact with the left side since d2 < d3. The diameters (sectional areas) are set as follows; d5 > d4 > dl > d3 > d2
\
D SJYOOP 71
.
If abnormal pressure in port A reaches the set pressure of spring (61, poppet (5) opens to drain the oil from chamber C through chamber D and periphery a of suction valve (1).
a
I
I
f\
C
\\\
5
60 9JYOO272
WA1 200-3
1o-1 57
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
l
If poppet (5) opens, the pressure in chamber C lowers and piston (3) moves to the right. Piston (3) touches the end of poppet (51, then the oil is drained from chamber D through throttle b.
9JYOO2
l
l
Since the pressure in chamber C is lower than that in port A, main valve (2) moves to the right and the oil flows from port A to port B to prevent generation of abnormal pressure. Even if abnormal pressure is generated, suction valve (1) having a larger diameter does not operate, since dl < d4.
‘6
12
9JYOO274 Operation as suction valve . If any negative pressure is generated in the cylinder circuit, the pressure in port A becomes negative, too, since port A is connected to chamber C. Since the tank pressure in port B is applied to port E, the oil pressure on suction valve (I) is increased by the degrees corresponding to the area difference between d5 and dl. Then, spring (6) is compressed to move suction valve (I) to the right. Accordingly, the oil flows from port B to port A to prevent generation of negative pressure in port A.
lo-158
A
E
.B
9JYOO275
WA1 200-3
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
FLOAT SELECTOR VALVE AND UNLOAD VALVE FUNCTION l
The float selector valve and unload valve are inside the work equipment valve. If the boom lever is set to the FLOAT position, the float selector valve operates. As a result, the unload valve operates to set the boom to the floating position.
OPERATION 1. LOWER position .
In the figure at right, the boom to the LOWER position.
lever is set
8 From valve
2. .
steering
FLOAT position If the boom lever is pushed further from the LOWER position, it is set to the FLOAT position. Boom spool (I) of the work equipment valve is kept under the same condition as at the LOWER position. Since oil pressure in port A becomes higher than that at the LOWER position, float selector valve (2) moves to the right and the back pressure on unload valve (3) is released. Accordingly, unload valve (3) opens and the boom is floated.
From steering va I ve
WA1 200-3
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
3. .
FLOAT position (Riding over) If the machine moves back and the boom is raised, the pressure on the cylinder rod side becomes higher. At this time, the oil is drained through port B and unload valve (3). Since the cylinder bottom side is evacuated, oil flows in this side from port C.
Pump
8 From valve
steering
FLOAT position (Lowered by weight) If the machine moves back and the boom is lowered by its weight, the pressure on the cylinder bottom side becomes higher. At this time, the oil is drained through port C. Since the cylinder rod side is evacuated, oil flows in this side from port B.
8 From steering va I ve
10-160
WA1 200-3
STRUCTURE
MAIN
AND FUNCTION
CONTROL
VALVE
BOOM AND BUCKET SPOOLS IN NEUTRAL POSITION
n
I
OPERATION Oil flows through the steering valve and work l equipment pumps 1 and 2 to port A, then its by relief pressure is regulated maximum valve (11). Since bucket spool (I) is in the neutral posil tion, the bypass circuit is open and the oil in port A flows through the periphery of the spool to port B. Since boom spool (2) is also in the neutral position, the bypass circuit is open and the oil in port B flows through the periphery of the spool to port C of the drain circuit, then it returns through the filter in the hydraulic tank.
WA1 200-3
l
n
I4
k
The oil from the PPC pump flows through check valve (13) to port L of the PPC valve. Since the boom and bucket levers are in the the oil returns neutral position, however, through PPC relief valve (12) to the hydraulit tank.
10-161
STRUCTURE AND FUNCTION
BOOM
MAIN CONTROL VALVE
SPOOL IN “RAISE”
Hydraul tank
OPERATION When boom lever (3) is pulled, the oil flows from port L of the PPC valve to port N and port S. In addition, the oil at port T passes through port M and flows to the drain circuit. The oil pressure at port S pushes boom spool (2) and moves it to the RAISE position. The oil from the steering valve passes through the bypass circuit of the bucket spool l
l
10-162
.
and flows to the bypass circuit of boom spool (2). The bypass circuit is closed by the spool, so the oil pushes open check valve (IO). The oil flows from port H to port I, and flows to the cylinder bottom. At the same time, the oil at the cylinder rod end enters drain port C from port K and returns to the tank. Therefore, the boom rises.
WA1 200-3
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
BOOM SPOOL IN “LOWER”
tank
-
L1,,,,,,,,,,,,.,,,,........
r,
SXW,-,A7Fiq
OPERATION l
l
When boom lever (3) is pushed, the oil flows from port L of the PPC valve to port M and port T. In addition, the oil at port S flows to the drain circuit. The oil pressure at port T pushes boom spool (2) and moves it to the LOWER position. The oil from the steering valve passes through the bypass circuit of the bucket spool and flows to the bypass circuit of boom spool
WA1 200-3
l
(2). The bypass circuit is closed by the spool, so the oil pushes open check valve (IO). The oil flows from port J to port K, and flows to the cylinder rod end. At the same time, the oil at the cylinder bottom enters drain port C from port I and returns to the tank. Therefore, the boom goes down.
10-163
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
BOOM SPOOL IN “FLOAT”
HYdrauI tank
ic
ii!&_
1
SXWO4760
OPERATION When boom lever (3) is pushed to the FLOAT position, the PPC valve spool moves beyond the LOWER position to the FLOAT position. The pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W. In addition, the pressurized oil at port S flows to port N. The pressurized oil at port T pushes boom spool (2) to the LOWER position. . If a difference in pressure greater than the specified pressure is generated at port W and port X, valve (7) moves to the right, l
l
10-164
l
opens port Cl and port C, and connects to the drain circuit. When port Cl is connected to the drain circuit, unload valve (8) moves up and the oil from the pump flows to the drain circuit. Therefore, the oil at the cylinder rod end passes from port K through unload valve (8) and flows to the drain circuit. The oil at the cylinder bottom flows from port I to port C, and then flows to the drain circuit. Therefore, the boom is set to the FLOAT condition.
WA1 200-3
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
BUCKET SPOOL IN “DUMP”
OPERATION l
l
When bucket lever (4) is pushed, the sure oil at port L of the PPC valve from port Q to port V. In addition, the port R flows to the drain circuit. The sure oil at port V moves bucket spool the DUMP position. The bypass circuit is closed by bucket (I), so the oil from port A pushes open
WA1 200-3
presflows oil at pres(1) to
valve (IO). The oil from checkvalve (IO) flows from port F to port G, and then flows to the cylinder rod end. At the same time, the oil at the cylinder bottom flows from port D to drain port C, and returns to the tank, so the bucket is
spool check
dumped.
10-165
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
BUCKET
SPOOL IN “TILT BACK”
w
PPC valve
lx
SXW04762
OPERATION When bucket lever (4) is pulled, the pressure oil at port L of the PPC valve flows from port P to port R. In addition, the oil at port V flows to the drain circuit. The pressure oil at port R moves bucket spool (I) to the TILT position. The bypass circuit is closed by bucket spool l
l
lo-166
l
(I 1, so the oil from port A pushes open check valve (IO). The oil from check valve (IO) flows from port E to port D, and then flows to the cylinder bottom. At the same time, the oil at the cylinder rod end flows from port G to drain port C, and returns to the tank, so the bucket is tilted.
WA1 200-3
WORK EQUIPMENT
STRUCTURE AND FUNCTION
WORK EQUIPMENT
LINKAGE
LINKAGE
;;
I,
Ii Ii i~~_~___-,____.,_-il ;--..--____.__._.____,--
1. 2. 3. 4.
Bucket Bucket link Bellcrank Bucket cylinder
lo-168
5. 6. 7. 8.
Boom Boom cylinder Tooth with tip Sweeper wing
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT
LINKAGE
B-B
D-D
E-E
G-G
F-F
H-H SJWO4764
WA1 200-3
lo-169
OPERATION OF PROXIMITY SWITCH
STRUCTURE AND FUNCTION
OPERATION
OF PROXIMITY
SWITCH
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.
switch Proximity positioner bucket
l
for
SVW03369
Cam Bucket
lever
\ Detector
Proximity
Solenoid
switch SEW02327
.
switch Proximity positioner bucket
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.
for -To
battery relay
I
II
Positioner
relay
SVW03369
Bucket
Detector
Proximity
switch +PPC
10-170
lever
valve
SEW02326
WA1 200-3
STRUCTURE AND FUNCTION
l
OPERATION OF PROXIMITY SWITCH
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.
Proximity switch bucket positioner
for -To
battery relay
I
Cam Bucket
Detector
Proximity
lever
switch SEW02329
Action of proximity switch
Position
When sensor is in position at detection surface of proximity switch
When sensor is separated from detection surface of proximity switch
Proximity actuation
switch display
Lights up
Goes out
Positioner
relay
Current flows
Solenoid
WA1 200-3
(for bucket)
I
Current
is shut off
I I
Current
is shut off
Current flows
10-171
STRUCTURE AND FUNCTlON
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER PIPING
SWWO4785
1. 2. 3. 4. 5. 6. 7.
Air vent Air vent Condenser (right) Dry reservoir Compressor Condenser (left) Air conditioner Unit
1o-172
WA1 200-3
STRUCTURE AND FUNCTION
AIR CONDITIONER
AIR CONDITIONER CONDENSER
1. 2. 3. 4.
Electric wiring Fan Refrigerant gas inlet port Refrigerant gas outlet port
SWWO4786
AIR CONDITIONER COMPRESSOR
1. 2. 3. 4.
Refrigerant outlet port Refrigerant inlet port Relief valve Clutch
Specifications Type: Piston pump type Refrigerant used: R134a
4707
WA1 200-3
10-173
STRUCTURE AND FUNCTION
AIR CONDITIONER
DRY RESERVOIR
1. 2. 3.
10-174
Body Drier Filter
WA1 200-3
STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
OUTLINE • The machine monitor system monitors the machine condition by means of the sensors installed to various parts of the machine and displays the result immediately on the monitor panel to notify the operator of the machine condition. • The machine monitor system consists of a main monitor, CGC monitor, various sensors, switches, relays, an alarm buzzer, and a power supply unit. • The displayed items are roughly classified into two groups; The items in one group are various caution items displayed on the monitor when any trouble occurs in the machine, and those in the other group are the machine conditions which are displayed constantly by the gauges, speedometer, service meter, pilot lamps, etc. • There are various switches inside the monitor panel which are used to control the machine. WA1200-3
•
•
•
The main monitor has a function to send and receive signals through the network circuit to display the following items. 1 Shift indicator: 1st – 3rd gear speeds, N, F, R 2 Remedy code, failure code, time after failure (failure history mode) The CGC monitor consists of a display and touch switches. The monitor screen to display the gauges, maintenance screen, fuel consumption screen, positioner screen, load meter screen, etc. can be selected on the display. If any trouble occurs, the CGC monitor receives signals from the VHMS controller and displays the warning screen. The VHMS controller monitors the data of the machine condition and maintenance condition, and saves them in itself.
10-175 10-175 (7)
STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
System configuration
I
INPUT I
1 Alternator R terminal voltage
D A D D D A
Small lamp ON voltage Boom cylinder bottom pressure Boom proximity sensor Sub total switch Cancel switch PPC relief pressure Torque converter inlet oil pressure
A
Torque converter outlet oil pressure Transmission main relief pressure Transmission lubricating oil pressure
A A A
Transmission modulation oil pressure Steering relief pressure Work equipment relief pressure Boom cylinder head pressure
OUTPUT
P: Pulse signal A: Analog signal D: ON-OFF signal
10476
WA1 200-3
MAIN MONITOR
STRUCTURE AND FUNCTION
MAIN MONITOR
5C
5D
SE
4E
4F
SWWO4789
1. Check lamp Caution lamp Caution item 3A. Operation of emergency steering system 4. Pilot items 4A.Turn signal lamp (Left) 4B. Turn signal lamp (Right) 4C. Shift indicator 4D. Tachometer/Speedometer 4E. Parking brake 4F. Remedy code 5. Switches 5A. Auto grease switch 5B. Tire slip control ON/OFF switch 5C. Working lamp (Front) switch 5D. Working lamp (Rear) switch 5E. Transmission cut-off switch
2. 3.
WA1 200-3
OUTLINE l
l
.
The main monitor has functions to display travel speed, etc. and switch functions to control electrical equipment, controllers, etc. The main monitor has one CPU (Central Processing Unit) in itself to process, display, and output the signals from the sensors, etc. The main monitor uses LCD and LED to display various items. The switches are embossed (convex) sheet switches.
1o-177
MAIN MONITOR
STRUCTURE AND FUNCTION
DISPLAY FUNCTION OF MAIN MONITOR Division of display
Symbol
Check
0
Display range
Indicated item
Display method
Check
When maintenance monitor trouble is displayed
Flashing of displayed items (For details, see display functions of maintenance monitor)
Operation of emergency steeringI system
When system operates
Flashing of displayed items
When parking brake is applied while shift lever is not in N
Flashing of displayed items and sounding of buzzer
When maintenance monitor trouble is displayed
Flashing of displayed items (Buzzer may sound) (For details, see display functions of maintenance monitor)
Turn signal lamps (Right, Left)
When lamp is turned on
Lighting of pilot lamp
Parking brake
When parking brake is applied
Lighting of pilot lamp If parking brake is applied while shift lever is not in N, buzzer sounds.
Tachometer/ Speedometer
Travel speed
x 100 rpm 0 - 99 km/h MPH
Digital display (Selection of tachometer/speedometer)
Shift indicator
Shift indicator
l-3,N
Digital display
Remedy code
If controller detects failure and operator must, take remedy, CALL is displayed, or CALL and E 0 0 (Remedy code) are displayed alternately.
Forward/Reverse (When joystick steering system is installed)
F, R
CHECK
Caution
0
Caution
CAUTION
D
3 Pilot
c $w
p
Remedy code
Shift indicator
lo-178
LF/R dilrllr SDW02342
Digital display Sounding of buzzer (For failure history mode, see failure history mode)
Digital display
WA1 200-3
MAIN MONITOR
STFWCTUREAND FUNCTION
SWITCH FUNCTIONS OF MAIN MONITOR Item
Auto grease
Tire slip control
Working lamps (Front)
Function
When pilot lamp lights up, grease is supplied forcibly only while switch is pressed.
Tire slip control function is turned on and off each time switch is pressed.
Display
Operation
Flashing (Quick)
Auto grease controller has trouble.
OFF
Auto grease controller is not installed.
ON
Tire slip control function is turned on
OFF
Tire slip control function is turned off.
While small lamp lights up, rear working lamp is turned on and off each time switch is pressed. head lamp, lamp in front of axle)
Working lamp (Rear)
Transmission cut-off
WA1 200-3
While small lamp lights up, front working lamps are turned on and off each time switch is pressed.
Transmission cut-off function is turned on and off each time switch is pressed.
ON
Rear working lamp lights up.
OFF
Rear working lamp goes off
ON
Cut-off function is turned on.
OFF
Cut-off function is turned off.
10-179
MAIN MONITOR
STRUCTURE AND FUNCTION
TROUBLE DATA DISPLAY MODE Item
Actuation
Switch operation
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 emergency 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. (I) 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) (2) 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). (3) 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.
SDW01254
swwo479 1
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 from travel data display mode
Press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds, or start the engine.
Changes to normal display
lo-180
WA1 200-3
STRUCTURE AND FUNCTION
CGC MONITOR
CGC MONITOR
ª1: Use the PC tool to select the default setting and the setting when replacing the controller. Outline • On the CGC monitor, the monitor screen to display gauges, maintenance screen, setting screen, fuel consumption screen, etc. can be selected with the buttons on the screens (touch switches). • If any trouble occurs in the machine, the warning screen appears automatically.
WA1200-3
•
In addition to the screen for operator which is normally displayed, the screen for serviceman is available to check and set the machine data and clear the saved data. (A special ID is required to open the screen for serviceman).
10-181 10-181 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Monitor screen
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Engine water temperature gauge Torque converter oil temperature gauge Fuel gauge Clock Tachometer Brightness adjustment button Maintenance screen button Setting screen button Fuel consumption screen button Positioner screen button Load meter screen button Failure list screen button
After the initial screen disappears, the monitor screen appears automatically. This screen is composed of the following gauges and buttons (touch switches). •
•
The display range is 60 – 108°C. The red range is above 102°C. If the pointer enters the red range, its color changes from green to red. Torque converter temperature gauge: The display range is 27 – 140°C. The red range is above 120°C. If the pointer enters the red range, its color changes from green to red. Fuel gauge: The display range is 555 – 3700 ¬. The yellow range is below 1250 ¬. If the pointer enters the yellow range, its color changes from green to yellow. Clock: This clock indicates the present time. For setting method of this clock, see the setting screen. Tachometer: This meter indicates the engine speed digitally.
•
Brightness adjustment button:
•
•
•
Engine water temperature gauge:
This button is used to select the brightness and contrast adjustment screen. Brightness button: Used to adjust brightness. Contrast button: Used to adjust contrast. EXIT button: Used to turn off the screen and display the monitor screen.
10-182 10-182 (7)
WA1200-3
STRUCTURE AND FUNCTION
•
Maintenance screen button:
CGC MONITOR
This button is used to select the maintenance screen. See the maintenance screen. The color of this button changes to display the maintenance condition. Yellow: One or more parts need to be maintained in 30 hours. Red: One or more parts have passed the maintenance time.
• • • • •
Setting screen button: Fuel consumption screen button: Positioner screen button: Load meter screen button: Failure list screen button:
WA1200-3
This This This This This
button button button button button
is is is is is
used used used used used
to to to to to
select select select select select
the the the the the
setting screen. fuel consumption screen. positioner screen. load meter screen. failure list screen
10-183 10-183 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Maintenance screen
1. Display of maintenance items (Maintenance item selector buttons) 2. Display of time before periodic maintenance 3. Page button 4. Monitor screen button
If the maintenance screen button is pressed on the monitor screen, the maintenance screen appears. •
•
• • •
Display of maintenance items:
Maintenance items are displayed. The buttons to select maintenance items are formed in this area. The color of each button changes to display the maintenance condition. Yellow:The time before periodic maintenance is shorter than 30 hours. Red: The displayed part has passed the maintenance time (The time before periodic maintenance is negative). Display of time before periodic maintenance: The time before the next periodic maintenance is displayed. If the displayed part has passed the planned maintenance time, a negative value is displayed. Page button: This button is used to turn over the displayed page. Monitor screen button: This button is used to select the monitor screen. Maintenance item selector button: If this button (one of displayed maintenance items) is pressed, it flashes. If it is pressed again, the following pop-up screen appears. When maintenance is executed, set the time before the next periodic maintenance to the initial value on this screen. YES button: Press this button if maintenance has been executed, and the time before the periodic maintenance is set to the initial value. NO button: Press this button if maintenance has not been executed, and the time before the periodic maintenance is kept as it is. If the YES or NO button is pressed, the popup screen disappears and the maintenance screen appears.
10-184 10-184 (7)
WA1200-3
STRUCTURE AND FUNCTION
Maintenance
CGC MONITOR
items list
No.
Interval
1
250H
Change
Corrosion
250H
Change
Fuel Filter
3
250H
Change
Engine Oil Filter
4
250H
Change
Engine
5
250H
Change
Transmission
250H
1 Change
2
6
I
I
Item Resistor
Oil Oil Filter
Brake Oil Filter
7
1OOOH
Change
8
1OOOH
Clean Transmission
Breather
9
IOOOH
Clean Transmission
Strainer
1OOOH
Change
By-pass Engine Oil Filter
2000H
Change
Brake Oil
12
2000H
Change
Brake Oil Tank Breather
13
2000H
Change
Hyd. Tank Breather
14
2000H
Clean Hyd. Tank Strainer
15
2000H
Change
2000H
Clean Pilot Line Strainer
17
2000H
Change
Axle Oil
18
2000H
Change
Linkage
19
2000H
Change
Hyd. Oil Filter
20
2000H
Change
Hyd. Oil
10 11
16
WA1 200-3
I I
I
Transmission
Oil
Element
Brake Line Strainer
Pin Lube Oil
lo-185
STRUCTURE AND FUNCTION
CGC MONITOR
Setting screen
1. 2. 3. 4. 5. 6. 7.
DATE button TIME button UNIT button USER ID button SET button Monitor screen button Language selection button
When the setting screen button is pressed on the monitor screen, the screen changes to the setting screen. This screen is used to set the unit for displaying the data and to set the user ID. To confirm or set the present time and date, use the PC tool (see TESTING AND ADJUSTING). •
DATE button: This button is used to check the date. (Do not set the date on the setting screen; use the PC tool to carry out the setting.) If the DATE button is pressed, the popup screen to select the year, month, or day appears. If the year, month, or day is selected (pressed), the data inputting screen appears, but if the Previous button is pressed, the screen returns to the confirmation screen.
10-186 10-186 (7)
WA1200-3
STRUCTURE AND FUNCTION
•
CGC MONITOR
TIME button: This button is used to check the time. (Do not set the time on the setting screen; use the PC tool to carry out the setting.) If the TIME button is pressed, the popup screen to select the hour or minute appears. If the hour or minute is selected (pressed), the data inputting screen appears, but if the Previous button is pressed, the screen returns to the confirmation screen.
•
UNIT button: This button is used to set the unit for displaying the data. If the UNIT button is pressed, and the set language is English or Spanish, the pop-up screen to select the unit appears. The unit can be selected from METRIC, ENGLISH, and SI. If the set language is Japanese, the unit is set to SI. Even if the UNIT button is pressed, the pop-up screen does not appear.
•
SUMMER (daylight saving time) button If the set language is English or Spanish, the SUMMER setting button appears. If the SUMMER setting button is pressed, a check mark is displayed on the button, and the time advances by one hour.
•
USER ID button: This button is used to set the user ID No. If this button is pressed, the pop-up screen to input the user ID No. appears. As the user ID No., any one of 1-digit – 10-digit values can be input. If the user ID is changed, even if the failure history has been deleted with the failure history un-display button, the warning/failure display is displayed again. This makes it possible to check the condition of the machine even when the operator has changed.
WA1200-3
10-187 10-187 (7)
STRUCTURE AND FUNCTION
•
• •
CGC MONITOR
SET button:
If this button is pressed, the input date, time, unit, and user ID are saved. If this button is not pressed, the input data are not saved, and the present data not updated. Monitor screen button: This button is used to select the monitor screen. Language selection button: This button is used to select the language used for the display. It is possible to select from Japanese, English, and Spanish. When the selection is made, the CGC monitor is automatically reset and the display switches to the selected language. Use this switch also for setting the time difference from GMT.
10-188 10-188 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Fuel consumption screen
1. 2. 3. 4. 5. 6.
Display of data measurement period Display of productivity in Ton/Hour Fuel consumption ratio in Liter/Hour Display of kind of material Productivity history screen button Monitor screen button
If the fuel consumption screen button on the monitor screen is pressed, the fuel consumption screen appears. The fuel consumption is calculated from the data recorded on the load meter screen, then the data measurement period, productivity in Ton/Hour, and fuel consumption ratio in Liter/Hour are displayed. The displayed data are based on the kind or material (KIND) selected on the load meter screen. The unit set on the setting screen is used for the displayed data. • •
Productivity history screen button: This button is used to select the productivity history screen. Monitor screen button: This button is used to select the monitor screen.
WA1200-3
10-189 10-189 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Productivity history screen
1. 2. 3. 4. 5.
Display of kind of load (Memory clear button) Display of fuel consumption ratio Display of productivity Display of date when memory is cleared Fuel consumption screen button
If the productivity history screen button on the productivity screen is pressed, the productivity history screen appears. The fuel consumption ratio in Liter/Hour and productivity data in Ton/Hour for each kind of load (KIND) are calculated from the data recorded on the load meter screen, then displayed. The unit set on the setting screen is used for the displayed data. •
Memory clear button: This button is used to clear the data of the selected kind of load (KIND). If this button is pressed, the pop-up screen to ask if your are really clearing the data of the selected kind of load (KIND) appears. YES button: Press this button if you wish to clear the data. NO button: Press this button if you do not wish to clear the data. If the YES or NO button is pressed, the pop-up screen disappears, and the productivity history screen appears.
•
Fuel consumption screen button: This button is used to select the fuel consumption screen.
10-190 10-190 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Positioner screen
1. 2. 3. 4. 5.
UPPER STOP selector button UPPER STOP POSITION setting button LOWER STOP selector button LOWER STOP POSITION setting button Monitor screen button
If the positioner screen button on the monitor screen is pressed, the positioner screen appears. This screen is used to set ON/OFF and stopping positions of the remote positioner function. (The set condition is saved even if the starting switch is turned off.) •
• •
• •
UPPER STOP selector button:
Each time this button is pressed, it lights up (green) and goes off alternately. While this switch is lighting up, the upper stopping function is effective. UPPER STOP POSITION setting button: After setting the upper stopping position according to the given procedure, press this button to save the set data. LOWER STOP selector button: Each time this button is pressed, it lights up (green) and goes off alternately. While this switch is lighting up, the lower stopping function is effective. LOWER STOP POSITION setting button:After setting the lower stopping position according to the given procedure, press this button to save the set data. Monitor screen button: This button is used to select the monitor screen.
WA1200-3
10-191 10-191 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Load meter screen (integration mode) 1. 2. 3. 4. 5. 6. 7. 8. 9.
Display of kind of load Display of integrated load Display of bucket load Kind of load selector button Subtraction mode button Calibration screen button Total load screen button Monitor screen button Gauge display button
If the load meter screen button on the monitor screen is pressed, the load meter screen appears. The load is measured each time, and the bucket load and integrated load are displayed. The integrated load is added up and displayed for each of the seven kinds of load (KIND). •
Kind of load selector button: This button is used to select the kind of load (KIND). If this button is pressed, the pop-up screen to select the kind of load (KIND) appears. Select one of seven kinds A – G.
•
Subtraction mode button: This button is used to select the load meter screen (subtraction mode).
10-192 10-192 (7)
WA1200-3
STRUCTURE AND FUNCTION
• • • •
CGC MONITOR
Calibration screen button: This button is used to select the calibration screen. Total load screen button: This button is used to select the total load screen. Monitor screen button: This button is used to select the monitor screen. Gauge display button: This button is used to display the gauges on the right side of the screen. If this button is pressed, the engine water temperature gauge, torque converter oil temperature gauge, and fuel gauge are displayed. If it is pressed again, the displayed gauges disappear.
WA1200-3
10-193 10-193 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Load meter screen (Subtraction mode) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Display of kind of load Display of remaining load Display of bucket load Kind of load selector button Subtraction standard value setting button Integration mode button Calibration screen button Total load screen button Monitor screen button Gauge display button
If the subtraction mode button on the load meter screen (Integration mode) is pressed, this screen appears. The load measured each time is subtracted from the subtraction standard value which is set in advance, and the bucket load and the remaining load are displayed. •
Kind of load selector button: This button is used to select the kind of load (KIND). If this button is pressed, the pop-up screen to select the kind of load (KIND) appears. Select one of seven kinds A – G.
10-194 10-194 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
•
Subtraction standard value setting button: This button is used to set the subtraction standard value. If this button is pressed, the screen to input the subtraction standard value appears.
• • • • •
Integration mode button: This button is used to select the load meter screen (Integration mode). Calibration screen button: This button is used to select the calibration screen. Total load screen button: This button is used to select the total load screen. Monitor screen button: This button is used to select the monitor screen. Gauge display button: This button is used to display the gauges on the right side of the screen. If this button is pressed, the engine water temperature gauge, torque converter oil temperature gauge, and fuel gauge are displayed. If it is pressed again, the displayed gauges disappear.
WA1200-3
10-195 10-195 (7)
CGC MONITOR
STRUCTURE AND FUNCTION
Calibration screen
2 CALIBRATION
buctet 2. Raise
at carrl
I/cw
1. 2. 3. 4. 5.
mition.
Display of calibration method Engine water temperature gauge Torque converter oil temperature Fuel gauge Load meter screen button
gauge
t
If the calibration screen button on the load meter screen in the integration mode or subtraction mode is pressed, the calibration screen appears. Operate the machine according to the displayed procedure for calibration, and the load meter is calibrated automatically.
.
Load meter screen button: This button
(For the engine water temperature the monitor screen.)
10-196
is used to select the load meter screen again.
gauge, torque converter
oil temperature
gauge, and fuel gauge, see
WA1 200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Total load screen
1. 2. 3. 4. 5.
Display of kind of load (Data clear button) Display of number of loading times Display of load Display of date where data are cleared Load meter screen button
If the total load screen button on the load meter screen in the integration mode or subtraction mode is pressed, the total load screen appears. On this screen, the total number of loading times, load, and date when the data are cleared are displayed for each kind of load (KIND). The unit set on the setting screen is used for the displayed data. •
Data clear button: This button is used to clear the data of each kind of load (KIND) or the data of the total load. If the display area of a kind of load (KIND) is pressed, the pop-up screen to clear the data appears. YES button: Press this button if you wish to clear the data and update the display of the date when the data are cleared. NO button: Press this button if you do not wish to clear the data.
•
Load meter screen button: This button is used to select the load meter screen in the integration mode or subtraction mode.
WA1200-3
10-197 10-197 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
FAILURE LIST SCREEN
1. 2. 3. 4. 5. 6. 7.
Detected failure total display Number display Error code display Failure occurrence detection start time display Display item UP/DOWN button Display page selector button Service menu selection screen button
If the failure list screen button is pressed on the service menu selection screen, the screen changes to this screen. The currently existing failures are displayed in turn starting from the newest. (Only the error codes displayed on the CGC monitor are displayed on the failure list screen.) If the problem is removed, the problem is automatically deleted. • • •
Display item UP/DOWN button: The display goes up or down one item Display page selector button: The display goes up or down one page Service menu selection screen button: The screen changes to the service menu selection screen
10-197-1 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Warning screen 1. 2. 3. 4. 5. 6. 7.
Display of warning item Display of warning message Display of error code Display of warning page Cancel switch Hold switch (cancel switch) Jump switch
If any trouble occurs, the CGC monitor automatically displays the warning screen. The CGC monitor then displays the currently used screens (displays in item order) and the warning screen alternately. • • •
• •
Display of warning item: Each warning item is displayed in yellow or red, depending on its type. Display of warning page: The position of the currently detected trouble is displayed. (Example: 1/5 means the first of five troubles.) Cancel switch: If the cancel switch is displayed on a warning screen, this screen can be put out temporarily by pressing the cancel switch. (A warning screen which does not have the cancel switch on it cannot be put out.) If the trouble displayed on the warning screen is not repaired, it is detected again and displayed on the warning screen when the starting switch is turned on next time. It is possible to cancel any warning display that has been canceled with the cancel switch when the user ID has been changed. Hold switch: If the hold switch is pressed, the currently displayed warning item is held for 2 minutes. The hold switch changes into the cancel switch. Jump switch: If the cancel switch is pressed, the screen displays the next warning item. The cancel switch changes into the hold switch and the monitor screen is held for 2 minutes. If the trouble is not repaired, the screen returns to the warning display screen after 2 minutes.
10-198 10-198 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Warning items list Warning output No.
Item
1 Engine oil level 2 Engine oil pressure 3 Engine water temperature 4 Fuel level
Display range
Below LOW level
Warning Main monitor output display Color on screen CHECK CAUTION on CGC lamp lamp
Buzzer
Cancel switch
Error code No.
Displayed
C253
Remarks
Abnormal
Red
Flashing
–––
–––
Below specified pressure Abnormal
Red
–––
Flashing
ON
Red
–––
Flashing
ON
Below specified level Insufficient
Yellow
Flashing
–––
–––
Displayed B@BFZK Before engine starts
Below specified level Insufficient
Yellow
–––
Flashing
–––
Displayed b@BFZK While engine is running
Above 102°C
Abnormal
Not displayed C143 Displayed
C151
Above 120°C
Abnormal
Red
–––
Flashing
–––
Displayed B@CENS
Above 130°C
Abnormal
Red
–––
Flashing
ON
Displayed b@CENS
Above 105°C
Abnormal
Red
–––
Flashing
–––
Displayed B@HANS
Below 14.7 MPa {150 kg/cm2}
Being raised
Yellow
–––
Flashing
–––
Displayed 2G41BM
Abnormal
Red
–––
Flashing
ON
Not displayed 2G42ZG
Below 14.7 MPa {150 kg/cm2}
Being raised
Yellow
–––
Flashing
–––
Displayed 2G41BM
Abnormal
Red
–––
Flashing
ON
Not displayed 2G43ZG
9 Battery fluid level (1)
Below LOW level
Abnormal
Yellow
Flashing
–––
–––
Displayed B@GAZK
10 Battery fluid level (2)
Below LOW level
Abnormal
Yellow
Flashing
–––
–––
Displayed B@GBZK
11 Battery fluid level (3)
Below LOW level
Abnormal
Yellow
Flashing
–––
–––
Displayed B@GCZK
Below specified level Abnormal
Yellow
Flashing
–––
–––
Displayed B@C5ZK Before engine starts
Below specified level Abnormal
Red
–––
Flashing
ON
Not displayed b@C5ZK While engine is running
5 Torque converter oil temperature 6 Hydraulic oil temperature 7 Brake oil pressure (F)
8 Brake oil pressure (R)
12 Brake oil level
Below LOW level
Abnormal
Yellow
Flashing
–––
–––
Displayed B@BCZK Before engine starts
Below LOW level
Abnormal
Red
–––
Flashing
ON
Not displayed b@BCZK While engine is running
Above specified pressure Abnormal
Yellow
Flashing
–––
–––
Displayed 15BONX
15 Clogging of air cleaner (1) Above specified pressure Abnormal
Yellow
Flashing
–––
–––
Displayed AA1ANX
16 Clogging of air cleaner (2) Above specified pressure Abnormal
Yellow
Flashing
–––
–––
Displayed AA1BNX
17 Clogging of air cleaner (3) Above specified pressure Abnormal
Yellow
Flashing
–––
–––
Displayed AA1CNX
18 Clogging of air cleaner (4) Above specified pressure Abnormal
Yellow
Flashing
–––
–––
Displayed AA1DNX
19 Abnormal charging voltage When charge is abnormal Abnormal
Yellow
Flashing
–––
–––
Displayed AB00MA
13 Engine water level 14 Clogging of transmission
WA1200-3
10-199 10-199 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Service ID inputting screen
1. Service ID inputting screen button (Lower) 2. Service ID inputting screen button (Upper)
The service ID inputting screen buttons are hidden at the right bottom and right top of the setting screen (They are not displayed on the screen). Press the lower button, then press the upper button, and the screen changes to the following service ID input screen.
1. Display of message 2. Operator display screen button
Input the correct service ID (the service ID is the VHMS controller part No. (with no hyphens), first nine digits + 0) through the keys and press the enter key, and the screen for serviceman appears. If a wrong service ID is input, the message changes to “Please input Service ID”. •
Operator display screen button: If this button is pressed, the serviceman display screen does not appear, but the operator display screen appears again.
10-200 10-200 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Service menu selection screen
1. 2. 3. 4. 5. 6. 7. 8.
Real-time monitor screen button Maintenance time setting screen button Failure history screen button PM clinic screen button Machine serial No. setting screen button Snapshot operation screen button Memory clear ID inputting screen button Operator display screen button
If the correct ID is input on the service ID inputting screen, the service menu selection screen appears. If each screen button on this screen is pressed, the selected screen appears. If the operator display screen button is pressed, the operator display screen appears.
WA1200-3
10-201 10-201 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Real-time monitor screen
1. 2. 3. 4. 5. 6. 7.
Engine system display button Transmission system display button Load meter system display button Modulated clutch system display button Remote positioner system display button Joystick steering system display button Service menu selection screen button
If the real-time monitor screen button on the service menu selection screen is pressed, the real-time monitor screen appears. On this screen, select the data of a desired controller. If a display button is pressed, the data of the selected system are displayed. If the service menu selection screen button is pressed, the service menu selection screen appears again.
On the data display screen, the information of the selected controller is displayed in real time. Select the page to be displayed with the arrow keys. If the Previous screen key is pressed, the realtime monitor screen (for selection of a system) appears again.
10-202 10-202 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Real-time monitor display items Engine DISPLAYED PAGE
NAME OF SIGNAL
SAMPLING TIME
UNIT
DETECTED COMPONENT
ON/OFF: LOGIC
1/2
ENGINE SPEED
2s
1 rpm
VHMS
—
1/2
COOLANT TEMP.
2s
1°C
CENSE
—
1/2
ENGINE OIL TEMP.
2s
1°C
CENSE
—
2s
0.01MPa {0.1kg/cm2}
CENSE
1/2
FUEL RAIL PRESSURE
(ON/OFF) CENSE
— Normal: OK Insufficient: NG
1/2
ENGINE OIL LEVEL
2S
2/2
EXH GAS TEMP LIST
2s
1°C
CENSE
—
SAMPLING TIME
UNIT
DETECTED COMPONENT
ON/OFF: LOGIC
Transmission DISPLAYED PAGE
NAME OF SIGNAL
1/4
T/M DIRECTION SIG. F
2s
(ON/OFF)
T/M
1/4
T/M DIRECTION SIG. N
2s
(ON/OFF)
T/M
1/4
T/M DIRECTION SIG. R
2s
(ON/OFF)
T/M
1/4
T/M UP SHIFT SW
2s
(ON/OFF)
T/M
1/4
T/M DOWN SHIFT SW
2s
(ON/OFF)
T/M
2/4
ENGINE SPEED
2s
1 rpm
VHMS
J/S lever OFF: OFF (OPEN) J/S lever ON: ON (24V) J/S lever OFF: OFF (OPEN) J/S lever ON: ON (24V) J/S lever OFF: OFF (OPEN) J/S lever ON: ON (24V) SW OFF: OFF (Others) SW ON: ON (2 inputs for detection are normal) SW OFF: OFF (Others) SW ON: ON (2 inputs for detection are normal)
— SW SW SW SW SW SW SW SW SW SW
OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND)
2/4
FILL SIGNAL F
2s
(ON/OFF)
T/M
2/4
FILL SIGNAL R
2s
(ON/OFF)
T/M
2/4
FILL SIGNAL 1st
2s
(ON/OFF)
T/M
2/4
FILL SIGNAL 2nd
2s
(ON/OFF)
T/M
2/4
FILL SIGNAL 3rd
2s
(ON/OFF)
T/M
3/4
ENGINE SPEED
2s
1 rpm
VHMS
—
3/4
SOLENOID F
2s
1 mA
T/M
—
3/4
SOLENOID R
2s
1 mA
T/M
—
3/4
SOLENOID 1st
2s
1 mA
T/M
—
3/4
SOLENOID 2nd
2s
1 mA
T/M
—
3/4
SOLENOID 3rd
2s
1 mA
T/M
—
4/4
ENGINE SPEED
2s
1 rpm
VHMS
4/4
AUTO SHIFT SIGNAL
2s
(ON/OFF)
T/M
4/4
MANUAL SHIFT SIGNAL
2s
(ON/OFF)
T/M
4/4
T/M CUTOFF SIGNAL
2s
(ON/OFF)
T/M
4/4
KICK DOWN SW SIGNAL
2s
(ON/OFF)
T/M
WA1200-3
— AUTO: ON MANUAL: OFF MANUAL: ON AUTO: OFF When normal: ON (GND) When cut off: OFF (OPEN) SW OFF: OFF (OPEN) SW ON: ON (GND)
10-203 10-203 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Load meter DISPLAYED PAGE
NAME OF SIGNAL
SAMPLING TIME
DETECTED COMPONENT
ON/OFF: LOGIC
1/1
BOOM BOTTOM PRESSURE
2s
1/1
MEASURED PRESSURE
2s
1/1
CAL. PRESSURE
2s
1/1
NO LOAD PRESSURE
2s
0.01MPa {0.1kg/cm2} 0.01MPa {0.1kg/cm2} 0.01MPa {0.1kg/cm2} 0.01MPa {0.1kg/cm2}
VHMS
—
VHMS
—
VHMS
—
VHMS
—
1/1
MEASURED LOAD
2s
1 TON
VHMS
—
UNIT
DETECTED COMPONENT
ON/OFF: LOGIC
UNIT
Modulated clutch DISPLAYED PAGE
NAME OF SIGNAL
SAMPLING TIME
1/6 1/6 1/6 1/6 1/6 2/6 2/6 2/6 2/6 2/6 2/6 3/6 3/6 3/6 3/6 3/6 3/6 4/6 4/6 4/6 4/6 4/6
T/M CUTOFF SIGNAL TRACTION CONT. SIGNAL SPEED CONT. SIGNAL VEHICLE SPEED SETTING VEHICLE SPEED ENGINE SPEED MOD/C OUTPUT SPEED VEHICLE SPEED MOD/C SLIP RATE MOD/C SOLENOID MOD/C FILL SIGNAL ENGINE SPEED BOOM RAISE SIGNAL BOOM LOWER SIGNAL BUCKET TILT SIGNAL BUCKET DUMP SIGNAL NC SOL OUTPUT SIGNAL ENGINE SPEED TIRE REV. SPEED VEHICLE SPEED MOD/C SOLENOID TRACTION
2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s
(ON/OFF) T/M 0.1 V MOD 0.1 V MOD 0.1 km/h MOD 0.1 km/h MOD 1 rpm VHMS 1 rpm MOD 0.1 km/h MOD 1% MOD 1 mA MOD (ON/OFF) MOD 1 rpm VHMS (ON/OFF) J/S (ON/OFF) J/S (ON/OFF) MOD (ON/OFF) MOD (ON/OFF) MOD 1 rpm VHMS 1 rpm MOD 0.1 km/h MOD 1 mA MOD 1 TON MOD
4/6
TIRE SLIP SIGNAL
2s
(ON/OFF) Main monitor
5/6 5/6 5/6 5/6
BOOM RAISE SIGNAL BUCKET TILT SIGNAL FILL SIGNAL F FILL SIGNAL 1st
2s 2s 2s 2s
(ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF)
5/6
TIRE SLIP SIGNAL
2s
(ON/OFF) Main monitor
6/6 6/6 6/6 6/6 6/6 6/6
ENGINE SPEED RH BRAKE PROXIMITY SW ACCELERATOR SIGNAL CONT. OUTPUT SIGNAL SET/ACCEL RESUME/DECEL
2s 2s 2s 2s 2s 2s
1 rpm VHMS (ON/OFF) MOD 0.1 V MOD 0.1 V MOD (ON/OFF) MOD (ON/OFF) MOD
10-204 10-204 (7)
J/S MOD T/M T/M
When normal: ON (GND) When cut off: OFF (OPEN)
— — — — — — — 1% (VHMS is calculated from outlet rpm) — Fill switch ON: ON (GND) ELSE: OFF (OPEN)
— RAISE: ON (OPEN) N: OFF (GND) LOWER: ON (OPEN) N: OFF (GND) TILT: ON (OPEN) N: OFF (GND) LOWER: ON N: OFF When output: ON ELSE: OFF (GND)
— — — — Data are updated only when drive force is controlled. ON: Tire slip is controlled. OFF: Tire slip is not controlled. (Turned on and off each time switch is pressed) RAISE: ON (OPEN) N: OFF (GND) TILT: ON (OPEN) N: OFF (GND) Switch OFF: OFF (OPEN) Switch ON: ON (GND) Switch OFF: OFF (OPEN) Switch ON: ON (GND) ON: Tire slip is controlled. OFF: Tire slip is not controlled. (Turned on and off each time switch is pressed)
— Switch ON: ON (GND) Switch OFF: OFF (OPEN)
0.1 V (Command value of electronic governor) — Switch Switch Switch Switch
ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Remote positioner DISPLAYED PAGE
NAME OF SIGNAL
SAMPLING TIME
UNIT
DETECTED COMPONENT
1/1
BOOM ANGLE SIGNAL
2s
0.1 V
J/S
ON/OFF: LOGIC — RAISE: ON (OPEN) N: OFF (GND) LOWER: ON (OPEN) N: OFF (GND) DETENT ON: ON DETENT OFF: OFF Positioner UPPER switch ON: ON Positioner UPPER switch OFF: OFF Positioner LOWER switch ON: ON Positioner LOWER switch OFF: OFF
1/1
BOOM RAISE SIGNAL
2s
(ON/OFF)
J/S
1/1
BOOM LOWER SIGNAL
2s
(ON/OFF)
J/S
1/1
DETENT SIGNAL
2s
(ON/OFF)
J/S
1/1
UPPER SET SIGNAL
2s
(ON/OFF)
VHMS
1/1
LOWER SET SIGNAL
2s
(ON/OFF)
VHMS
SAMPLING TIME
UNIT
DETECTED COMPONENT
ON/OFF: LOGIC
Joystick steering DISPLAYED PAGE
NAME OF SIGNAL
1/2
J/S ON/OFF SIGNAL
2s
(ON/OFF)
J/S
—
1/2
S/T LEVER POTENTIO
2s
0.1 V
J/S
—
1/2
ARTICULATE ANG.
2s
0.1 V
J/S
—
1/2
J/S SOL OUTPUT
2s
1 mA
J/S
1/2
STEERING LOCK
2s
(ON/OFF)
J/S
2/2
T/M DIRECTION SIGNAL F
2s
(ON/OFF)
T/M
2/2
T/M DIRECTION SIGNAL N
2s
(ON/OFF)
T/M
2/2
T/M DIRECTION SIGNAL R
2s
(ON/OFF)
T/M
2/2
S/T N SIGNAL OUTPUT
2s
(ON/OFF)
J/S
WA1200-3
— LOCK: ON (OPEN) FREE: OFF (GND) Joystick lever OFF: OFF (OPEN) Joystick lever ON: ON (24 V) Joystick lever OFF: OFF (OPEN) Joystick lever ON: ON (24 V) Joystick lever OFF: OFF (OPEN) Joystick lever ON: ON (24 V) N: ON (Relay output OFF) ELSE: OFF (Relay output ON)
10-205 10-205 (7)
CGC MONITOR
STRUCTURE AND FUNCTION
Maintenance
time setting screen
1. 2. 3. 4. 5.
If the maintenance
time
setting
screen appears. l Display of maintenance
screen
Display
of time before periodic
.
Display
of maintenance
.
Page button: Service menu selection
.
Maintenance
1O-206
maintenance:
period:
screen button:
item selector
on the service
menu
selection
screen is pressed,
this
The maintenance items are displayed. The buttons to select maintenance items are formed in this area. The color of each button changes to display the maintenance condition. Yellow:The time before periodic maintenance is shorter than 30 hours. The displayed part has passed the mainRed: tenance time (The time before periodic maintenance is negative).
items:
.
l
button
Display of maintenance items (Maintenance item selector button) Display of time before periodic maintenance Display of maintenance period (Maintenance period setting button) Page button Service menu selection screen button
button:
The time before the next periodic maintenance is displayed. If the displayed part has passed the planned maintenance time, a negative value is displayed. The maintenance period set for each maintenance item is displayed. The buttons to set the maintenance period are formed in this area. This button is used to turn over the displayed page. This button is used to select the service menu selection screen. If this button is pressed, it flashes. If it is pressed again, a pop-up screen appears, and the time before periodic maintenance is displayed again. (This function is the same with the maintenance screen.)
WA1 200-3
STRUCTURE AND FUNCTION
•
CGC MONITOR
Maintenance period setting button: If this button is pressed, the screen to set the maintenance period appears. If a new maintenance period is input and the enter button is pressed, the maintenance period is updated. Then, the time before the next periodic maintenance is calculated again on the basis of the new maintenance period. For the maintenance items and maintenance period, see the maintenance screen.
WA1200-3
10-207 10-207 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Failure history screen 1. Display of number of detected failures 2. Display of history No. (History un-display button) 3. Display of error code 4. Display of failure occurrence time 4A. Time when detection was started 4B. Time when detection was finished 5. Display item UP/DOWN button 6. Page button 7. Service menu selection screen button 8. Display of number of failure occurrences
If the failure history screen button on the service menu selection screen is pressed, this screen appears. On this screen, the failures are displayed in the order of the time from the newest one. If a trouble has not been repaired, the “time when detection was finished” is not displayed for that trouble. • History un-display button: If this button is pressed, the corresponding history is not displayed. Once a history is set un-displayed, it cannot be displayed on the CGC monitor any more. (The memory of the VHMS controller is kept, however.) If a history is set un-displayed, it is not counted in the detected failures. (If one history is set un-displayed, the number of the detected failures is reduced by one.) • Display item UP/DOWN button: This button is used to move the displayed items up or down one by one. • Page button: This button is used to turn over the displayed page. • Service menu selection screen button: This button is used to select the service menu selection screen. • Display of number of failure occurrences: If the same failure occurs repeatedly within a short time, the number of occurrences is displayed. If more than 30 minutes passes after the failure was canceled, the display is added to a different column and the number of occurrences is fixed.
10-208 10-208 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
PM clinic screen 1. 2. 3. 4. 5. 6.
Display of items Display of page Display of data Page button Service menu selection screen button Hold button (cancel button)
If the PM clinic screen button on the service menu selection screen is pressed, this screen appears. On this screen, the data necessary to the PM clinic are displayed. • Page button: This button is used to turn over the displayed page. • Service menu selection screen button: This button is used to select the service menu selection screen. • Hold button (cancel button): If the hold switch is pressed, the data for the display is held. The hold switch changes into the cancel switch. If the cancel switch is pressed, the latest data is displayed, and the cancel switch changes into the hold switch. PM clinic items DISPLAYED PAGE
NAME OF SIGNAL
SAMPLING TIME
UNIT
DETECTED COMPONENT
1/4
ENGINE SPEED
2s
rpm
VHMS
1/4
ENGINE OIL PRESSURE
2s
kPa
Quantum
1/4
ENGINE OIL TEMP
2s
°C
CENSE
1/4
COOLANT TEMP
2s
°C
Quantum
2/4
ENGINE SPEED
2s
rpm
VHMS
2/4
BLOW-BY PRESSURE
2s
Pa
Quantum
2/4
BOOST PRESSURE
2s
kPa
Quantum
2/4
EXH GAS TEMPERATURE
2s
°C
CENSE
2/4
AMBIENT AIR TEMP
2s
°C
VHMS
2/4
FUEL RAIL PRESSURE
2s
kPa
Quantum
3/4
T/C TEMP
2s
°C
VHMS
3/4
T/C IN PRESSURE
2s
MPa
VHMS
3/4
T/C OUT PRESSURE
2s
MPa
VHMS
3/4
T/M MAIN PRESSURE
2s
MPa
VHMS
3/4
T/M LUB PRESSURE
2s
MPa
VHMS
3/4
T/M MOD PRESSURE
2s
MPa
VHMS
4/4
HYD. OIL TEMP
2s
°C
VHMS
4/4
PPC. OIL PRESSURE
2s
MPa
VHMS
4/4
HYD. OIL PRESSURE
2s
MPa
VHMS
4/4
S/T PUMP PRESSURE
2s
MPa
VHMS
4/4
F BRAKE OIL PRESSURE
2s
MPa
VHMS
4/4
R BRAKE OIL PRESSURE
2s
MPa
VHMS
WA1200-3
10-209 10-209 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Machine serial No. setting screen 1. 2. 3. 4.
Machine serial No. button Component serial No. setting screen button Service menu selection screen button Confirmation screen button for satellite communications ground station (GCC)
If the machine serial No. setting screen button on the service menu selection screen is pressed, this screen appears. Confirmation is carried out for the serial No. display and the setting, or for the machine model, specification, and type. Use the PC tool to set the machine model, specification, and type. (See TESTING AND ADJUSTING) •
Machine serial No. button: If the button is pressed, the serial No. input screen is displayed. If the serial No. is input and the input button is pressed, the serial No. is set. The screen then returns to the machine serial No. set screen. If the Previous screen button is pressed, the screen returns immediately to the machine serial No. set screen and the serial No. is not set. A maximum of 10 digits can be set for the serial No. If the machine serial No. is set, the popup screen for clearing the VHMS memory appears when the screen returns to the service menu. The machine serial No. is important for the VHMS record data, so if it is changed, it is necessary to clear all the data. If necessary, download the internal data to the PC tool.
•
Component serial No. setting screen button: If this button is pressed, the component serial No. setting screen appears.
•
Service menu selection screen button: This button is used to select the service menu selection screen.
•
Confirmation screen button for satellite communications ground station (GCC): This button is used to select the confirmation screen for the satellite communications ground station (GCC).
10-210 10-210 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Component serial No. setting screen
1. 2. 3. 4. 5.
Engine serial No. button Transmission serial No. button Machine serial No. setting screen button Service menu selection screen button Confirmation screen button for satellite communications ground station (GCC)
If the component serial No. setting screen button on the machine serial No. setting screen is pressed, this screen appears. Confirmation is carried out for the component serial No. display and the setting, or for the engine model. Use the PC tool to set the engine model. (See TESTING AND ADJUSTING) •
Engine serial No. button, transmission serial No. button: If the button is pressed, the serial No. input screen is displayed. If the serial No. is input and the input button is pressed, the serial No. is set. The screen then returns to the component serial No. setting screen. If the Previous screen button is pressed, the screen returns immediately to the component serial No. setting screen and the serial No. is not set. A maximum of 10 digits can be set for the serial No.
•
Machine serial No. setting screen button: If this button is pressed, the machine serial No. setting screen appears.
•
Service menu selection screen button: This button is used to select the service menu selection screen.
•
Confirmation screen button for satellite communications ground station (GCC): This button is used to select the confirmation screen for the satellite communications ground station (GCC).
WA1200-3
10-211 10-211 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Confirmation screen button for satellite communications ground station (GCC)
1. Machine serial No. setting screen button, component serial No. setting screen button 2. Message display
If the confirmation screen button for satellite communications ground station (GCC) is pressed on the machine serial No. setting screen or component serial No. setting screen, the screen changes to this screen. The present set value is displayed. If no setting has been made in the VHMS, the value displayed is 248 to show that the satellite communications ground station (GCC) is not effective. Use the confirmation screen for satellite communications ground station (GCC) for checking the set value. Use the PC tool to carry out the setting. (See TESTING AND ADJUSTING)
10-211-1 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Snapshot operation screen
1. 2. 3. 4. 5. 6.
Clock Snapshot start button Tachometer Torque converter oil temperature gauge Display of message Service menu selection screen button
If the snapshot operation screen button on the service menu selection screen is pressed, this screen appears. This screen is used to take in the snapshot data and save them manually. (Normally, the snapshot data are taken in automatically by using an error as the trigger. See “Snapshot items”.) When a manual snapshot has been taken, the error code is recorded as MFAO.
•
Snapshot start button: If this button is pressed, the system gets ready to take in the data. If YES in the message area is pressed, the snapshot data are taken in.
10-212 10-212 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
While the data are being taken in, the snapshot start button is not displayed, and the snapshot stop button, the message “Executing . . .”, the time elapsed, and the progress bar are displayed. If the snapshot cancel button is pressed, the data take-in operation is canceled.
If the data take-in operation is completed, the snapshot start button is displayed again and the message of “Snapshot finished” is displayed.
• •
Snapshot cancel button: This button is used to cancel the data take-in operation. Service menu selection screen button: This button is used to select the service menu selection screen.
WA1200-3
10-213 10-213 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Snapshot items If an error is made, the data in set time before and after that error (5 minutes 30 seconds before the error and 2 minutes after the error) are saved. The cause of the error can be found out easily by checking the data of the sensors concerned to the error. 1) This system can be applied to an error which cannot be reproduced. 2) Troubleshooting can be executed by collecting the data freely with the manual trigger function. Sampling period of data Every 10 seconds in the period from 5 minutes 30 seconds to 30 seconds before the error Every 1 second in the period from 30 seconds before the error to 2 minutes after the error
MOD/C related
Engine related Engine oil level
MOD/C system
Engine oil temperature
Transmission, torque converter related Transmission system
Hydraulic related Hydraulic oil temperature
Torque converter oil temperature
Engine oil pressure Engine overrun Coolant level Coolant temperature Trigger item/memory, data item
Coolant pressure Intake temperature Fuel temperature Blow-by pressure Cylinder exhaust gas temperature Manual trigger (manual operation) (trigger items only)
(Number of saved errors: 9 errors max. 1 of them can be saved manually.)
10-214 10-214 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
Memory clear ID inputting screen
1. Display of message 2. ID inputting button 3. Service menu selection screen button
If the memory clear screen button on the service menu selection screen is pressed, this screen appears. The memory clear screen appears only when the person of the input ID is proved to be qualified for clearing the memory. Input the memory clear ID with the ID inputting button, then press the enter button. If a wrong ID is input, the message changes to “Please Input Memory Clear ID”. If the correct ID is input, the memory clear screen appears. If the service menu selection screen button is pressed, the service menu selection screen appears again.
WA1200-3
10-215 10-215 (7)
STRUCTURE AND FUNCTION
CGC MONITOR
Memory clear screen 1. Display of message 2. Memory clear buttons 2A. Failure history data 2B. Trend data 2C. Snapshot data 2D. Maintenance data 2E. Load map data 3. Service menu selection screen button
If the correct ID is input on the memory clear ID inputting screen, this screen appears. This screen is used to clear various saved data. •
Memory clear buttons: These buttons are used to select the data to be cleared. If the memory clear button is pressed, the button flashes. If the memory clear button is pressed again, the YES and NO buttons are displayed. YES: Press this button if you wish to clear the data. NO: Press this button if you do not wish to clear the data. If the YES button is pressed, the selected data are cleared. If the selected data are cleared, the message that those data have been cleared is displayed.
•
Service menu selection screen button: This button is used to select the service menu selection screen.
10-216 10-216 (7)
WA1200-3
STRUCTURE AND FUNCTION
CGC MONITOR
SMR confirmation screen
1. SMR confirmation screen button
On the memory clear screen, the SMR confirmation screen button is hidden at the bottom right of the screen (it is not displayed on the screen). If the SMR confirmation button is pressed, it is possible to change to the next SMR confirmation screen. Use the SMR confirmation screen for checking the set value. Use the PC tool to carry out the setting. (See TESTING AND ADJUSTING)
1. Service meter display 2. Service meter input button 3. Service menu selection screen button
•
Service meter input button: If this button is pressed, the service meter input screen is displayed, but if the Previous screen button is pressed, the screen returns to the confirmation screen.
•
Service menu selection screen button: If this button is pressed, the screen changes to the service menu selection screen.
WA1200-3
10-217 10-217 (7)
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM OUTLINE OF SYSTEM
Auto gear shift ECMV control of all gear speeds Kickdown function L Safety functions Manual shift Kickdown function t Safety functions Travel control function
(Forward/Reverse
travel,
gear shift range)
Self-diagnosis function Display of condition (Output, failure code) t Troubleshooting (Detection of system trouble, Communicating
l
l
l
l
.
wire breakage
and short circuit in system)
function
The electronically controlled full-automatic transmission system consists of a transmission controller, FNR switch, shift-up and shift-down switches, engine rotation sensor, modulated clutch outlet rotation sensor, speed sensor, transmission oil temperature sensor, and ECMV (transmission clutch modulation valve) for the all gear speeds. The transmission controller selects the proper gear speed according to the operation signals of the operator and travel speed. Modulation control is applied to the all-gear speed ECMV to reduce the shocks made when the gear is shifted (when the clutch is engaged). This system prevents the machine from starting when the engine is started and protects the transmission when the travel direction is changed at high travel speed and the gear is shifted down (Priority shift control). With these functions, the transmission and clutch are protected and their durability is heightened. The self-diagnosis system monitors the input and output conditions constantly and displays them on the two “7-segment LED’s” of the transmission controller. If it detects any failure, it displays the failure code, and displays the “remedy code” on the main monitor and turns on the alarm for higher safety, depending on the degree of the failure. The transmission controller has a communicating function and transmits the gear speed information (“F”, “N”, “R”, “1 M - “3”) to the main monitor during travel, and the main monitor displays it.
1O-218
WA1 200-3
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
SYSTEM
CONFIGURATION Input signals
J/S N SW
1
D
1 J/S F SW J/S R SW J/S SHIFT UP SW
1J/S SHIFT DOWN SW
Transmission cut-off SW KDS (Kick Down SW)
D
1
D
1
Dx2
1
Dx2
1
D
1
D
b
Output signals
1+
ECMV F
b b ECMV 1
ID Manual/Auto gear shift selector SW
+
1
ECMV 3
b b D
Engine speed Modulated clutch outlet rotation signal
1
P
1
P
IP Travel speed Neutralizer relay signal
b
D
b b
1
D
Monitor ---_-.-.-.-_-_-_-_-_-_-_-,
b s
-1 Steering lever lock signal
D
Monitor ___________-_-_-_-_-_-_-_-_-_-
I I I I
I
I I~__________________-_-_-_-_-_-A
Fill SW F Fill SW R
Fill SW 3 Transmission oil temperature
I I
Main monitor F.N.R
I
I
I
I I
i
L_-_-_-_-_-_-_-_-_-_-_-__J
l
A
1
D
1
D D
1
D
1
D
I
A
Auto gear shift call display
b b ä
Fl output
J
b R clutch drain valve b b
S: S-NET signal D: Digital signal
b
A: Analog signal P: Pulse signal J/S: Joystick
WA1 200-3
I+
\
1
Fill SW 1 Fill SW 2
I
Troubleindicatingbuzzeroutput
i S
Tire correction
Memory clear signal
I I
Shift indicator (Actual gear speed)
b s
I i I
j I I
steering
10-219
STRUCTURE AND FUNCTION
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
FUNCTIONS 1. Auto gear shift function When the modulated clutch outlet speed is 1,450 rpm or higher, shifting up and shifting down operations of the transmission are controlled with the signals of the travel direction, gear shift range, and travel sensor, according to the “automatic gear shift change points table” (Table 1) stored in the transmission controller. See combination of gear speeds and output ECMV (Table 4), auto gear shift operation table (Table 21, and the section of contents of control by transmission controller. 1) Gear shift range (I - 3) The highest gear speed (gear shift range) for the auto gear shift is limited. Example: Gear shift range 3: Between 2nd and 3rd gear speeds Gear shift lever 2: Only 2nd gear speed Gear shift lever 1: Only 1st gear speed 2) When direction switch is in “N” position If the direction switch is in the neutral position, only the gear speed clutch of the transmission is operated. 3) When direction switch is in “F” position If the direction switch is set from the N position to F position, ECMV of F of the transmission is turned on. If the gear shift range is 2 or 3 at this time, the machine starts with the 2nd gear. a) When the gear is shifted up (when gear shift range is 3) When the accelerator pedal is pressed to accelerate the machine and the modulated clutch outlet speed is 1,450 rpm or higher, if the travel speed reaches about 10.4 km/ h, the 3rd gear speed of ECMV is turned “ON” and the second gear speed is turned “OFF”. (The transmission is set in the F3 position.) b) When the gear is shifted down (when gear shift range is 3) If the accelerator pedal is released and the travel speed lowers to about 9.8 km/h while traveling in the 3rd gear speed, the second gear speed of ECMV is turned “ON” and the 3rd gear speed is turned “OFF”. (The transmission is set in the F2 position.)
1O-220
If the modulated clutch outlet speed is below 1,450 rpm, however, ECMV is kept in the 3rd gear speed. (Coast4)
5)
6)
2.
ing) When direction switch is in “R” position Similarly to the operation in the F position, the 2nd or 3rd gear speed (when the gear shift range is 3) is selected automatically according to the travel speed when the modulated clutch outlet speed is 1,450 rpm or higher. Skip shift If the accelerator pedal is pressed while the machine is coasting in the 3rd gear speed at speed below 8 km/h (with the auto gear shift function turned OFF), the 2nd gear speed is selected immediately so that the machine can be accelerated easily. If the travel speed is 8 km/h or higher, however, the present gear speed is maintained. Period in which gear speed cannot be changed A certain period to keep each gear speed after gear shifting operation is set to prevent gear shift hunting. This period depends on the gear shifting pattern. See “automatic gear shift change points table” (Table I).
Modulation
control
The modulation control system controls the clutch oil pressure (including the rising characteristics) matched to the condition of the hydraulic circuit in the all gear speeds according to the engine speed, transmission oil temperature, gear shifting pattern, and data stored in the transmission controller to reduce the shocks made when the gear speed is changed (when the clutch is en-
gaged). The modulation control system is also applied to ECMV to be turned off to prevent lowering of the torque.
WA1 200-3
STRUCTURE AND FUNCTION
3.
Kickdown function If the operation (the operation of turning “ON” the kickdown switch) by the operator satisfies the conditions (travel mode, gear speed, and travel speed), the transmission is shifted down to the 1st gear forcibly. The transmission controller outputs the cutoff signal to the engine (electronic governor) controller in the kickdown mode (while the 1st gear signal is output). See the section of contents of control by transmission controller. 1) Auto gear shift mode The kickdown system becomes effective when the forward or reverse travel speed is below 13 km/h. It is also effective while the gear speed is held (while the auto gear shift function is turned off). The resetting condition is either rise of the travel speed or change of the travel direction. If either condition is satisfied, the transmission is set in the 2nd gear speed. See the auto gear shift operation table (Table 2) in the section of the protective functions of the transmission (gear speed control table). 2) Manual gear shift mode The kickdown system becomes effective when the machine travels forward in the 2nd gear speed. The resetting condition is either operation of the shift up/down switch or change of the travel direction. If either condition is satisfied, the transmission is set in the 2nd gear speed.
4.
Travel mode The auto or manual gear shift mode can be selected with the travel mode selector switch. In the manual gear shift mode, the gear speed is changed with the shift up/down switch.
5.
Safety functions I) Transmission neutralizer function This function sets the transmission in the neutral position when the steering lock lever is operated (set in the LOCK position) or when the machine is stopped and the engine has not been started.
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
2)
3)
4)
5)
Table 1 Automatic gear shift change Applicable
item
2. IModulated clutch outlet speed signal OFF (Below 1,450 rpm) 3. Modulated clutch outlet speed signal OFF (Below 1,450 rpm) + ON (1,450 rpm or higher) 4. When direction switch is changed
Dints table ‘eriod to keep ear speed af. ?r gear shift lg operatior
orward (F)
Reverse (8)
Speed (km/h)
Speed (km/h)
5.4
5.4
2
10.4
10.4
2
3+2
9.8
9.8
2
3+2
1.0
1.0
0
3-2
8.0
8.0
+3
10.4 -
10.4 -
+2
- 10.4
- 10.4
Solenoic signal
1. 3asic gear shift :hange
F-+N+F R-+N-+R
WA1 200-3
Neutral safety When the engine is started, if the direction switch is not in the N position, the transmission controller keeps itself in the neutral state and the machine cannot start (Prevention of abrupt start). This function is reset if the N signal is input once after the engine is started. Shift-down switch priority The transmission can be shifted immediately with the gear shift-down switch and the engine can be used as a brake when the machine travels downhill. Protective function of transmission If the gear is shifted down or the travel direction is changed while the machine is traveling in the 3rd or 2nd gear speed, the gear speed and warning buzzer are controlled to protect the transmission. See the section of the protective functions of the transmission (gear speed control table). Manual gear shift mode If the travel speed data cannot be obtained because of a travel speed sensor trouble, the manual gear shift mode is selected.
XC)
1o-22 1
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
Table 2 Auto gear shift operation table Gear shift range
Period to keep Remarks
1. Basic gear shift change Modulated clutch outlet speed is 1,450 rpm or higher. Operation
of only
accelerator
pedal
Basic gear shift in auto
Gear can be shifted to 1st gear speed with shift-down switch or by KDS @
0 5.4
2. Modulated clutch outlet speed is below 1,450 rpm. (During coasting braked to stop)
Basic gear shift when auto mode is turned off
1.0 --@
or until
3. Modulated clutch outlet speed is below 1,450 rpm + above 1,450 rpm. Operation
Gear shift just after auto mode is turned on
of only
accelerator pedal (During coasting or acceleration after braking)
4. Kickdown Only in moment operation
* Kickdown system operates at any engine speed. Travel speed is limited, however, to
after
of switch
prevent overrun. * If accelerator pedal is pressed and travel speed rises, gear is shifted up in auto mode. 5. When direction switch changed (Part 1)
-Whendirection
is changed or machine starts in neutral in another case than the left, gear
is
Lever is changed or machine starts in neutral. (F+)N+R,
(R+)N-tF
o_
@ All range
protection of transmission. 6. When
direction
changed
switch
is
(Part 2)
Lever is returned position. F+N+F, R+N+R Gear is shifted
to same
according
to travel speed at time when lever is changed. A” ra”se below s.3
1o-222
All range below 9.3
WA1 200-3
STRUCTURE AND FUNCTION
6.
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
Self-diagnosis function The transmission controller constantly monitors the input and output signals of the travel control system, and executes self-diagnosis and displays the result with the LED of the controller. The transmission controller also transmits the following data to the main monitor. I) Normal display: The output gear speed is displayed with the LED of the transmission controller. 2) Display of failure code: If any trouble is detected, its contents are displayed by the code (See the table below).
Table 3 Failure codes table
WA1 200-3
1 O-223
STRUCTURE AND FUNCTION
7.
Communicating
function
The transmission controller has a communicating function through S-NET, and it receives the tire correction data from the main monitor. If the transmission controller has a signal trouble in its control system, it displays the remedy code on the main monitor to notify the operator for higher safety, depending on the degree of the trouble.
The failure code saved in the main monitor can be checked in the failure history mode of the main monitor.
1O-224
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
Power source of transmission
controller
When the starting switch is turned on and the source voltage is 20 V or higher and a voltage of +20 V or higher is applied to the transmission controller solenoid, drive of each solenoid valve can be controlled. If the source voltage lowers below 19 V, all
the outputs are turned off and control is not executed. (The machine cannot travel.) If the source voltage rises to 20 V, the neutral safety function works, and the machine can travel.
WA1 200-3
ALL-RANGE STRUCTURE
AND
FUNCTION
ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
INPUT SIGNALS 1. Steering lever lock signal This signal is a GND/OPEN digital signal, which becomes OPEN when the steering lever is stopped (locked) and becomes GND when the steering lever is operated (free). If the steering lever is operated, the direction switch becomes effective. 2.
3.
4.
Neutralizer relay signal This signal is a +24V/OPEN digital signal. If the parking brake switch is turned off, +24 V is input. When this signal is OPEN, the transmission controller keeps itself in neutral state. (The machine cannot travel.) Transmission cut-off switch signal This signal is a GND/OPEN digital signal, which becomes OPEN when the left brake is used (pressed) while the transmission cutoff switch is effective, and becomes GND when the left brake is released. If the left brake is used, the transmission controller outputs the neutral signal. If the transmission controller is reset, the gear speed matched to the current travel speed is set. Manual/Auto gear shift selector switch signal This signal is a GND/OPEN digital signal, which becomes GND when the switch is pressed and becomes OPEN when the switch is released. If this signal changes from OPEN to GND, the manual and auto travel modes are selected alternately.
5.
Direction switch (F, N, RI signal This signal is a +24V/OPEN digital signal. When the machine is normal, one of the F (Forward), N (Neutral), and R (Reverse) signals is input (+24 V).
6.
Shift-up/Shift-down switch signal This signal is a +24V/OPEN digital signal. If the switch is pressed, its N.C side is opened and its N.0 side becomes +24 V. If the switch is released, its N.C side becomes +24 V and its N.0 side is opened. The operation of the switch is judged by these signals. If both shift-up switch and shift-down switch
WA1 200-3
are operated simultaneously, their operations are judged as follows. . After either switch is turned ON, the turnon operation of the shift-up switch or shift-down switch is not accepted for 0.2 seconds. . If the shift-up and shift-down switches are operated simultaneously (for 0.01 second), the operation of the shift-down switch is accepted. 7.
Fill switch (F, R, 1st gear, This signal is which becomes turned ON and ECMV is turned
2nd gear, 3rd gear) signal a GND/OPEN digital signal, GND when each ECMV is becomes OPEN when each OFF.
8.
Engine rotation sensor signal This signal is a pulse signal. The number of pulses sent from the electromagnetic pickup sensor is converted into rpm and used for control.
9.
Modulated clutch outlet rotation sensor signal This signal is a pulse signal. The number of pulses sent from the electromagnetic pickup sensor is converted into rpm and used for control. The mode where the engine speed is 1,450 rpm or higher is called the “auto-shift ON” mode, and the mode where the engine speed is below 1,450 rpm is called the “auto-shift OFF” mode.
10. Travel speed sensor signal This signal is a pulse signal. The number of pulses sent from the electromagnetic pickup sensor is converted into rpm and used for control. When this signal is converted into the travel speed, the tire correction data (sent from the main monitor) are added to it. 11 Communication signal (S-NET) The tire correction data set in the main monitor are received and used for control. The accurate travel speed is obtained by adding the correction value (ranging from 0.86 to 1.14) to the rpm data sent from the travel speed sensor.
1o-225
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
OUTPUT SIGNALS 1.
Transmission modulation valve (ECMV) Command current
4.
This signal is a current output (0 - 1 A). There are five types of ECMV for directions of “R” and “F”, and for gear speeds of “Ist”, “2nd”, and “3rd”. This valve is a pressure control valve which converts the current supplied to the solenoid into the pressure. Accordingly, the oil pressure on the clutch selected for each gear speed is controlled to control the engagement of the clutches independently. When the transmission is in neutral, only the gear speed clutch is turned on. (The gear speed is selected according to the gear shift range and travel speed in the auto mode. In the manual mode, the gear speed before the transmission is set in neutral is maintained. When the engine is started, the 2nd gear speed is selected.)
Fl (Cut-off) signal This signal is a Lo side output, which becomes GND when the forward 1st gear (Fl) is selected by the kickdown operation, etc.
5.
Gear shift range display LED I)
Table 4 Combination of gear speed and drive ECMV (Holding state) 2) 6.
This LED indicates the gear shift range (range of auto gear shift operation) in the auto mode. Gear shift range “1”: LED 1 is turned on and only the 1st gear speed is selected. Gear shift range “2”: LED 2 is turned on and only the 2nd gear speed is selected. (If the gear is shifted down to the 1st gear speed by the kickdown operation, the 2nd gear speed is selected, depending on the travel speed.) Gear shift range “3”: LED 3 is turned on and the 2nd or 3rd gear speed is selected automatically. This LED goes off in the manual mode.
Backup lamp relay signal This signal is a digital (ON/OFF) output of +24 V, which is turned ON when the direction switch is in the R position to turn on the backup lamp and backup alarm.
7.
Communication signal (Data of disolav on main monitor)
I) t
R3
1
-
1
-
0: ON AZ One of 1 - 3 is turned on according to the condition.
2.
Bypass valve (For F, R, and 1st gear speed)
2)
Display of gear speed 1st gear speed output: “I” 2nd gear speed output: “2” 3rd gear speed output: “3” In neutral: “N” Display of F and R When travel direction is forward: When travel direction is reverse: In neutral: Nothing is displayed.
“F” “R”
This signal is a digital (ON/OFF) output of +24 V, which is turned ON for the stored period (data) when each ECMV is turned ON.
3.
R clutch drain valve This signal is a digital (ON/OFF) output of +24 V, which is turned ON for the stored period (data) when the R ECMV is turned OFF.
1 O-226
WA1 200-3
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION IATM) SYSTEM
STRUCTURE AND FUNCTION
LED DISPLAY When the engine is started, the LED is set in 1. “Program speed display mode”. If any trouble is detected,
1.
however,
70
-0
80
20
Al
2.
the LED is set in the “Troubleshooting
Program part No. display mode When the power is turned on, the following -0
30
Al
part No. display mode”,
1,
are displayed
9,
Al
A,
1,
ti
0,
then 2. “Output
display mode”
in order at the interval
immediately.
of 1 second.
+ To display mode 2
1,
hl
gear
w
Output gear speed display mode LED display ‘X 0 Y 0’ (Dots of both are turned off.) X: Drive condition of direction ECMV Forward “F”: ‘F’, Reverse “R”: ‘A’, Neutral: ‘0 Y: Drive condition of gear speed ECMV l-4 Display
Example
Contents
‘0 0 2 0’
Neutral,
‘F o 1 0’
Forward,
2nd gear speed 1st gear speed
‘A 0 2 0’
Reverse,
2nd gear speed
‘F o F 0’
Neutral
safety state + If trouble is detected, Display mode 3 is selected.
I Gear shifting (Gear speed F2 is displayed continuously)
N
3.
Troubleshooting display mode (Trouble currently detected) “E - (2 set)” and “Code (2 set)” are repeated as one routine. 1) When there is only one trouble
item
-+ Repeat +=I=% 2)
When there are two trouble E,
-0
20 hl
WA1 200-3
30
E, Ll
items
-0
1, Ll
+ Repeat
80 ti
1O-227
STRUCTURE AND FUNCTION
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
CONTENTS OF CONTROL BY TRANSMISSION
CONTROLLER
1.
Devices used and display on monitor Auto
Manual
Joystick steering lever
0
0
Manual/Auto
0
0
FNR seesaw switch (Joystick knob)
0
0
Shift-up switch (Joystick knob)
0
0
Shift-down
0
0
KDS
0
0
Display of setting of FNR
0
0
Main monitor
0
1 Main monitor
Section
Device
Steering
Transmission
shift selector switch
switch (Joystick knob)
1 Display of actual gear speed
Display
1
1
0
Display of gear shift range (In AT)
2.
0
OFF
Remarks
Displayed with LED (Only in auto shift mode)
Actual gear speed (II, gear shift range (III, and travel mode (Auto shift/Manual) I)
Actual gear speed (1) and gear shift range changed to each other
Manual/Auto shift selector switch @ Auto shift
J
@
(Ill)
shift and auto shift modes
are
After change
ä [Manuall
(1)Actual gear speed (II) Gear shift range
Manual L Auto shift
manual
Before change [Auto shift1
Manual
(II) when
b (1)Actual gear speed is the same as that in auto shift mode. x (II)Gearshiftrangeisnotapplied,andisturnedoff.
--------------------b
b [Auto shift]
[Manual]
(1) [In F or RI Actual gear speed is set according to travel speed. IIn N12nd gear speed 6%)
(1) Actual gear speedT’ --‘-+
(II) Gear shift range is the same as actual gear speed in manual mode (~4):When gear shift range is [ll, 1st gear speed is selected.
2)
3.
Initial condition after power is turned on : (I) Actual gear speed [In manual mode] : [In auto shift model (II) Gear shift range [Only in auto shift model: : (III) Travel mode (Auto shift/Manual)
Actual gear speed before key is turned to OFF 2nd Gear shift range before key is turned to OFF Travel mode before key is turned to OFF
Solenoid output when FNR signal is changed The FNR signal is constantly
monitored
prior to the other controls.
Manual mode Joystick knob switch
F
F
0
Solenoid R
N R
Auto shift mode
output
Gear speed
before
N is selected
Joystick knob switch
F
F
0
0
R
N
0
R EWhen
1O-228
Solenoid
output 2nd gear %
0 0 gear shift range is 111, 1st gear speed
is selected.
WA1 200-3
ALL-RANGE STRUCTURE
4.
AND
FUNCTION
Gear shifting pattern I) Manual mode l The gear is shifted shift-down switch.
with
the shift-up
switch
ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
and
Actual gear speed
Gear shift mode
Gear shift operation
1
I
2
Initial value (When power is turned on)
3
Actual gear speed (Solenoid output) .Gear speed before key is turned to OFF
Conditions
for resetting
kickdown
function
Condition before resetting
Resetting operation
is effective
only
Condition after resetting
in F2) Remarks
Fl
2 Joystick knob switch F -+ R
Fl
R2
3
Fl
F2
Actual gear speed is shifted up only whenkickdown is applied
Fl
Fl
Gear speed is shifted down from 2 to 1, too.
Fl
-
Shift-up
switch
switch
5 Turn-off of power 2)
I
Auto shift mode l The shift-up switch and shift-down
Sear shifting mode
I
switch function
as gear shift range selector
Actual gear speed Gear shifting operation g
2
1
3
Initial value (When power is turned on)
I@Ei5q
g I
1
Range 1
’’ ’’
E r 4 ”
m
N2
-1
1 1Jovstick knob switch F + N 1
4 Shift-down
r
(Kickdown
II I
& h
!I II
5
’ i “an~2~’
1
$z$&
- Actual gear speed (Solenoid output) . .2nd (s) 1%) . . When gear shift range is [ll, 1st gear speed is selected.
3,: *,
0
- Gear shift range..
01
O
Gear shift range before power is turned o
0
,AUtmlBflC resetwhenLiirenion
KICK DOWN SW
i* changed between F and FL)
I I b
Condition before resetting
Resetting condition (Operation)
Condition after resetting
Kickdown in F 1Kickdown in R Fl
-
2 Joystick knob switch F -+ R
Fl
-
R2
3 Joystick knob switch R + N
-
RI
N2
1 Joystick knob switch F+ N
I
I
N2
I
4 Joystick knob switch R + F
-
RI
F2
5 Shift-up switch
Fl
Rl
Shifting up to 2
6 Shift-down switch
Fl
RI
7 Turn-off of power
Fl
RI
8 Rise of travel speed
Fl
RI
WA1 200-3
Remarks
I
As per auto gear shift operation table
1 O-229
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
PROTECTIVE 1.
FUNCTIONS
OF THE TRANSMISSION
(GEAR SPEED CONTROL
TABLE)
Protection functions in auto shift mode I) Control
of kickdown Gear speed before kickdown
Command
from controller
Brd+lst
1st
3rd is held (Kickdown signal is ignored).
2nd+lst
1st
2nd is held (Kickdown signal is ignored). \t
Travel speed (km/h)
’ ’ ’ ’ ’ ’ ’ ’ 9’ ’ ’ ’
o
13
5
’ 15 ’ ’ ’ ’ ’ 20’ ’ ’ ’
Period in which gear speed cannot be changed (5 set)
2)
Control
of shift-down
operation
Operation of shift-down switch
Control when
from controller 14
3rd-12nd
2nd
3rd &caution
3rd+lst
2nd
3rd &caution
2nd+lst
1st
Travel speed (km/h’
3)
Command
direction
o
4
When travel speed is 14 km/h or higher and shih-down switch is accepted 2 times
2nd & caution
’ ’ ’ ’ 5’ ’ ’ ’ 9’ ’ ’ ’
’ ’ ’ ’ ’ ’ 20’ ’ ’ ’
1314
is changed
Gear speed before change of direction
Gear speed after change of direction (Command from controller)
3rd
@
2nd
@
3rd &caution
2nd
@
2nd
@
3rd &caution
When gear shift range is 2nd, 3rd
1st
0
2nd
@
3rd &caution
Restoration from kickdown
When gear shift range is 1st
1st
@I
1st
@
3rd &caution
1st is held and direction is changed.
@ E$$n
\ Travel speed (km/h’
o
’
’
’
’
’ 5
’
’
’
9
’
’
’
’
14
’
’
’
’
’
’ ’ 20
’
’
Period in which gear speed cannot be changed
Gear speed is changed according to operation. Range 0: Range @J: Gear speed is controlled according to travel speed and caution
1 O-230
(2 set)
signal is output.
WA1 200-3
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
4)
Control after change of direction
When 9ear shift range
@I
3rd+lst
j
1
/ @
Pnd-tlst
is 1 and travel speed is 14 km/h or higher
3rd &caution
1a&diiction
1
IstI
@
is
2nd &caution
Travel speed (km/h)
Range 0: Range @:
Gear speed is changed according to operation. Gear speed is controlled according to travel speed and caution
signal is output.
2. Protective functions in manual shift mode 1) Control of shift-down
operation
Operation of shift-down switch
Command from controller 14
3rd+2nd
3rd+lst / 1
0
Znd+lst
Travel speed (km/h)
WA1 200-3
0
Range
0:
Gear
speed
is changed
Range
@:
Gear
speed
is controlled
@
1st
I I I I I I I I 5
according according
1 accepted2 times
I
I 9
I
I
I I 1314
I I
2nd &caution
I I
I I I I
I
I
20
to operation.
to travel speed and caution signal is output.
lo-231
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
STRUCTURE AND FUNCTION
2)
Control when
direction
is changed
(The following control is also applied coasting with the gear is in NJ
when the direction
is changed
to F or R while the machine
is
Gear speed after change of direction (Command from controller)
3rd
2nd
@
2nd
@
3rd &caution
@
2nd
@
3rd &caution
@
1st
@
3rd &caution
I. When range is judged to be 1st
1st
@ z2$!&
1st is held and direction is changed.
\ Travel
speed
o
’ ’ ’ ’ ’ ’ ’ ’
9
5
(km/h)
’ ’ ’ ’
14
’ ’ ’ ’ ’ 20’ ’ ’ ’
Period in which gear speed cannot be changed
Range 0: Range @:
3)
Control
Gear speed is changed according to operation. Gear speed is controlled according to travel speed and caution
after change
I
I
Operation of shift-down switch
Pnd-+lst I
Travel
speed
Command
1Olst
1
1
,
@
2nd &caution
Gear speed is changed according to operation. Gear speed is controlled according to travel speed and caution
of gear speed when
signal is output.
auto shift mode is in neutral
kI:Tnge
1
1
Travel speed (km/h)
lo-232
from controller
’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ 10 5 20 15
i
(km/h)
Control
signal is output.
of direction
I
Range 0: Range @:
(2 set)
Gear speed selected when in neutral (Co2myd from con_lerl 3rd
1st
o
’ ’ ’ ’ ’ ’ ’ ’ 5
3rd
2nd
9
’ ’ ’ ’
14
’ ’ ’ ’ ’ ’ ’ ’ ’ 20 WA1 200-3
STRUCTURE AND FUNCTION
MODULATED
MODULATED
CLUTCH (MOD/C)
CLUTCH (MOD/C) CONTROL SYSTEM
CONTROL SYSTEM
SYSTEM CONFIGURATION
Modulated clutch controller -o
___________________________________.
Travel
g;
speed control
8:
‘0, g:
oi
5’
Modulated clutch ECMV current
2i
Engine speed signal (output)
RPM set ON/OFF switch signal SET/ACCEL switch signal RESUME/DECEL switch signal
D D
? E
D
8
D
:: S 2
Low idle switch signal
D 5 A
WA1 200-3
e
Electronic governor voltage command
A: Analog signal D: Digital signal P: Pulse signal S: S-NET signal
1O-233
STRUCTURE
AND
FUNCTION
MODULATED
CLUTCH
(MOD/C)
CONTROL
SYSTEM
Control function Modulated
clutch control
Travel speed control function Drive force control function I-
Tire slip control function
RPM set control function I
Troubleshooting
function
Modulated clutch control The modulated clutch control system has the following functions. I) Travel speed control function Since the travel speed can be limited to the maximum speed set with the travel speed control lever, the operator can keep the travel speed low without releasing the accelerator pedal when approaching a dump truck. As a result, the operator can work easily. This function can be applied with the travel speed control ON/OFF switch only when it is required. The travel speed control ON/OFF switch is turned ON. The transmission is set in the Fl, F2, RI, or R2 position. The travel speed is 1.5 km/h or higher. The maximum travel speed can be set as shown below according to the gear speed of the transmission and the position of the travel speed control lever.
2)
l
l
l
3)
Drive force control function Since the drive force set with the drive force control lever can be set at a properly low level, slip of the tires can be prevented on a clayey ground (red clay), in mud, etc. Accordingly, the operator can work without paying attention to the acceleration work. The maximum drive force can be changed to 20% - 100% with the drive force control lever. . The transmission is set in the Fl position. (If the travel speed control function is turned on, however, it is applied first.) Tire slip control function Even if the drive force is lowered with the drive force control function, the tires may still slip. If slip of the tires is detected in this case, the drive force is further lowered to minimize the slip. The tire slip control switch is turned ON. The transmission is set in the Fl position. The work equipment is not operated. l
l
l
1 O-234
WA1 200-3
STRUCTURE
AND
FUNCTION
MODULATED
CLUTCH
(MOD/C)
CONTROL
SYSTEM
RPM SET CONTROL FUNCTION Since the operator can set the idling speed of the engine freely, unnecessary lowering of the engine speed can be prevented while the operator is working with the accelerator, and the engine is accelerated sharply and the cycle time is shortened. Since the travel speed can be kept constant during load-and-carry operation, the operator is less fatigued and the machine consumes less fuel. How to set engine speed 1) Turn on the RPM set ON/OFF switch. 2) The RPM set pilot LED lights up. 3) Press the accelerator pedal until the engine speed rises to the desired level. 4) Press the SET/ACCEL switch to save the engine speed data. Then, even if the accelerator pedal is released, the engine runs at the saved speed. How to change set engine speed Use the following method to change the save engine speed. 1) How to raise set engine speed i) Setting with accelerator pedal a) Press the accelerator pedal until the engine speed rises to the desired level. b) Press the SET/ACCEL switch to save the new engine speed data. Then, even if the accelerator pedal is released, the engine runs at the saved speed. ii) Setting with switch a) Press and hold the SET/ACCEL switch for more than 0.5 seconds, and the engine speed rises. b) When the engine speed rises to the desired level, release the SET/ACCEL switch, and the new engine speed data is saved.
WA1 200-3
2)
How to lower set engine speed i) Setting with accelerator pedal a) Press the right brake pedal, and the memory of the engine speed is canceled temporarily and the engine speed is lower to the low idling level. b) Press the accelerator pedal until the engine speed rises to the desired level. c) Press the SET/ACCEL switch to save the new engine speed data. Then, even if the accelerator pedal is released, the engine runs at the saved speed. ii) Setting with switch a) Press and hold the RESUME/DECEL switch for more than 0.5 seconds, and the engine speed lowers. b) When the engine speed lowers to the desired level, release the RESUME/ DECEL switch, and the new engine speed data is saved.
How to cancel memory of engine speed temporarily Press the right brake pedal, and the memory of the engine speed is canceled temporarily and the engine speed lowers to the low idling level. How to restore canceled engine speed Press the RESUME/DECEL switch, and the engine speed rises to the saved level again. (Note) If the engine starting switch or the RPM set ON/OFF switch is turned OFF, the saved engine speed is cleared, then the engine runs at the low idling speed. In this case, repeat the above procedure to set the engine speed again.
lo-235
STRUCTURE AND FUNCTION
Troubleshooting
MODULATED
CLUTCH (MOD/C) CONTROL SYSTEM
function
The controller constantly monitors the electronic devices such as the potentiometers to receive input signals, solenoid valves to receive output signals, etc. If any one of those devices has a trouble, the controller detects it and displays is as a “failure code” on the main monitor to notify the operator.
1O-236
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM SYSTEM
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
AND JOYSTICK
STEERING CONTROL
CONFIGURATION
Work equipment and joystick steering controller
D +/
Boom lever kick-out SOL
1
Boom raising switch (Pressure switch)
Boom lowering
switc Remotepositionerswitch input checkbuzzeroutput Engine rotation signal
P Display of lower setting of remote positioner S
-1 Lower setting switch of remote positioner
Display of upper setting of remote positioner
s
Upper setting switch of Display of lower stop of remote positioner Lower selection switch o Pilot LED of upper stop of remote positioner
J Upper selection switch of remote positioner
s Pilot LED of lower stop of remote positioner
1
Selection of remote positioner
function
x:: j Steering lever potentiometer
%
Joystick main pressure control EPC SOL
1
Joystick caution buzzer relay
Joystick neutral caution buzzer relay Steering potentiometer
calibration reset switch A: D: P: S:
WA1 200-3
Analog signal Digital signal Pulse signal S-NET signal
1o-237
STRUCTURE AND FUNCTION
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
COMPOSITION OF WORK EQUIPMENT (REMOTE POSITIONER) CONTROL CIRCUIT
10-238 10-238 (7)
WA1200-3
STRUCTURE AND FUNCTION
COMPOSITION
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
OF JOYSTICK STEERING CONTROL CIRCUIT
Steer lever
ins
Travel Steering lever Potentiometer
Speed
L
Work eauipment h joystick steerino controller
,_____-_____________-__-,
: Steer in0 lever lock switch
I
I
I
I
I I I
Rotary valve
I II ______--__-___--I
Frame angle Potentiometer
I
I
r
I
fI I II
I 0
i -
I
!
I
t
I
sxw0491.3
Control function Remote positioner control Boom “raising” and “lowering” position stop Boom “raising” and “lowering” position setting E Sensor adjustment function Joystick steering control Potentiometer calibrating function t Neutral interlock function Troubleshooting function
Outline With the remote positioner control function, the operator can set the boom stopping (lever kick-out) position freely so that the boom will stop smoothly. As a result, the operator can operate the machine safely and easily when driving in reverse, digging the earth, or approaching a dump truck. l
WA1 200-3
l
With the joystick steering control function, the flow gain in the steering hydraulic system is controlled according to the deviation of the frame angle from the operating angle of the joystick steering lever to improve the narrow steering characteristics and response to high-speed steering for higher maneuverability.
1 O-239
0
STRUCTURE AND FUNCTION
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
REMOTE POSITIONER CONTROL Functions of remote positioner 1. Stopping boom at “raising” and “lowering” oositions . The boom is decelerated and stopped at the set raising and lowering positions. The controller constantly detects the operating direction signal of the lever sent from the pressure switch installed to the PPC valve of the boom. It also detects the boom angle (position) signal sent from the boom angle potentiometer. I) Raising kick-out (When “UPPER” button lights up) If the boom lever is set to the “RAISE DETENT” position, the boom rises to the set position, then decelerates and stops. The detent is reset at this position. When the boom lever is not in the “RAISE DETENT” position, the boom is raised as the operator operates. lowering boom (When 2) Stopping “LOWER” button lights up) If the boom lever is in the “FLOAT” or “MAX. LOW” position, the boom lowers to the set position, then decelerates and stops. If the lever is held as it is, the boom is fixed. If the lever is returned to the neutral and set to the “LOWER” position, the boom lowers again. The operator can freely set the positions at which the boom stops when it rises and lowers.
(2) Each time the “LOWER” button is pressed, it lights up and goes off alternately. While it is lighting up, the lowering stop function is effective. (The setting is maintained even if the starting switch is turned off.) There is an indicator on the right console, in addition to the “UPPER” and “LOWER” buttons on the CGC monitor screen, so that the operator can see the setting condition.
2.
Setting of “raising” stop position of remote positioner 1) Press the “UPPER” button to light it up. 21 Operate the boom lever to move the boom to the stop position, then set it in neutral. (The boom must be higher than the level position.) 3) Press the raising stop position setting button. 4) The “UPPER” button flashes (for 2.5 seconds). 5) If the “UPPER” button lights up again, the raising stop position is saved.
3.
Setting of “lowering” stop position of remote positioner 1) Press the “LOWER” button to light it up. 2) Operate the boom lever to move the boom to the stop position, then set it in neutral. (The boom must be lower than the level position.) 3) Press the lowering stop position setting button. 4) The “LOWER” button flashes (for 2.5 seconds). 5) If the “LOWER” button lights up again, the lower stop position is saved.
Setting range of stop position
( (Angle is 0 degree when boom is horizontal.) Setting of the control can be changed as explained below. (1) Each time the “UPPER” button is pressed, it lights up and goes off alternately. While it is lighting up, the raising stop function is effective.
1 O-240 0
Sensor adjustment function This function is used to offset the error caused by installation of the potentiometer so that the correct position data of the work equipment can be obtained. Be sure to adjust the sensors with this function after the controller, potentiometer, or work equipment is replaced. (For the setting method, see TESTING AND ADJUSTING, “Initial setting procedure for remote positioner”.) l
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT
AND JOYSTICK STEERING CONTROL SYSTEM
JOYSTICK STEERING CONTROL Potentiometer calibrating function This function is used to measure the difference between the steering lever angle and the frame angle sensing potentiometer (offset angle), and correct it automatically.
l
Neutral interlock function . Interlock relays are installed to the engine and the starting line of the starting motor so that the frame will not articulate and the machine will not start abruptly when the engine is started. If the difference between the operating angle of the steering lever and the frame angle is 6 degrees or wider, the interlock operates so that the engine will not start. At this time, the buzzer sounds, If the steering lever is set in neutral and the FNR switch is set to the “N” position, the interlock is reset and the engine can start. .
If the FNR switch is not in the “N” position, the neutral safety function prevents the engine from starting.
Troubleshooting function The controller constantly monitors the electronic devices such as the potentiometers to receive input signals, solenoid valves to receive output signals, etc. If any one of those devices has a trouble, the controller detects it and displays is as a “failure code” on the main monitor to notify the operator.
Failure codes table Failure code on
58
frame angle sensor, and potentiometer signal
-
-
EOl + CALL
59
from each other Frame angle sensor
0
0
EOI + CALL
61
Steering lever lock switch
0
0
EOl + CALL
62
Joystick neutral interlock relay
0
0
EOO
63
Joystick main pressure control EPC SOL
0
0
EOI + CALL
E44 and E45 cannot be distinguished,
WA1 200-3
and they are turned on simultaneously.
1O-241 0
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
STRUCTURE AND FUNCTION
POTENVOMETER
A4
A-A
SW04882
1. 2. 3. 4.
Connector Case Shaft Element
5. 6. 7.
Potentiometer
Potentiometer
Bearing Contact Mold
output
anole
f1
sxwo4919
Function The potentiometer senses the operating angle. In the potentiometer, the source voltage of 5 V is converted with a variable resistor into a signal voltage according to the angle, then sent to the controller. The hatched area in the above figure is the abnormality detection area. If the controller receives
1 O-242
the above signal in this area, it judges that the potentiometer system has a trouble such as wire breakage, short circuit, etc. Since the correct position cannot be sensed in this case, the control output is turned off and the failure code is displayed on the main monitor.
WA1 200-3
STRUCTURE AND FUNCTION
WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER
WORK EQUIPMENT
AND JOYSTICK
STEERING CONTROLLER
C.N3
cy2
CN,l
Connector signal CN2
CNI
CN3 Pin No.
Cl
/ i
1Boom
1 3
I -
PPC dumping
I41
I
-
5
Boom PPC dumping
6
J/S EPC SOL (+)
I101 I 11 I 12 13
SOL2 (+)I Output
SOL1 (t)
power
-
1
-
I -1 I - I
-
I
I
I 5 I Boom RAISE pressure switch
Output
6
output
-
I
-
I
S-NET (+)
1Sensor
-
I 121
(+24V)
-
I
-
I
Boom LOWER pressure switch
Input
I I
6
-
-
( output
13
-
-
-
I -
I
-
I
I
I
I Pulse
13
I
14
Sir potentio CAL. reset switch
Input
15
Boom PPC dumpmg
SOL1 H
Output
15
-
-
I 15
16
-
-
16
17
-
-
I 18
I Power
I Input I
input (+24V)
I but I
lever kick-out
I but I I Output I I Output I
input
1 19 1 GND I 20
I Boom
I 21 I S/T neutral
WA1 200-3
interlock
output relay
-
I
12
Output
power
Remote positioner UPPERstop LED Output
I
SOL2 H
I SOL
1
1 8
Boom PPC dumping
I 17
In:
I
I
12
/
I 7
14
I
1Frameangle”““iometer
1 ,” ~:;,9:~;,s,p,e,e,“,s:gnal (+) 1;;w;;1
Input
Input
Input/ output
Name of signal
input
GND
-
I
Input
I
-
1 14 1 Remote positioner LOWERstop LED/ Output
I J/S
caution
buzzer output
Buzzer output
I Output output
1O-243
I I I
STRUCTURE AND FUNCTION
ENGINE STARTING
Starting
ENGINE STARTING CIRCUIT
CIRCUIT
switch
-
tiler xrv~ce meter Main monitor
t Slow fuse
Work equipment
blow 30A Battervl
Cummins
engine
inject ion solenoid
Alternator _-__r----r
l___
-.-
&
__-__
s
IE
Voltage regulator
1 ‘I
E:-___I !I’
I
Prelub timer
-
rreluu 0 Pressure ,. swltcn
Conventional starter
sxwo4920
Function l
.
When the direction switch and the joystick steering lever are in the N (Neutral) position, the neutral safety circuit prevents the engine from starting to secure the safety when the engine is started. If the starting switch is set to the START position, the engine oil is circulated first by the pre-lubricating function. After the oil pressure has risen, the engine is started.
1o-244
Operation . If the starting
.
switch is turned to the ON position, a current flows from the BR terminal of the starting switch to the battery relay, then the battery relay contacts are “closed”. The power is supplied to the machine by this operation. If the direction switch is set to the N (Neutral) position, a current flows in the neutral relay, then the contacts 5 and 3 of this relay are connected to each other. On the other hand, when the joystick steering lever is set to the N (Neutral) position, contacts 6 and 3 of the steering neutral relay are connected to each other, and the contacts 6 and 3 of the alternator hold relay are also connected to each other. At this time, if the starting switch is set to the START position, the current flows through the following route.
WA1 200-3
STRUCTURE AND FUNCTION
.
.
ENGINE STARTING CIRCUIT
Positive terminal of the battery + Terminal B of the starting switch + Terminal C of the starting switch + Terminals 5 - 3 of the neutral relay + Terminals 6 - 3 of the steering neutral relay + Terminals 6 - 3 of the alternator hold relay + Pre-lubrication hold relay coil + Ground. As a result, contacts 1 and 2, and contacts 3 and 4 of the pre-lubrication hold relay are connected to each other respectively, and the following circuit is formed and the current flows through it. Terminal BR of the starting switch + Terminals 1 - 2 of the pre-lubrication hold relay + Terminal 3 of the pre-lubrication timer. As a result, the contacts of the pre-lubrication timer are “closed”. Then, the current flows from the positive terminal of the battery through the battery relay to the prelubrication starting motor to circulate the engine oil. At this time, the following circuit is formed, too; Terminal BR of the starting switch + Terminals 3 - 4 of the pre-lubrication hold relay + Neutral relay + Steering neutral relay + Alternator hold relay -_j Pre-lubrication hold relay coil + Ground. Accordingly, the current flows in the coil of the pre-lubrication hold relay continuously to hold the circuit from the starting switch through the pre-lubrication hold relay to the pre-lubrication timer. Accordingly, even after the starting switch is returned from the START position to the ON position, the engine starting operation is continued. That is, it is not necessary to keep the starting switch at the START position until the engine starts successfully. The star-ting operation of the engine is stopped by returning the starting switch to the OFF position. If the oil is supplied all over the engine and the oil pressure rises, the contacts of the pre-lubrication oil pressure switch are “opened”. Upon receiving the signal from this oil pressure switch, the pre-lubrication timer “opens” its own contacts. As a result, the current flowing in the prelubrication starting motor is turned off and pre-lubrication is completed.
WA1 200-3
1 O-245
STRUCTURE AND FUNCTION
Start
ine
ENGINE STARTING CIRCUIT
-VHMS -Service -Main
switch
controller meter monitor
Slow fuse
blow 30A
r
Battery
Prelub hold relay
r Alternator
I
_
I
starter
,
I
i-.---c____-3
3
Pr club oil pr essure switch
:
G
t Conventional starter
sxwo4921
l
l
Several seconds after pre-lubrication is completed, a current flows from terminal 5 of the pre-lubrication timer to terminal 1 of the safety relay to “close” the contacts of the safety relay, then the electric power is supplied to the pre-lubrication starting motor and conventional starting motor. At this time, the current flows in both holding coil and pull-in coil of each starting motor to “close” the contacts. Since the current also flows through the pull-in coil to the motor, the starting motor starts slowly.
1 O-246
.
If the starting motor rotates slowly and meshes with the gear of the engine, the contacts of the starting motor are “closed” by the suction force of the pull-in coil, then the starting motor starts quick rotation to start the engine. The current does not flow in the pull-in coil any more, but the contacts of the starting motor are kept “closed” by the current flowing in the holding coil.
WA1 200-3
STRUCTURE AND FUNCTION
Sta rtins
ENGINE STARTING CIRCUIT
VHMS controller Service meter Main monitor
switch 3
------I
LLllrl
injection
11
&
3 3
Slow blow
/
-
I
I
Battery
I
Cummins controller Ether injection solenoid
engine
9
:i
SafZ relay
’
c
T
+
8
pressure switch
=
Conventional starter
sxwo4922
.
If the engine starts, the alternator starts generation and outputs the power through terminal B. At this time, the same voltage is generated at terminals B and L, and a current flows into terminal 2 of the safety relay to “open” the contacts of this relay to break the power for the starting motor. The current flows from terminal L of the alternator through the alternator hold relay coil to the ground, and the circuit to the prelubrication hold relay is broken to break the
WA1 200-3
.
connection between terminals 6 and 3 of the alternator hold relay, then the starting circuit is not held any more. The current from terminal L of the alternator is supplied as the signal that the engine is rotating to the service meter, etc. If the direction switch and/or the joystick steering lever is not in the N (Neutral) position, the circuit is broken by the steering neutral relay and the engine does not start.
lo-247
STRUCTURE AND FUNCTION
ENGINE STOPPING CIRCUIT
ENGINE STOPPING CIRCUIT
Starting
VHMS controller Service meter Main monitor
switch
Cummins
Voltage reeulato
Alternator ----__-__-_B
-
engine
r
+ IE
111; -__-
E:
Prelub Pressure switch
oi
Conventional starter
sxwo4923
Operation . If the starting switch
is turned to the OFF position, the signal from terminal BR of the starting switch to the CUMMINS electronic governor controller is turned off, and the fuel supply to the engine is stopped to stop the engine. If the engine speed lowers, the alternator does not generate the voltage at its termi-
lo-248
nals B and L any more, and the signal that the engine is rotating is stopped. The power is not supplied from terminal BR of the starting switch to the battery relay any more, and the contacts of the battery relay are “opened” to turn off the power supplied to the machine.
WA1 200-3
STRUCTURE AND FUNCTION
ETHER INJECTION
Starting
ETHER INJECTION CIRCUIT
CIRCUIT
VHMS controller Service meter Main monitor
switch
Cummins
engine
Ether injection solenoid
Alternator -__-__-__--8
8
Voltage regulator
Prelub oil Pressure switch
=
Conventional starter
sxwo4924
Operation The ether injection system can operate only while the starting switch is at the START position. If the ether injection switch is turned l
l
on while the starting switch is at the START position, a current flows as follows. The current flows from terminal R2 of the starting switch through ether injection switch and ether start relay coil to the ground, and terminals 3 and 5 of the ether start relay are closed. As a result, the circuit from terminal R2 of the starting switch through terminals
WA1 200-3
.
3 and 5 of the ether start relay, and ether injection solenoid to the ground is formed, then the ether is injected. If the ether injection switch is turned to the OFF position, the current flowing in the ether start relay coil is broken to stop injection of ether. If the starting switch is not at the START position, the current does not flow from terminal R2 of the starting switch, and ether is not injected accordingly.
1 O-249
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
ELECTRIC PARKING BRAKE CONTROL
6
Y SWWO4852
OUTLINE l
The parking brake is a wet multi-disc brake built in the transmission. If the current flows in the parking brake solenoid valve, the oil pressure from the transmission pump is applied to the parking brake cylinder to release the parking brake. If the current is broken, the oil pressure from the transmission pump is shut off and the pressurized oil in the parking brake is drained through the parking brake valve, then the parking brake is operated with the spring force.
1O-250
1. 2. 3. 4. 5. 6. 7. 8. 9.
Parking brake switch Emergency parking brake reset switch Parking brake display switch Accumulator Emergency brake switch Parking brake solenoid valve Emergency parking brake reset solenoid valve Neutralizer relay Parking safety relay
WA1 200-3
STRUCTURE
AND
FUNCTION
FUNCTION 1. Applying and releasing parking brake The parking brake is applied or released using the parking brake switch.
ELECTRIC PARKING
6. by
2.
Automatic parking brake When the engine stops (when the starting switch is OFF), the parking brake is automatically applied to prevent the machine from running away when the operator is away from his seat.
3.
Emergency brake If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be ensured, the parking brake is applied automatically to act as an emergency brake.
4.
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 that the brake cannot be released unless the starting switch is turned ON and then the parking brake switch is also turned ON.
5.
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.
WA1 200-3
BRAKE CONTROL
Parking brake emergency release solenoid valve If the supply of pressure oil from the transmission pump should stop because of some failure, it is possible to actuate the emergency relief solenoid valve with the parking brake emergency release switch in the operator’s compartment. This sends the accumulator charge pressure in the brake piping to the parking brake cylinder to release the parking brake.
10-251
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
OPERATION 1.
Starting switch OFF
Parking OFF
Start ins switch
brake (manual)
-
-
switch ON
(Applied)
Parking brake seftv relay
Emergency (installed
brake switch to accumulator)
Neutralizer relay
To transmission controller
sxwo4925
l
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. (Automatic parking brake)
1o-252
WA1 200-3
STRUCTURE
2. When
AND
starting
2-l.ln case where ON
FUNCTION
switch
ELECTRIC PARKING
is turned
ON
parking brake switch has been turned
Parking
Battery
BRAKE CONTROL
OFF
Battery
-
ON (operated)
brake (manua I) -
before starting switch is turned
switch ON (Applied)
Parking seftu
brake relay
Neutralizer relay
Battery
Battery
_--!i%~~-~l L---A
L-_ t -
Starting switch
l
l
@ Since the current flows from the positive (+I terminal of the battery through the starting switch and battery relay coil to the ground, the battery relay is “closed”. Then, @ the current flows from the positive (+) terminal of the battery through the battery relay, terminals 1 - 2 of the parking brake switch, and terminals 1 - 2 of the parking safety relay to the ground. As a result, the parking safety relay operates and its terminals 3 and 5 are “closed”. Then, @the following circuit is formed; Positive (+) terminal of the battery + Battery
WA1 200-3
Emergency (installed
.
.
brake switch to accumulator)
SXWO4926
relay + Terminals 5 - 3 of the parking safety relay + Terminals 1 - 2 of the parking safety relay + Ground. From this time on, the parking safety relay is kept in the circuit of @ until the starting switch is turned to the OFF position. Under this condition, since the current does not flow in the parking brake solenoid valve, the parking brake is applied. Under this condition, since the terminals 3 and 5 of the neutralizer are “opened”, the transmission is set in neutral by the transmission controller.
lo-253
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
2-2.ln case where parking brake switch has been turned OFF (released) before starting switch is turned ON
Parking
5
@ Start switch
ins
brake (manua I)
switch
To t.an!mission controller Emergency (installed
brake switch to accumulator) sxwo4927
l
@ Since the current flows from the positive (+I terminal of the battery through the starting switch and battery relay coil to the ground, the battery relay is “closed”. Since the parking brake switch is turned off (released), however, the parking safety relay does not operate. Accordingly, the current does not flow in the parking brake solenoid
1O-254
l
valve. Even if the starting switch is turned to the ON position after the automatic parking brake is operated, the parking brake is not released automatically. Since the current does not flow in the transmission controller, the machine does not move.
WA1 200-3
STRUCTURE
3.
AND
FUNCTION
ELECTRIC PARKING
BRAKE CONTROL
When parking brake switch is turned OFF (released) In case where parking brake switch is turned OFF after starting switch is turned ON
Parking
Battery
brake (manua I)
switch
(Applied)
Battery relay
Parking seftu
brake relay
Neutral relay
izer
Battery
Battery y R
@ Start
switch
.
To
ine
If the parking brake switch is turned “OFF” (released), its terminals 2 and 3 are connetted to each other. Since the parking brake safety relay is turned on at this time, @ the current flows from positive (+I terminal of the battery through the battery relay and parking brake safety relay to parking brake switch, then it flows as follows.
WA1 200-3
Alternator terminal
L
!ran!nission
controller Emergency (installed
@
@
brake switch to accumulator)
SXWO4928
The circuit of the emergency brake switch through the parking brake solenoid valve to the ground is formed, and the parking brake is released. The signal flows from terminal 3 of the neutralizer to the transmission controller, and the machine can travel.
1o-255
STRUCTURE
4.
When
AND
parking
FUNCTION
ELECTRIC PARKING
brake switch
is turned
ON (operated)
Parking
Bat terv
@ Start switch
l
ina
If the parking brake switch is turned ON (operated) after operating the machine with the parking brake switch turned “OFF”, the above circuit is formed. Since the current does not flow in the parking brake solenoid valve, the pressurized oil supplied to the parking brake cylinder is shut off and the pressurized oil in the parking brake cylinder is drained through the parking brake valve. As a result, the parking brake is operated with the spring force.
1 O-256
brake (manual)
switch
Battery relay
y n
.
BRAKE CONTROL
Alternator terminal
L
To !ran!mission controller Emergency (installed
l
brake switch to accumulator)
SXWO4926
Since the neutralizer is reset at this time, the circuit of 3 and 5 is “opened” and the signal does not flow from terminal 3 of the neutralizer to the transmission controller, then the transmission is set in neutral. In this way, the transmission is set in neutral while the parking brake is operated to prevent the machine from traveling with the parking brake applied to seizure of the parking brake.
WA1 200-3
STRUCTURE
5.
When
ELECTRIC PARKING
AND FUNCTION
main brake oil pressure
lowers
(When
emergency
Parking
BRAKE CONTROL
brake operates)
brake (manua I)
switch
Neutralizer relay
Battery
Battery
Battery
Starting switch
controller Emergency (installed
brake switch to accumulator) sxwo4930
Operation . If the oil pressure in the main brake line lowers, the emergency brake switch installed to the accumulator is “opened”. Accordingly, the current does not flow in the parking brake solenoid valve and the pressurized oil in the parking brake cylinder is drained and the parking brake operates. In this case, however, the current is still flowing in the neutralizer coil, unlike the case where the parking brake is turned ON (operated).
WA1 200-3
l
As a result, the signal flows to the transmission controller and the transmission clutch can be engaged. By this operation, the engine can be used as a brake when the emergency brake is operated. Consequently, the braking distance can be shortened. In addition, when the emergency brake operates but the machine needs to be moved (e.g. when the emergency brake operates while the machine is traveling through a railroad crossing), the machine can be moved by operating the transmission switch.
lo-257
ELECTRIC PARKING BRAKE CONTROL
STRUCTURE AND FUNCTION
6.
Parking brake emergency release
(Re
Parking brake emergency release switch_-.-_
I eased) ON
____
Main
monitor
Battery
Battery
_--
-7-l
l&Z
1
c
--@J+--0 t
-
OFF
I Battery relay_
--”
I
Buzzer
I
III
IOA
I
B Parking emergency solenoid
BR
8-
Start switch
ins
Operation . If the machine should stop because of engine trouble, the oil pressure form the transmission pump to the parking brake cylinder is shut off and the parking brake is applied. When this happens, the oil pressure in the main brake line is stored in the accumulator. When the emergency release switch is turned on (released), the buzzer sounds, and at the same time, electric current flows to the emergency parking brake release solenoid valve.
l
lo-258
brake release valve sxwo4931
l
The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the parking brake. The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position after the emergency release.
WA1 200-3
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
PARKING SAFETY RELAY NEUTRALIZER RELAY
3 6 5
1 2
Relay
connection Terminal
chart
Relay actuation
table
No. 1
I
I
I
I
EMERGENCY BRAKE SWITCH
0 0
:a @g--D
0
SWWO4860
PARKING BRAKE EMERGENCY RELEASE SWITCH Connection
table
OFF
4
2
3
I
If SEW00319
WA1 200-3
1O-259
PARKING BRAKE SOLENOID VALVE
STRUCTURE AND FUNCTION
PARKING BRAKE SOLENOID
VALVE
SWWO486I
1. 2.
Solenoid valve assembly Block
Outline . This solenoid valve is turned on and off ac-
B. Outlet port P. Inlet port (From transmission) T. Drain port l
1O-260
cording to the ON-OFF operation of the parking brake switch to supply or stop the pressurized oil from the transmission to the parking brake spring cylinder to apply or release the parking brake. When the parking brake solenoid valve is turned on: Parking brake is released. When the parking brake solenoid valve is turned off: Parking brake is applied.
WA1 200-3
STRUCTURE AND FUNCTION
EMERGENCY
EMERGENCY PARKING BRAKE RESET SOLENOID VALVE
PARKING BRAKE RESET SOLENOID
VALVE
1. Valve assembly 2. Solenoid valve
A. B. C. T. P.
To parking brake From parking brake solenoid valve From transmission Drain From brake (Accumulator circuit)
SWWO4862
Function l
The emergency parking brake reset solenoid valve is installed between the transmission and brake circuit. When the transmission pump cannot supply oil pressure because of an engine trouble, etc., the solenoid of the parking brake reset switch on the operator’s seat is turned on to apply the accumulator charge pressure of the brake circuit to the parking brake cylinder.
To Parking brake
From brake
parking solenoid
Operation . If emergency
parking brake reset switch @ is turned “ON”, solenoid valve @ operates. As a result, the pressurized oil in accumulator @ flows in port P to change the circuit with the pilot pressure, then flows through port A to the parking brake to reset the parking brake.
WA1 200-3
1O-261
STRUCTURE AND FUNCTION
KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT SELECTOR SWITCH
KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT SELECTOR SWITCH
Kick-down switch 1. 2. 3. 4. 5.
Kick-down switch Spring Spring Auto shift/Manual shift selector switch Harness
10-262 10-262 (7)
Operation • The kick-down switch is installed to the boom lever. While the conditions of the travel mode, gear speed, and travel speed are satisfied, if this switch is turned ON (pressed), the gear is shifted down to the 1st gear speed. • In the manual shift mode, the kick-down switch is effective only when the transmission is in the forward 2nd gear position. If it is pressed at this time, the gear is shifted down to the 1st gear speed. • In the auto shift mode, if the kick-down switch is pressed when the machine is traveling forward or in reverse at a speed below 13 km/h, the gear is shifted down to the 1st gear speed.
WA1200-3
STRUCTURE AND FUNCTION
KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT SELECTOR SWITCH
Resetting (In manual shift mode) • When the direction switch is set to the “N” or “R” position • When the shift-up switch or shift-down switch is pressed (When the shift-down switch is pressed, the gear is kept in the 1st gear speed.) • When the starting switch is turned off (In auto shift mode) • When the direction switch is set to the “N” position • When F or R of the direction switch is changed to the opposite direction • When the shift-up switch or shift-down switch is pressed • When the travel speed rises • When the starting switch is turned off
Auto shift/Manual shift selector switch Operation • The auto shift/manual shift selector switch is installed to the boom lever. Each time it is pressed, the travel mode (auto shift/manual shift) is changed. • In the auto shift mode, the indicator (one of the three) under the main monitor lights up. • When the starting switch is turned ON, the travel mode (auto shift/manual shift) saved when the starting switch was turned off last time is selected.
WA1200-3
10-263 10-263 3 (7)
20
TESTING AND ADJUSTING
Standard value table Standard value table for engine ........................................................................................................ Standard value table for chassis .......................................................................................................
Standard value table for electrical parts .......................................................................................... Testing and adjusting ............................................................................................................................ Troubleshooting ......................................................................................................................................
Note the following troubleshooting.
20- 2 20- 3 20- 9 .20-101 20-201
when making judgements using the standard value tables for testing, adjusting, or
The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. These standard values are not the standards used in dealing with claims. a
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving.
g
When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
g
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.
g
Be careful not to get caught in the fan, fan belt or other rotating parts.
WA1 200-3
20-l 0
STANDARD VALUE TABLE FOR ENGINE
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE Machine model
Item
1 Measurement conditions /
Unit
( f~~~~~r~~$‘~e
Low idling Rotation speed
High idling
rpm
Intake air pressure Torque converter stall
650 + 50
650 f 75
2,050 f 50
2,050 + 100 -
kPa
165.6 & 15
130
11,293 r 1131
11,000~
Max. 4.5 f 0.5
Max. 4.5 * 0.5
Max. 1.0 f 0.5
Max. 1.0 f 0.5
1.25 {I271
I3301
80 - 110
Min. 120
N {kg1
4,893 1498.951
4,893 1498.951
N (kg)
4,893 1498.951
4,893 (498.95)
At sharp acceleration
Bosch index
At high idling (Watertemperaturein operatingrange) Torque converter stall
h-
Se~~~~mit
ImmHgI
Exhaust gas color
Blow-by pressure (15W-40 oil)
(
1,900
Rated rotation speed
(Boost pressure)
WA1200-3
I
3.29
(Watertemperaturein operatingrange)
Oil pressure (I 5W-40 oil)
Oil temperature
Tension of fan belt
When new (~1 When re-tensed t-i
Tension of air conditioner compressor belt
I
All rotation range (In oil pan)
Measure belt tension with belt tension gauge.
Press intermediate point I between drive pulley and air conditioner compressor pulley with force of about 98 N (IO kg}.
%: If new one is installed, be sure to readjust
20-2 0
{k;::?
"C
)
I
I
I mm
it after operating
9 - 12.5
9 - 12.5
24 hours.
WA1 200-3
STANDARD VALUE TABLE FOR CHASSIS
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS Machine
WA1 200-3
model Unit
/
Standard value for new machine
Ser$tdmit
13.7 f 2.0 (1.4 * 0.2)
;;:zrting
wi
l
4.9 +: (0 .5+q 0 N{kgI 6.9 + 1.0 (0.7 f 0.11
6.9 f 1.0 IO.7 f 0.11
HOLD+RAISE
Max. 23.52 (2.41
Max. 35.28 (3.61
RAISE+HOLD
Max. 15.68 Il.61
Max. 23.52 (2.41
l
Max. 24.5 (2.5)
HOLD-+LOWER
E 8 m
Max. 37.24 (3.81 I
LOWER+HOLD
-
l
Run engine at low idling. Hydraulic oil temperature: 45 - 55°C
-
Max. 34.3 13.5)
Max. 51.94 (5.31
FLOAT-tHOLD
Max. 14.7 (1.5)
Max. 23.54 (2.31
HOLD+DUMP
Max. 23.52 (2.4)
Max. 35.28 (3.61
Max. 23.52 (2.41
Max. 35.28 I3.6)
Max. 14.7 (I.51
Max. 23.54 (2.31
HOLD-tRAISE
67_+ 15
67 ?I 30
HOLD+LOWER
53_+ 15
53 + 30
672
15
67 ?I 30
HOLD-DUMP
60+_ 15
60 + 30
HOLD-TILT
60f
60 + 30
l
t 8
Stop engine. Measure at center of lever knob.
13.7 + 2.0 (1.4 * 0.2)
N{kgI
I
m
l
HOLD-FLOAT
z 5 m3
WA1 200-3
l
Run engine at low idling. Hydraulic oil temperature: 45 - 55°C
mm
15
20-3 0
STANDARD
TESTING AND ADJUSTING
VALUE TABLE FOR CHASSIS
model
Machine
I
l
Operating effort
l
Operating angle
l
deg.
Max. 8
Max. 10
On flat, level, straight, dry, paved road.
Wgl
13.7 f 5.0 (I.4 f 0.51
23.5 (2.41
Run engine at high idling. Left lock position - Right lock position.
deg.
80 k 8
Max. 90
NIkgl
58.8 f 2.45 IS.0 + 0.25)
Max. 88.2 (9.0)
I l
Operating time
Start engine. Hydraulic oil temperature: 45 - 55°C Left lock position - Right lock position.
l---i l
Low idling
l
High idling
Pressing force
Neutral (a I) Pressing angle
Fig. A. Run engine at low idling. Hydraulic oil temperature: 45 - 55°C
*See l
l
Max. (a 2)
Fig. B. Run engine at low idling. Hydraulic oil temperature: 45 - 55°C
45
*See
Pressing angle
l
l
A
2 i=
Clearance of wheel rock ring
-0
B
*See Fig. C. Tire inflation pressure: Specified pressure
l
Torque converter stall speed
8
. Coolant: ln operating range Torque converter oil tempera-
Max. 4.0
-
2 - 10
-
1,950 k 100
1,950 k 200
1,990 * 100
1,990 + 200
1,745 f 200
1,745 _+300
l
rpm
z .P
mm
c
,P
w
tTq--Tdeg.
y--e+-+
Play
Fitting condition of wheel lock ring
-
Torque converter stall speed + Hydraulic stall speed
20-4 0
l
Gear shift lever: F4 or R4
WA1 200-3
STANDARD VALUE TABLE FOR CHASSIS
TESTING AND ADJUSTING
Machine
Item
I
model
I l
Torque converter relief (inlet) pressure
l
Torque converter oil temperature: 60 - 80°C Run engine at high idling. MPa @cm9
Torque converter outlet oil pressure
ECMV output (clutch) oil pressure
1st 2nd, 3rd MOD/C, F-R
Lubricating oil (oil cooler outlet) pressure
l
l
l
l
l
Steering relief pressure l
Orbit roll output pressure
l
Torque converter oil temperature: 60 - 80°C Run engine at high idling. Turn ON manual switch. Torque converter oil temperature: 60 - 80°C Run engine at high idling.
. Run engine at low idling. Hydraulic oil temperature: 45 - 55°C
Forward
l
When rising oil pressure starts
2nd
3rd
WA1 200-3
21 (27 +f 0.2 2.8
2.8 + 0.2 127 + 2)
2.8 + 0.2 (27 f 2)
1.05 + 0.1 (IO.7 * 1.0)
1.05 + 0.1 I10.7 + 1.0)
0.89 + 0.1 19+ 11
0.88 f 0.1 {9f 11
2.25 i 0.15 I23 f 1.51
2.25 + 0.15 (23 f 1.51
2.45 + 0.15 {25 + I.51
2.45 + 0.15 (25 f 1.51
0.1 c 0.05 11.o c 0.5)
0.1 f 0.05 11.o * 0.5)
17.6 %” {180+,6)
+I.47 17.6 o 1180 +;“I
20.6 ‘;.” I210 $5,
20.6 %” (210 +o”,
MPa :g/cm3
I Travel speed
I
When brake oil
l
Charge cut-out pressure
21 {27 C+ 0.2 2.8
Hydraulic oil temperature: 45 - 55°C Run engine at high idling.
l
Charge cut-in pressure
Servf$imit
Standard value
conditions
Measurement
WA1 200-3
6.3 f 0.3
I
6.3 + 0.3
11.5 + 0.6
11.5 f 0.6
19.8 + 1.0
19.8 k 1.0
7.4 f 0.4
7.4 * 0.4
:m/h
20-5 0
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Machine
Measurement
Item Brake oil pressure
I
model conditions
Unit
Standard value for new machine
l
Brake oil pressure drop
l
l
l
Performance l
l
m
Max. 6
Max. 6
mm
0
7.0
2.65 + 0.2 47 + 21
2.65 + 0.2 (27 rf 2)
2.94 It 0.29 130 f 31
2.94 * 0.29 {30 + 31
2.65 f 0.2 (27 + 2)
2.65 f 0.2 07 + 2)
-
stop
stop
mm
3.2 + 0.1
Stop engine. Continue pressing brake pedal to 4.9 MPa 150 kg/cm3 and measure oil pressure drop after 5 minutes. Tire inflation pressure: Specified pressure On flat, level, straight, dry, paved road. Set initial speed for braking to 20 km/h. Delay in pressing must be 0.1 set max. Pressing force of brake pedal: Specified pressing force 294 +- 29.4 N (30 f 3 kg} Measure braking distance.
*See Fig. D. Measure wear of disc by measuring piston stroke.
l
High idling
IParkina I I
l
l
Torque converter oil temperature: 80 - 80°C Run engine at high idling.
MPa kdcm3
Parking brake pilot pressure ,
Setvic&tmit
- Hydraulic oil temperature: 45 - 55°C
l
Wear of disc
WA1200-3
*See Fig. E. Tire inflation pressure: Specified pressure On flat, paved, dry road having gradient of l/5 (11’20’). Set machine in operating state.
l
Performance
l
l
Thickness of disc l
PPC pump pressure l
l
PPC valve main pressure l
PPC valve 3utput Jressure
Raising/Floating of boom and dumping/tilting of bucket
l
l
Lowering of i boom
20-6 0
l
I
2.77
Hydraulic oil temperature: 45 - 55°C Run engine at high idling. Hydraulic oil temperature: 45 - 55°C Run engine at high idling.
Hydraulic oil temperature: 45 - 55°C Run engine at high idling. Operate work equipment control lever full stroke.
MPa :Qlcm3
3.72 2” I38’,1
3.72 + 0.2 i38+21
3.72 T’ 08’: 1
3.72 f 0.2 138 f 2)
2.54 T!Z 0.05 (26 z!z0.51
2.54 + 0.05 126 + 0.51
WA1 200-3
STANDARD VALUE TABLE FOR CHASSIS
TESTING AND ADJUSTING
Machine
Work equipment relief pressure
l
l
WA1 ZOO-3
model
Hydraulic oil temperature: 45 - 55°C Run engine at high idling.
3 1.36 %‘;; f320”’ -13 )
31.36%: {320+” -3 )
MPa
I’kg/cm3 I
I
Max. 14.0
12.5 f 0.5 I
set
I
When tilted through
C g
Hydraulic drift of bucket hinge pin
*See Fig. H. Hydraulic oil temperature: 45 - 55°C Stop engine and leave it for 15 min, then measure for I5 min. Empty bucket and set boom and bucket level.
l
l
!-----I Hydraulic drift of 5 bucket tooth edge s
WA1 200-3
I}I
l
5.0 f 0.5
3.7 * 0.3
I
I
Max. 7.0
Max. 5.0
2.3 + 0.3
Max. 3.4
Max. 250
Max. 250
mm Max. 100 Max. 100 (Excluding (Excluding hydraulic drift of hydraulic drift of bucket hinge pin) bucket hinge pin)
20-7 0
STANDARD VALUE TABLE FOR CHASSIS
TESTING AND ADJUSTING
*
Illustration
of components
related to standard
values table
*Fie.A
face
*Fig.
C
*Fig.
E
*Fig.
) f
Fio. F
*Fig.
*Fig.G
D
H
When fully
I
Work equipment Posture
Horizontal
rim
A
I
20-B 0
TWW0243
I
WA1 200-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
Systen n
Name of comioonent
T
(Zonnector No.
Judgement
Measurement conditions
table
Normal ranges are as follows.
-1
SW power supply
1 Between C2(1), (12) -(II),
20_30”
(21) 1
Normal ranges are as follows. Sensor power supply
Between (6) - (17) 20C3A
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
30 v
Between (6) - chassis
1) Turn starting switch OFF. 2) Inset-t Tadapter. 3) Ts;cpo;ng 4) Turn parking brake switch OFF.
Normal ranges are as follows. 1 Between (4). (12) - chassis
S-NET
1 4- 8V
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
II Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
C3B Manual shift switch
Transmission cut-off switch C3A
Kickdown switch
Joystick FNR button switch “F” C3B
Joystick FNR button switch “N”
WA1 200-3
20-9
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
T
Syste:m
Name of comDonent
Connect0 No.
Judgement
Measurement conditions
table
Normal ranges are as follows. Joystick gear shift switch R
C3B
Neutralizer relay signal
J
I
I
L
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) T~;c~ort$g
C3A
Joystick shift-up switch (N.0 c5 Joystick shift-down switch (N.0
When joystick shiftup switch is “ON” When joystick shiftup switch is “OFF”
Joystick shift-up switch (N.CI
Between ,.i.$&
c5
Transmission oil temperature
20-10 0
Max. 1 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Ts;c,staOrt$g
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
C3B
C3A
17 -30 v
Normal ranges are as follows. Joystick shift-down switch (N.C)
Steering lock signal
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
WA1 200-3
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
7
Syste!m
Name of comeonent
I
Engine rotation sensor
Connectc No.
iOll
Judgement
Od
Measurement conditions
table
Measure in AC range. :, j
1 Between (1) - (9)
Min. 0.5 V
Normal ranges are as follows.
Backup lam relay signal
~~
Normal ranges are as follows.
Buzzer signal ON
>
Sl
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
II Turn starting switch OFF. 2) Insert Tadapter. 3) Turn manual shift switch ON. 4) Start engine
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Set directional lever in F or FL j) Turn manual shift switch OFF.
I
I t
If shift-down switch is kept pressed, gear is shifted down to 1st.
Normal ranges are as follows.
kit0 range
1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. ‘1 signal XJtput
Jut0 range 1st LED rignal
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine
*
!nd LED #ignal * Do not operate shift-up switch or shiftdown switch when default mode is in 2nd (Leave as set when engine was started). Normal ranges are as follows.
I) Turn starting switch OFF. !I Insert Tadapter. I) Turn starting switch ON. 1) Set directional lever in F or R. i) Turn manual shift switch OFF.
) Turn starting switch OFF. !I g”lsepsee;-
Uto range :rd LED ignal Ir If shift-up switch is kept pressed, gear is shifted up to 3rd.
WA 1200-3
I) Turn st&ing switch ON. ,I Set directional lever in F or R. 1)Turn manual shift switch OFF.
20-11 0
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
Name of component
Syste
Manual shift switch
Connect0r No.
Judgement
Measurement conditions
table
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 4) Start engine. 5) Turn transmission cut-off switch OFF. 6) Turn parking brake switch OFF. 7) Press brake pedal to prevent machine from moving.
L15 (Male)
1 When FORWARD
1
I measuring point
I
I
1
F: T14 (Male)
Normal ranges are as follows.
R: Tl2 (Male)
~~
ECMV fill switch
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. %)Start engine. 5) Set directional lever in N. 6) Turn manual shift switch ON.
Normal ranges are as follows.
1st: T4 (Male) 2nd: T6 (Male) 3rd: T8 (Male)
Transmission cut-off switch
~~
* When default after starting of engine is 2nd, if shift-down switch is kept pressed, gear is shifted down to lst, and if shift-up switch is kept pressed, gear is shifted up to 3rd. Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
L12 (Male)
f Kickdown switch
Transmission oil temperature sensor
Speedometer sensor
20-12 0
L15 (Male)
T19 (Male)
T15 (Male)
1 Between (1) - (2)
I500-1,OOOR
1
1 Between (11, (2) -chassis
1 Min. 1 MR
1
WA1 200-3
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
Name of component
System
Speedometer sensor
Connectc No.
-
Judgement
Measurement conditions
table
1) Screw in speed sensor until it touches ring gear, then return it by l/2 - 1 turn. 2) Speed sensor must operate normally after above adjustment. Normal ranges are as follows.
Engine rotation sensor
T17 (Male)
Between (1) - (2)
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
500 - 1,000 R Min. 1 MR
Between (1). (2) - chassis
1) Screw in engine rotation sensor until it touches ring gear, then return it by l/2 1 turn. 2) Engine rotation sensor must operate normally after above adjustment.
Engine rotation sensor
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. Modulated clutch outlet rotation sensor
Modulated clutch outlet rotation sensor
Parking brake switch
F bypass solenoid
T16 (Male)
-
500 - 1,000 R
Between (1) - (2)
Min. 1 MR
Between (11, (2) - chassis
1) Screw in modulated clutch outlet rotation sensor until it touches ring gear, then return it by 314 - 1 turn. 2) Modulated clutch outlet rotation sensor must operate normally after above adiustment.
-
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
LO1
T22 (Male)
1 Between (1) - (2)
1
5-15R
1
Min. 1 MR
Between (1). (2) - chassis
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. R bypass solenoid
T21 (Male)
5-15n
Between (1) - (2)
Min. 1 MR
Between (11, (2) - chassis Normal ranges are as follows.
R drain solenoid
T23 (Male)
1 Between (1) - (2)
I
1 Between (11, (2) - chassis I
5-15R Min. 1 MB
Normal ranges are as follows. 1st bypass solenoid
T20 (Male)
Between (1) - (2) Between (11, (2) - chassis
WA1 200-3
5-15R Min. 1 MQ
I 1
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
20-13 0
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
Name of comoonent
Syste
Zonnectc No.
Judgement
Measurement conditions
table
Normal ranges are as follows. FFFMV solenoid
T13 (Male)
Between (1) - 12) Between (I), (2) - chassis
5-15n Min. 1 MfZ
Normal ranges are as follows. ECMV solenoid (R)
Tll (Male)
Between (1) - (2) Between (l), (2) - chassis
5-15R Min. 1 MR
Normal ranges are as follows. ECMV solenoid (1st)
Between (I) - (2) Between (11, (2) - chassis
5-15R Min. 1 MR
Normal ranges are as follows. ECMV solenoid (2nd)
Between (1) - (2) (Mze)
Between (l), (2) - chassis
5-I5R Min. 1 MQ
Normal ranges are as follows. ECMV solenoid (3rd)
Between (1) - (2) (M;e)
Between (l), (2) - chassis
5-15R Min. 1 MR
Normal ranges are as follows. SW power supply
Between (8) - chassis Between (18) - chassis
20 - 30 v
Normal ranges are as follows. Solenoid power supply
Between (17) - chassis
MO1
20 - 30 v
Normal ranges are as follows. Between (11, (12) - chassis
S-NET
4-8V
Normal ranges are as follows.
PPC pres-
sure switch (Raise boom)
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. I) Turn starting switch OFF. 21 Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) ~;;anp~ T1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. U Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. !) Insert Tadapter_ 3) Start engine
M02A
f
20-14 0
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal).
WA1 200-3
TESTING
T
Systern
AND
ADJUSTING
Name of comDonent -I-
STANDARD
T
(Ionnectoi No.
VALUE
Judgement
TABLE FOR ELECTRICAL
Measurement conditions
table
Normal ranges are as follows. I Work equipment
I
PARTS
I
PPC pressure switch
I
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine
&:)r * Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows.
PPC pressure switch (Tilt bucket)
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
* Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows.
PPC pressure switch [Dump bucket)
+ Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal).
M02A
Normal ranges are as follows. Right brake pedal signal
11
Normal ranges are as follows.
24 :%
H’
WA1 200-3
I) Turn starting
Normal ranges are as follows.
I) Turn starting switch OFF. !) Insert Tadapter. 1) Turn starting switch ON.
Normal ranges are as follows.
1 Turn starting switch OFF. t) Insert Tadapter. 1) Turn starting switch ON.
Transmission cut-off switch signal
RPM set DLE-UP signal
I) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
switch OFF. !I Insert Tadapter. s) Turn manual shift switch ON. C) Start engine
??a -1 signal input
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine
20-15 0
TESTING
I-
Systern
AND ADJUSTING
Name of lmponent
STANDARD
T
Connector No.
Xl
d
VALUE
Judgement
TABLE FOR ELECTRICAL
Measurement conditions
table
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
RPM set IDLE-DOWN signal
When accelerator
Low idling (Li) switch signal
PAFfTS
1
1
M02A Normal ranges are as follows. Between M02A(lO) - M02A(9) 14.75 - 5.25 V Between M02Al19) - M02A(9) 1 0.5 - 4.75 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Between M02A(19) - M02A(9) Accelerator pedal signal * Above table shows standard value of potentiometer voltage at which controller can recognize dial range normally. When potentiometer is readjusted, set margin of error judging area. y3100w,i$$rg, set voltage in range from (Error jddging area is potentiometer voltage < 0.5 V or potentiometer voltage > 4.5 V.) Normal ranges are as follows. Between M02AUO) - M02A(9) 14.75 - 5.25 ~1
Drive force control dial
M02A M02B
Between M02BU) - M02A(9)
0.5 - 4.75 v
Between M02BH) - M02A(9) IMAXI
0.5 - 1.6 V
Between M02BU) - M02A(9) (MINI
3.5 - 4.75 v
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
rlr When potentiometer is readjusted, set margin of error judging area. At MIN, set voltage in range from 1.3 to 1.6 V. (Error judging area is potentiometer voltage c 0.3 V or potentiometer voltage > 4.7 V.)
20-16 0
WA1 200-3
TESTING
I
Syste m
AND
ADJUSllNG
Name of comoonent
STANDARD
Connector No.
VALUE
Judgement
TABLE FOR ELECTRICAL
Measurement conditions
table
Normal ranges are as follows.
1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
Between M02A(lO) - M02A(9) Between M02BHO) - M02A(9)
Travel speed control dial
Between M02B(lO) - M02A(9) (MINI
M02A M02B
3.5 - 4.75 v
f When potentiometer is readjusted, set margin of error judging area. At MIN, set voltage in range from 1.3 to 1.6 V. (Error judging area is potentiometer voltage c 0.3 V or potentiometer voltage > 4.7 V.)
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 31 Turn starting switch ON.
Measure in AC range. Min. 0.5 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Min. 0.5 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
RPM set ON/OFF switch signal
Engine .otation iensor
PARTS
M02B
Between (5) - (12)
Measure in AC range. Engine -0tation signal .output)
Between (14) - chassis
Normal ranges are as follows.
leutral-cut NC) solenoid
~~
MO1
f
I) Turn starting switch OFF. !) Insert Tadapter. $1 Start engine. 1) Travel in F3 at 10 km/h or higher.
Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal).
Normal ranges are as follows. Electronic governor voltage :ommand signal
WA1 200-3
20-17 0
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
Name of comoonent
Conner% No.
ion od
Measurement conditions
Judgement table Normal ranges are as follows.
RPM set ON/OFF switch indicator
:,
3 5 .
1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
)
MO1 Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Travel speed switch indicator
Travel speed set switch signal
M02A
When travel speed set switch is “ON” When travel speed set switch is “OFF”
Max. 1 V
Between (26) - (8)
Min 2 6 v
. .
Normal ranges are as follows. 1 When FORWARD
I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 4) Start engine. 5) Turn transmission cut-off switch OFF. 6) Turn parking brake switch OFF. 7) Press brake.
1
F: T14 (Male)
Normal ranges are as follows. 1 When REVERSE
I
R: T12 (Male)
Normal ranges are as follows.
ECMV fill switch
1When set to measur- 1 1st: T4 (Male) 2nd: T6 (Male) 3rd: T8 (Male)
20-l 8 0
I
* When default after starting of engine is 2nd. if shift-down switch is kept pressed, gear is shifted down to lst, and if shift-up switch is kept pressed, gear is shifted up to 3rd. Normal ranges are as follows.
M%C (Male)
I
~~
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 4) Start engine. 5) Set directional lever in N. 5) Turn manual shift switch ON.
I) Turn starting switch OFF. !I Disconnect connector. $1 Connect Tadapter.
WA1 200-3
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
Syster n
Name of component Wheel rotation sensor (on left side of front wheels)
Connect0 No.
IF151
Measurement conditions
Judgement table I) Screw in wheel rotation sensor (on left side of front wheels) until it touches flange, and measure clearance between rotation sensor flange and housing. 2) Adjust clearance to +{0.6 + 0.11 mm with shims. Normal ranges are as follows.
Modulated clutch outlet rotation sensor
Modulated clutch outlet rotation sensor
T16 (Male)
-
Between (I) - (2)
500 - 1,000 R Min. 1 MR
Between (11, (2) - chassis
1) Screw in modulated clutch outlet rotation sensor until it touches ring gear, then return it by l/2 - 1 turn. 2) Modulated clutch outlet rotation sensor must operate normally after above adjustment. Normal ranges are as follows.
Engine rotation sensor
Engine rotation sensor
T17 (Male)
-
Between (I) - (2)
500 - 1,000 R Min. 1 MQ
Between (I 1, (2) - chassis
I) Screw in engine rotation sensor until it touches ring gear, then return it by l/2 1 turn. 2) Engine rotation sensor must operate normally after above adjustment. Normal ranges are as follows.
Speedometer sensor
Speedometer sensor
T15 (Male)
-
Between (1) - (2)
500 - 1,000 R
Between (I), (2) - chassis
Min. 1 ML2
I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
-
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
-
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
I) Screw in speed sensor until it touches ring gear, then return it by II2 - 1 turn. 2) Speed sensor must operate normally after above adjustment. Normal ranges are as follows. Between (1) - (2) Between (I), (2) - chassis
WA1 200-3
-
5-15R Min. 1 MQ
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
20-19 0
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
T
Syste m
Name of )mponent
-T
Connector NO.
m d
Judgement
Measurement conditions
table
Normal ranges are as follows. SW power supply
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Between (8) - chassis 20 - 30 v
Between (18) - chassis
Normal ranges are as follows. Solenoid power supply
L26
Between (17) - chassis
I 20 - 30 v I
Normal ranges are as follows. Between (11, (12) - chassis
S-NET
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
4-8V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows. Workequipment PPC pressure switch (Raise boom)
I
I
I
* Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
PPC pressure switch I
!CZ%r L27
)I
20-20 0
I
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Steering rock pressure switch
Steering potentiomete calibration reset switch
I
* Operate lever just a little (to degree that -work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows.
Remote positioner function switch
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
WA1 200-3
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
T
m System
Name of ‘mponent
T
(Zonnector No.
Judgement
Measurement conditions
table
Normal ranges are as follows. When boom angle is UPPER. When boom angle is LOWER.
Boom angle sensor
4.33 ?:0.33 V Between (19) - (9) o 66 + o 33 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
L27 Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Steering lever angle sensor
Frame angle sensor
L28 L27
Joystick lever neutral interlock relay
~~
*
Set machine in straight travel position.
L26 Normal ranges are as follows.
1) Turn starting switch OFF. 2) insert Tadapter. 3) Start engine.
1 When boom Boom raising kick-out solenoid relay
used * Use remote positioner function. Normal ranges are as follows.
Joystick caution buzzer relay
L28
When joystick caution buzzer relay is output When joystick caution buzzer relay is not output
Between (15) chassis
17 - 30 v
1) Turn starting switch OFF. 2) Insert Tadapter. 3) T~;cyort$g
Max. 1 V
+ Signals are output to joystick caution buzzer relay when machine is set in straight travel position and joystick steering lever is set in position other than neutral. Normal ranges are as follows.
Boom dumping solenoid (1)
L26
When boom positioner function is turned on When boom positioner function is not turned on *
WA1 200-3
Min. 5 V Between (3) - (14)
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Max. 1 V
Lower boom lever fully by lowering operation of remote positioner.
20-21 0
STANDARD
TESTING AND ADJUSTING
Syster
Name of bmponent
Connect01 No.
VALUE TABLE FOR ELECTRICAL PARTS
Judgement
Measurement conditions
table
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows. Boom dumping solenoid (21
When boom positioner function is turned on Between (5) - (15) When boom positioner function is not turned on t
L26 L
*
Joystick main pressure contra EPC
Boom angle sensor
Steering lever angle sensor
CGC monitor screen
I
Max.
1 V
I
Lower boom lever fully and hold it by lowering operation of remote positioner.
Normal ranges are as follows. When joystick lever switch is 466k ,00 mA in neutral
,
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
F04 Between (1) - (2)
o-5kQ
Between (3) - (2)
4-5kQ
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
JS2
I
o-5ks2
1
4-5kQ
Between (3) - (2) Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
L30
1 Between (1) - (2)
I
o-5kQ
Between (3) - (2) Normal ranges are as follows. Speedometer sensor
Speedometer sensor
20-22 0
1) Turn starting switch ON.
Normal ranges are as follows.
1 Between (1) - (2)
Frame angle sensor
Min. 5 V
T15 (Male)
1 Between (1) - (2)
I 500 - 1,000 kQ
1 Between (11, (2) - chassis 1 Min. 1 MR
(
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
1) Screw in speed sensor until it touches ring gear, then return it by l/2 - 1 turn. 2) Speed sensor must operate normally after above adjustment.
WA1 200-3
TESTING
AND ADJUSTING
Name of comDonent
Systen
STANDARD
Eonnector No.
VALUE
Judgement
n&hod
TABLE FOR ELECTRICAL
Measurement conditions
table
19-23R
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
15-25R
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
15-250
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. Boom lever kick-out solenoid
L16
Between
Normal Boom dumping solenoid (I 1
HR8
ranges are as follows.
Between
Normal Boom dumping solenoid (2)
HR9
Between
Between
(6) - chassis
Between
(7) - chassis
VI
(8) - chassis
Between
(9) - chassis
Normal
(4) - chassis
Between
(5) - chassis
V3A
Normal Boom bottom pressure sensor
4-6V
4-8V
(1) - (12)
0.7 - 5.3 v
(Reference) When open to atmosphere: 0.5 - 1.5 V Normal
ranges are as follows.
Between
(IO) - (12)
0.7 - 5.3 v
(Reference) When open to atmosphere:
WA1 200-3
13v
ranges are as follows.
Between
VI
Boom head pressure sensor
11-
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
ranges are as follows.
Between (8), (18) - chassis
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
22 - 25 V
ranges are as follows.
Between
Normal S-NET
(3) - chassis
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
ranges are as follows.
Between
Sensor power &PPIY
20 - 30 v
ranges are as follows.
Between (2) - chassis
Normal Sensor power =$PlY
20 - 30 v
ranges are as follows.
Between
Normal Sensor power supply
(1) - (2)
ranges are as follows.
Normal SW power supply
(I) - (2)
ranges are as follows.
Normal NSW power supply
(1) - (2)
PARTS
0.5 - 1.5 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. :3) Turn starting switch ON.
20-23 0
TESTING AND ADJUSTING
l-
Systern
Name of comcronent
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
IZonnector No.
Judgement Normal
Flashing synchronizing signal (For main monitor)
ranges are as follows.
Whenflashingsynchronizingsignalis ON Whenflashingsynchronizingsignalis OFF Normal
Check lamp (For main monitor)
Measurement conditions
table
Between (13) chassis
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Max. 1 V 20 - 30 v
ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 4) Satisfv condition for turning on check lamp.
Vl
Ir Disconnect connector of battery fluid level sensor to output low fluid level alarm. Normal
ranges are as follows.
When buzzer is turned on When buzzer is stopped
Buzzer output *
Max. 1 V 20 - 30 v
Disconnect connectors of coolant level sensor, brake fluid level sensor, etc. to output low fluid level alarm.
Normal
ranges are as follows.
1 Between (1) - (12)
PPC relief pressure
Between (16) chassis
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 4) Satisfy condition for turning on buzzer.
I
0.7 - 5.3 v
Ir When open to atmosphere:
0.5 - 1.5 V
Normal
I
ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter.
Alternator terminal R voltage Ir If battery is deteriorated or in cold district, voltage may not rise for a while after engine is started. Normal Torque converter outlet oil pressure
ranges are as follows.
1 Between
1 Between (6) - (3)
20-24 0
0.5 - 1.5 V
I
0.7 - 5.3 v
1: When open to atmosphere:
0.5 - 1.5 V
ranges are as follows.
Between
(7) - (3)
0.7 - 5.3 v
Ir When open to atmosphere:
0.5 - 1.5 V
Normal Brake pressure (R)
1
ranges are as follows.
Normal Brake pressure (F)
1 0.7 - 5.3 v
Ir When open to atmosphere: Normal
Transmission main relief pressure
(5) - (3)
V2A
ranges are as follows.
Between
(8) - (3)
0.7 - 5.3 v
* When open to atmosphere:
0.5 - 1.5 V
1
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. WA1 200-3
TESTING AND ADJUSTING
T
Syster n
-
Name of lmponent
T
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
(lonnector
Judgement
No.
Measurement conditions
table
Normal ranges are as follows. Hydraulic oi temperature
1) Turn starting switch OFF. 2) Disconnect connector. 3. Insert Tadapter.
1oo”c 25°C Normal ranges are as follows.
Transmissior lubricating oil pressure sensor
1 Between (14) - (12)
I
0.2 - 4.8 v
I
Ir When open to atmosphere: 0.2 - 0.8 V Normal ranges are as follows.
Transmissior modulating oil pressure sensor
V2A
1 Between (15) - (12)
1 0.7 - 5.3 v
Ir When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
F;;;;ing Between (16) - (12)
pressure sensor
0.7 - 5.3 v
Ir When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
Work equipment relief pressure sensor
Between (18) - (12)
0.7 - 5.3 v
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
Battery fluid level (1)
Between (1) - chassis
Between (2) - chassis
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
5.5 - 6.5 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
5.5 - 6.5 V
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
5.5 - 6.5 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
0.7 - 5.3 v
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. Battery fluid level (2)
1
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
V2B Normal ranges are as follows. Battery fluid level (3)
Between (3) - chassis
Normal ranges are as follows.
Torque converter inlet oil pressure sensor
Between (IO) - (9)
Ir When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
Brake fluid level (RI
WA1 200-3
V3A
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
20-25 0
TESTING
T
Systenn
STANDARD
AND ADJUSTING
Name
of
co mponent
Tc
lonnector No.
Kp.40
VALUE
Judgement
nethoc
TABLE FOR ELECTRICAL
Measurement conditions
table
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
u
Coolant
PARTS
Ir When coolant level is low, sensor is OPENED. Normal ranges are as follows. Transmission oil filterr differential pressure Klogging)
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
V3A
* When filter is clogged, sensor is OPENED. Normal ranges are as follows.
Boom positioner proximity switch (For :oad meter)
E
Bemeeni Max.lV 1
receives rated load (16) - (17)
17 - 30 V
Normal ranges are as follows.
Just ndicator ‘I
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
li When air cleaner is clogged, dust indicator 1 is CLOSED and dust indicator relay 1 is OPENED. Normal ranges are as follows.
Dust indicator 2 t
V3B
When air cleaner is clogged, dust indicator 2 is CLOSED and dust indicator relay 2 is OPENED.
Normal ranges are as follows.
Dust indicator 3 t
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
When air cleaner is clogged, dust indicator 3 is CLOSED and dust indicator relay 3 is OPENED
Normal ranges are as follows.
3ust
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
ndicator 4 * When air cleaner is clogged, dust indicator 4 is CLOSED and dust indicator relay 4 is OPENED. L
20-26 0
WA1 200-3
TESTING AND ADJUSTING
Name of component
Systen
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
:onnectoi No.
Judgement
Measurement conditions
table
Normal ranges are as follows. V3B
When brake fluid level is normal When brake fluid level is low
Between (5) chassis
Max. 1 V I7 - 30 V
Normal ranges are as follows. Boom bottom pressure sensor
FO6
Between (3) - 111
0.7 - 5.3 V
Ir When open to atmosphere: 0.5 - I.5 V Normal ranges are as follows. Boom head pressure sensor
F14
Between (3) - (I)
0.7 - 5.3 v ~
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. PPC relief pressure sensor
HS4
1 Between (3) - (1)
I 0.7 - 5.3 v ~
f When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Transmission main relief pressure sensor
MT2
Between (3) - (1)
0.7 - 5.3 v
* When open to atmosphere: 0.5 - 1.5 V
Torque converter outlet oil pressure sensor
Torque converter inlet oil pressure sensor
Normal ranges are as follows. MT3
1 Between (3) - (1)
1 0.7 - 5.3 v /
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. MT4
1 Between (3) - (1)
I 0.7 - 5.3 v I
t When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
Transmission lubricating oil pressure sensor
MT1
1 Between (3) - (1)
10.2 - 4.8 V 1
t When open to atmosphere: 0.2 - 0.8 V Normal ranges are as follows. Transmission modulating oil oressure sensor
MT5
Between (3) - (1)
0.7 - 5.3 v
f When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Steering oil lressure sensor
HS3
) Between (3) - (I)
I 0.7 - 5.3 v I
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Nork equipment .elief pressure sensor
HS2
1 Between (3l-
(1)
I 0.7 - 5.3 v I
f When open to atmosphere: 0.5 - 1.5 V
WA1 200-3
11 Turn starting switch OFF. 21 InsertTadapter. 3) Start engine.
1) Turn starting switch OFF. 21 Insert Tadapter. 3) $;c~ort$g 11 Turn starting switch OFF. 2) Insert Tadapter. 31 Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 31 T$;cFort$g 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 21 Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
20-27 0
TESTING AND ADJUSTING
Syster
Name of component
Brake fluid level (R)
Brake fluid level (F)
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector No.
Judgement
Measurement conditions
table
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
HR6
HRlO
Normal ranges are as follows. Brake pressure sensor (F)
Between (3) - (1)
HR15
0.7 - 5.3 v
f- When open to atmosphere: 0.5 - 1.5 V
1) Turn starting switch OFF. 2) Insert Tadaoter. 3) Turn starting switch ON.
Normal ranges are as follows. Brake pressure sensor (RI
HR16
Between (3) - (1)
0.7 - 5.3 v
t When open to atmosphere: 0.5 - 1.5 V
Atmospheric temperature sensor
Hydraulic oil temperature sensor
Torque converter oil temperature sensor
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) CZ;;;;e;t T-
PHI
100°C
HSl
25°C
Between (‘1 - 12)
Approx. 3.5 - 4 kQ Approx. 37 - 50 kQ
Normal ranges are as follows. Normal (25°C)
T24
130°C
Approx.40 kQ
Between (1) - (2)
Approx.1.7 161
1) Turn starting switch OFF. 2) Disconnect connector. 3) Set fuel level sensor as shown at left. 4) Connect TadaDter.
Normal ranges are as follows. FULL (100%) Fuel level sensor
l/2 (50%)
R05
l/4 (25%)
Approx.10R Approx.32 R
Between (‘1 - (2)
Approx.49.5R
EMPTY (0%)
Approx.85 R
1) Turn starting switch OFF. 2) Disconnect connector. 3) Cb;gt T-
Normal ranges are as follows, Battery fluid level (1)
Between RA7 chassis ground
RA7
5.6 - 6.5 V
1) Turn starting switch OFF. 2) Disconnect connector. 3) Cbmgrt T-
Normal ranges are as follows. Battery fluid level (2)
Between RA8 chassis ground
RAB
5.6 - 6.5 V
Normal ranges are as follows. Battery fluid level (3)
I Between RA9 chassis ground
RA9 I
5.6 - 6.5 V I
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadauter.
1
1) Turn starting switch OFF. 2) Disconnect connector. 3) Insert Tadapter. WA1 200-3
TESTING AND ADJUSTING
Name of component
Syster
STANDARD
Zonnectoi No. &ha
VALUE TABLE FOR ELECTRICAL PARTS
Judgement
Measurement conditions
table
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
11 Turn starting switch OFF. 2) Insert Tadapter.
Power supply
LO5 Charge (Alternator) *
Starting switch terminal C
If battery is deteriorated or in cold district, voltage may not rise for a while after engine is started.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Connect Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter.
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter.
LO9 (Male)
2w PRE-LUBE
LO5
2P WZ i:
Starting switch terminal BR
LO7
I
Parking brake indicator switch
FNR switch (N)
,
I
1
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) CXI;~~ T-
Normal ranges are as follows.
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
I) Turn starting switch OFF. !I Insert Tadapter. 3) Turn starting switch ON.
T18 (Male)
LO5
When FNR switch is in “F” When FNR switch is not in “F”
FNR switch (F)
Between (7) chassis
20 - 80 V Max. 1 V
LO8 Normal ranges are as follows. FNR switch (R)
WA1 200-3
I) Turn starting switch OFF. 3) Insert Tadapter. 3) Turn starting switch ON.
20-29 0
STANDARD VALUE TABLE FOR ELECTRICAL PAFiTS
TESTING AND ADJUSTING
Systen
Name of comoonent
Connect01 No.
Judgement
Measurement conditions
table
Normal ranges are as follows. Parking brake solenoid
HR14
Between (I) - (2)
IO-40R
Between (I), (2) - chassis
Min. 1 MR
Normal ranges are as follows. Parking brake emergency reset solenoid
HRl9
Between (2) - (I 1
20 - 60 R
Between (1). (2) - chassis
Min. 1 MR
. L89 ~1
Normal ranges are as follows. Bucket positioner solenoid
L17
19-23R
Between (I) - (2) Between (I), (2) - chassis
Min. 1 MD
Normal ranges are as follows.
Emergency brake switch
HR17, HR18 (Male)
When accumulator pressure is 3.92 f 0.49 MPa {40 f 5 kg/cm3 or higher ,,,&~~dk;opeda’ lower accumulator pressure to below 3.63 + 0.49 MPa (37 k 5 kg/cm%
20-30 0
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. Parking brake emergency reset switch
7) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Max. 1 R
I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
HT;y8:;[Min 1 MR
WA1 200-3
TESTING AND ADJUSTING ITEMS TO BE PREPARED List of devices for troubleshooting ................... 20-102 ITEMS RELATED TO ENGINE Measuring engine speed .................................... 20-103 Measuring exhaust gas color ............................ 20-106 Measuring blow-by pressure ............................. 20-107 Measuring engine oil pressure ......................... 20-108 Measuring exhaust temperature ....................... 20-109 Measuring boost pressure ................................. 20-110 Testing and adjusting fan belt tension ............ 20-111 Testing and adjusting belt tension of air conditioner compressor ........................... 20-111 Adjusting rotation sensor .................................. 20-112 POWER TRAIN Testing and adjusting torque converter and transmission oil pressure ...................... 20-114 Flushing procedure for hydraulic circuit of torque converter and transmission .............. 20-117 How to move machine when transmission valve is broken ............................................... 20-118 STEERING SYSTEM Testing and adjusting steering oil pressure .... 20-120 Testing and adjusting emergency steering oil pressure ...................................... 20-121 Bleeding air from steering circuit ..................... 20-123 Adjusting steering stopper bolt ........................ 20-124 BRAKE SYSTEM Testing drop of wheel brake oil pressure ........ 20-125 Testing wheel brake function ............................ 20-126 Measuring wear of wheel brake disc ............... 20-127 Testing and adjusting charge cut-in and cut-out pressure of accumulator .................. 20-128 Testing parking brake performance .................. 20-129 Testing wear of parking brake disc .................. 20-130 How to reset parking brake manually .............. 20-131 Measuring parking brake oil pressure .............. 20-132 HYDRAULIC EQUIPMENT Testing and adjusting work equipment oil pressure ..................................................... 20-133 Testing and adjusting PPC oil pressure ........... 20-135 Adjusting PPC valve linkage .............................. 20-136 Bleeding air from each part ............................... 20-137 Releasing residual pressure from hydraulic circuit .............................................. 20-140 WORK EQUIPMENT SYSTEM Adjusting work equipment lever linkage ......... 20-141
WA1200-3
ELECTRICAL SYSTEM Testing and adjusting bucket proximity switch ............................................. 20-143 Testing and adjusting boom potentiometer .... 20-144 Adjusting boom horizontal detection switch .......................................... 20-144-1 Procedure for setting initial value for remote boom positioner (Method of inputting base point) .................................. 20-144-2 Checking proximity switch actuation pilot lamp ............................................................. 20-145 Initial learning method of transmission controller ......................................................... 20-146 Adjusting main monitor (Speedometer module) .................................. 20-147 Adjusting steering lever angle and frame angle sensors ...................................... 20-148 Procedure for checking diode ........................... 20-149 Method of adjusting auto-grease injector discharge amount .......................................... 20-150 Method of setting auto-grease timer ................ 20-151 VHMS CONTROLLER Basic precautions ................................................ 20-153 Setting up VHMS controller .............................. 20-156 Collecting and transmitting VHMS controller data ................................................ 20-158 Testing and maintaining VHMS controller ...... 20-163 Setup procedure for VHMS controller .............. 20-164 Operating procedure for quick PM clinic ......... 20-174 Setting procedure for replaced VHMS controller ............................................. 20-178 Operating procedure for quick PM clinic ......... 20-188 Outline of measurement procedure for PM clinic .......................................................... 20-192 Preparation for measurement for PM clinic .... 20-193 Measurement procedure by CGC monitor ....... 20-194 Measurement procedure by downloading data in VHMS controller ................................ 20-196 Operating procedure for quick PM clinic ......... 20-198 PM clinic check sheet ...................................... 20-199-1 Method of displaying remedy codes and error codes ........................................... 20-199-4 Error codes table ............................................ 20-199-11
20-101 20-101 1 (8)
TESTING
AND
ITEMS
ADJUSTING
TO BE PREPARED
ITEMS TO BE PREPARED LIST OF DEVICES FOR TROUBLESHOOTING inspection/Adjustment
item
Part
Symbol B
Coolant/Oil/Exhaust temperature
Part
No.
799-101-1502
Digital
799-101-5002
Hydraulic
790-261-I
Digital
Remarks
Name
thermometer
-99.9
set
tester
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25,60, 400, 600 kg/cm21
1 C
Oil pressure
Exhaust Pedal
G
gas color pressing
Hydraulic
1
799-201-9000
Handy
smoke
2
Purchase
Smoke
meter
Purchase
Angle
793-520-1805 Brake
I
oil pressure
l
1 Operating
793-520-1851
K
Purchase
Rule
L
Purchase
Stopwatch
1
1 transmission
valve
with
broken
N
l
792-415-l
l
792-415-1120
Fixed
110
valve
175-15-15540 238-15-12930
Spring
l
792-415-1150
Wrench
l
792-415-1160
I
assembly
Valve
2 Measurement of voltage/resistance
-
0 1
Adapter
79A-264-0211
Tester
799-60 I-7400
T-adapter
799-601-7500
AMP070connectoradapterassembly
l
For AMP07012
799-601-7530
l
799-601-7540
For AMP07018
l
799-601-7550
For AMP07020
799-601-7600
Adapter
For AMP07014
l
DTSeriesconnectoradapterassembly
l
799-601-7610
For DT Series
P-pin
l
799-601-7620
For DT Series
3-pin
l
799-601-7630
For DT Series
4-pin
Adapter
20- 102 0
Note: This kit is for dump trucks, so the following parts are included, but they are not used on the WA1200-3. 792-415-1130 (Soacer. with 3rd. H stamp) 792-415-1140 . (Spacer, with 4th, L stamp)
For AMP07010
799-601-7510
P
-
-
assembly
. 799-601-7520
3
N IO - 50 kg1
-
2
Check of sensors/harnesses
0 - 490.3
I
Spacer
l
N IO - 30 kg}
-
Cover
l
0 - 294.2 scale
1Slide calipers
Purchase
792-415-1200
of machine
-
79A-264-0090
speed
Movement
kit
79A-264-0020
drift
M
Pollutiondegree:0 - 70%(Withstandardcolor) (Pollution degree x l/10 4 Bosch index)
checker
-
Stroke/Hydraulic
Measurement of wear of brake disc
kg/cm21
Nipple
Work
equipment
1.0 MPa {lo
gauge
Push-Pull 2
Pressure gauge: 68.6 MPa 1700kg/cm21
tester
gauge
Brake test
J
effort
hydraulic
799-401-2320
H
angle
203
2
- 1,299”C
l
799-601-7640
For DT Series
5-pin
l
799-60 I-7650
For DT Series
B-pin
l
799-601-7660
For DTM
Series
2-pin
WA1 200-3
TESTING AND ADJUSTING
ITEMS TO BE PREPARED
Inspection/Adjustment item Symbol
Check of sensors/harnesses
P
Flushing torque converter, transmission hydraulic circuit
Setup of VHMS controller and setting of its replacement interval
3
—
Q
Part Name
Remarks
• 799-601-7710
Contact size #20 (Used for both DT Series and HD31 Series)
• 799-601-7720
Contact size #16 (Used for both DT Series and HD31 Series)
• 799-601-7730 Contact
Contact size #12 (Used for both DT Series and HD31 Series)
• 799-601-7740
Contact size #8 (Used for both DT Series and HD31 Series)
• 799-601-7750
Contact size #4 (Used for both DT Series and HD31 Series)
07063-41210
Element (for flushing)
1
799-608-3211
VHMS analysis tool
2
799-608-3220
Wiring harness
3
Commercially available
Notebook computer
21T-06-64590
Coupling assembly
21T-06-64392
Wiring harness
4
WA1200-3
Part No.
Standard element part number 07063-01210
(OS: Windows 98/2000) PM Clinic
20-102-1 (8)
TESTING AND ADJUSTING
ITEMS RELATED TO ENGINE
ITEMS RELATED TO ENGINE MEASURING ENGINE SPEED ¤ Be
careful not to touch any hot part when removing or installing the measuring tools. ¤ When measuring, confirm that there is nobody around the machine. ¤ Put blocks under the wheels to prevent the machine from moving. fl Measure the engine speed under the following condition. • Coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C • Power train oil temperature: 70 – 90°C
Measuring low idling and high idling speeds 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press Real Time Monitor button (1) to select the “REAL TIME MONITOR” screen. 3. Select the screen of the system of the items corresponding to “ENGINE SPEED” of the real time monitor list (See Preface of STRUCTURE AND FUNCTION or TROUBLESHOOTING). (In this example, select the screen of “Engine”, “Transmission”, or “MOD/C”). 4. Display the items of “ENGINE SPEED”. 5. Start the engine and measure its low idling and high idling speeds. fl Check that the engine speed is in the standard range. If not, ask CUMMINS distributor for adjustment. 6. If the PAUSE button is pressed while the engine speed is being measured, the engine speed is held. fl If the PAUSE button is pressed again, holding of the engine speed is reset.
WA1200-3
20-103 20-103 1 (8)
ITEMS RELATED TO ENGINE
TESTING AND ADJUSTING
Measuring
torque
converter
stall speed
1.
Similarly to “Measuring low idling and high idling speeds”, display the items of “ENGINE SPEED” on the REAL TIME MONITOR screen.
2.
Start the engine.
3.
Turn transmission cut-off switch (2) OFF and press the left brake pedal securely. (Check that the transmission cut-off pilot lamp goes off.)
4.
Turn the auto/manual shift selector switch “ON” (Turn it to MANUAL position). * At this time, the gear shift mode should be in “2nd”.
5.
Press the shift-up “3rd”.
switch to shift up the gear to
6.
Set the directional
(FNR) switch to “F” or “R”.
7.
Reset the parking
8.
Run the engine at full speed and stall the torque converter, and measure the engine speed at this time.
brake.
L
9JFOO366
Measuring
hydraulic
stall speed
1.
Similarly to “Measuring low idling and high idling speeds”, display the items of “ENGINE SPEED” on the REAL TIME MONITOR screen.
2.
Start the engine.
3.
Run the engine at full speed and extract the boom cylinder or bucket cylinder to relieve the oil, and measure the engine speed at this time.
20-104 0
WA1 200-3
ITEMS RELATED TO ENGINE
TESTING AND ADJUSTING
Measuring torque converter hydraulic stall speed
stall speed +
1.
Similarly to “Measuring low idling and high idling speeds”, display the items of “ENGINE SPEED” on the REAL TIME MONITOR screen.
2.
Start the engine.
3.
Turn transmission cut-off switch (2) OFF and press the left brake pedal securely. (Check that the transmission cut-off pilot lamp goes off.)
4.
Turn the auto/manual shift selector switch “ON” (Turn it to MANUAL position). Sr At this time, the gear shift mode should be in “2nd”.
5.
Press the shift-up switch to shift up the gear to “3rd”.
6.
Set the directional (FNR) switch to “F” or “R”.
7.
Reset the parking brake.
8.
Run the engine at full speed and stall the torque converter and extract the boom cylinder or bucket cylinder to relieve the oil, and measure the engine speed at this time.
9JFOO386
WA1 200-3
20-105 0
TESTING
AND ADJUSTING
MEASURING COLOR l
f
EXHAUST
ITEMS RELATED TO ENGINE
GAS
When measuring the exhaust gas color in the field without compressed air and power source, use handy smoke checker Gl. When taking records of official data, use smoke meter G2. Before measuring, heighten the coolant temperature to the operating range. careful not to touch any hot part when removing or installing the measuring tools.
A Be
1.
Measuring with handy smoke checker 1) Install filter paper to tool Gl. 2) Insert exhaust gas suction adapter in the exhaust pipe. Heighten the engine speed sharply and operate the handle of tool Gl simultaneously to have the filter paper absorb the exhaust gas. 3) Remove the filter paper and compare it with the attached scale.
2.
Measuring with smoke meter G2 1) Insert probe in the outlet of exhaust pipe and secure it to the exhaust pipe with the clip. 2) Connect the probe hose, accelerator switch outlet, and air hose to tool G2. * Limit the applied air pressure to 1.5 MPa 115 kg/cm21. 3) Connect the power cable to an AC 100 V outlet. * When connecting the power cable, check that the power switch of tool 62 is turned Off.
4)
5) 6)
7)
Loosen the cap nut of the suction pump and set the filter paper. * Set the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of tool G2. Heighten the engine speed sharply and press the accelerator pedal of tool G2 simultaneously to have the filter paper absorb the exhaust gas. Remove the contaminated filter paper and place it on clean filter paper (at least IO sheets) in the filter paper holder and read the indicated value.
20- 106 co
TLD00140
WA1 200-3
TESTING AND ADJUSTING
ITEMS RELATED TO ENGINE
MEASURING BLOW-BY PRESSURE fl Before measuring the blow-by pressure, increase the coolant temperature to the operating range. • Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the “PMCLINIC MENU” screen. 3. Select the screen of the “BLOW-BY PRESSURE” (“PM-CLINIC MENU” screen 2/4). 4. Run the engine at full speed and operate the bucket. When the relief valve operates, measure the blow-by pressure. ¤ Take care not to touch a hot part or rotating part during measurement. fl The blow-by pressure may vary largely with the engine condition. If the measured value is judged abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil, etc. which are related to the abnormal blow-by pressure. 5. If the PAUSE button is pressed while the blowby pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the blow-by pressure is reset.
WA1200-3
20-107 20-107 1 (8)
TESTING AND ADJUSTING
ITEMS RELATED TO ENGINE
MEASURING ENGINE OIL PRESSURE fl Before measuring the engine oil pressure, increase the coolant temperature to the operating range. • Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the “PMCLINIC MENU” screen. 3. Select the screen of the “ENGINE OIL PRESSURE” (“PM-CLINIC MENU” screen 1/4). 4. Start the engine and measure the engine oil pressure while the engine is running at high idling. ¤ Take care not to touch a hot part or rotating part during measurement. 5. If the PAUSE button is pressed while the engine oil pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the engine oil pressure is reset.
20-108 20-108 1 (8)
WA1200-3
TESTING AND ADJUSTING
ITEMS RELATED TO ENGINE
MEASURING EXHAUST TEMPERATURE fl Before measuring the exhaust temperature, increase the coolant temperature to the operating range. • Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the “PMCLINIC MENU” screen. 3. Select the screen of the “EXHAUST TEMPERATURE” (“PM-CLINIC MENU” screen 2/4). 4. If the PAUSE button is pressed while the exhaust temperature is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the exhaust temperature is reset. Measuring 1. When measuring maximum value for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. (Note) The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. fl Corrected value = Measured value + 2 x (Converted outside air temperature – Outside air temperature) fl Set the converted outside air temperature to 20°C. 2. When measuring periodically for preventive and safety service 1) Stall the torque converter fully (Relieve the torque converter and work equipment pump) and raise the exhaust temperature (Approx. 700°C: Standard value) 2) Stop relieving the hydraulic circuit and keep stalling the torque converter. (At this time, the temperature starts lowering. If the temperature does not lower but rises, increases the temperature at (1) in the figure at right.) 3) After the temperature lowers and is stabilized, measure it. fl If only the torque converter is stalled, it will be overheated before the exhaust temperature is stabilized.
WA1200-3
20-109 20-109 1 (8)
TESTING AND ADJUSTING
ITEMS RELATED TO ENGINE
MEASURING BOOST PRESSURE fl Before measuring the boost pressure, increase the coolant temperature to the operating range. • Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the “PMCLINIC MENU” screen. 3. Select the screen of the “BOOST PRESSURE” (“PM-CLINIC MENU” screen 2/4). 4. Run the engine and measure the oil pressure while the torque converter is stalled. fl Normally, the blow-by pressure should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter. 5. If the PAUSE button is pressed while the boost pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the boost pressure is reset.
20-110 20-110 1 (8)
WA1200-3
ITEMS RELATED TO ENGINE
TESTING AND ADJUSTING
TESTING AND ADJUSTING FAN BELT TENSION Testing .
Using belt tension gauge (I), measure the tension of fan belt (2) at the intermediate point between the pulleys.
Ir
Standard belt tension: 4,893 N (498.95 kg}
Adjusting 1.
Loosen 7 bolts (3) and adjust tension with rod (4). Sr Do not loosen the bolt marked with %. -k If rod (2) is turned in the direction of the arrow, the tension is heightened.
TESTING AND ADJUSTING BELT TENSION OF AIR CONDITIONER COMPRESSOR Testing .
*
Press the intermediate point of the belt between drive pulley (I) and air conditioner compressor pulley (2) with the force of about 98 N {IO kg), and measure deflection b of the belt. Deflection of belt (Standard value) b: 9 - 12.5 mm
Adjusting 1.
Loosen mounting bolts and nuts (31, (41, and (51, and locknut (6).
2.
Loosen locknut (8) of adjustment bolt (71, and adjust the tension of air conditioner compressor belt (9) with adjustment bolt (7).
3.
After positioning air conditioner compressor, tighten locknut (8) and mounting bolts and nuts (31, (41, (51, and (6).
4.
After adjusting the belt tension, check that it is in the standard range according to the above procedure.
WA1 200-3
I
9JFOO391
9JFOO392
20-111 0
ITEMS RELATED TO ENGINE
TESTING AND ADJUSTING
ADJUSTING SENSOR Engine
rotation
ROTATION sensor
1.
Screw in rotation sensor (1) until its tip touches gear (21, then return it by l/2 - 1 turn.
2.
Tighten locknut (3). m Locknut: 34.3 - 39.2 Nm 13.5 - 4.0 kgm} Handle the wires of the rotation sensor very * carefully so that an excessive force will not applied to them. * Take care that steel chips will not stick to the tip of the rotation sensor and the latter will not be scratched.
Transmission
output
shaft rotation
sensor
1.
Screw in transmission output shaft rotation sensor (4) until its tip touches gear (51, then return it by l/2 - 1 turn.
2.
Tighten locknut (6). m Locknut: 49.0 - 68.6 Nm I5.0 - 7.0 kgm}
I
9JFOO444
WA1 200-3
ITEMS RELATED TO ENGINE
TESTING AND ADJUSTING
Modulated
clutch
outlet
rotation
sensor
1.
Screw in modulated clutch outlet rotation sensor (7) until its tip touches gear (81, then return it by l/2 - 1 turn.
2.
Tighten locknut (9). w Locknut: 49.0 - 66.6 Nm 15.0 - 7.0 kgm1
9JFOO446
WA1 200-3
20413 0
TESTING AND ADJUSTING
POWER TRAIN
POWER TRAIN TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE Measuring • •
Engine coolant: In operating range Torque converter oil temperature: 60 – 80°C
¤ Put blocks under the wheels to prevent the machine from moving. 1. Main relief pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3) Display the items of “Transmission main relief pressure (A)” (3/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure when the engine speed is 1,900 rpm. 2. Modulating oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3) Display the items of “Transmission modulating oil pressure (B)” (3/4 of PM-CLINIC MENU screen). 4) Turn drive force control dial (2) and travel speed control dial (3) to the “right end”. 5) Set the directional lever in “Neutral” and run the engine at full speed, then measure the oil pressure. 3. Torque converter inlet oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3) Display the items of “Torque converter inlet oil pressure (C)” (3/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure while the engine is running at full speed. 4. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the oil pressure is reset.
20-114 20-114 1 (8)
WA1200-3
TESTING
AND ADJUSTING
4.
Torque converter outlet oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (I) to select the “PM-CLINIC MENU” screen. 3) Display the items of “Torque converter outlet oil pressure” (2/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure while the engine is running at full speed.
5.
Lubricating valve oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (I) to select the “PM-CLINIC MENU” screen. 3) Display the items of “Transmission lubricating valve oil pressure” (2/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure while the engine is running at full speed.
6.
ECMV clutch oil pressure 1) Remove the oil pressure pickup plug of the clutch to be measured. . Pickup plug for 1st gear speed clutch: (I) . Pickup plug for 2nd gear speed clutch: (2) . Pickup plug for 3rd gear speed clutch: (3) . Pickup plug for reverse clutch: (4) . Pickup plug for forward clutch: (5) 2) Install oil pressure gauge Cl i5.88 MPa (60
POWER TRAIN
kg/cm2H. 3)
4)
Star-t the engine and measure the oil pressure of the Ist, 2nd, and 3rd clutches under the following condition. 11 Keep the FNR (Forward/Reverse) switch in “N” (Neutral). 21 Set the auto shift/manual shift switch to “ON” (Manual) position. 31 Select each gear speed with the shift-up/ -down switches 41 Measure while the engine is running at full speed. Start the engine and measure the oil pressure of the forward and reverse clutches under the following condition. 11 Set the transmission cut-off switch to “OFF” position (to turn the light off). 21 Set the parking brake switch to “OFF” position. 31 Press the brake pedal.
WA1 200-3
20415 0
TESTING
POWER TRAIN
AND ADJUSTING
Set the auto shift/manual shift switch to “ON” (Manual) position, and set the shiftup switch to “3rd”. 51 Keep pressing the brake pedal, set the FNR (Forward/Reverse) switch to “F” (Forward) or “R” (Reverse). 61 Measure while the engine is running at full speed. Heighten the engine speed gradually + to the maximum. 41
Adjusting
a * *
1.
Adjust the oil pressure while the engine is stopped. When the main relief pressure cannot be measured accurately, do not adjust it. If the main relief pressure is out of the standard range, adjust it according to the following procedure. Adjusting transmission main relief pressure 1) Remove cover (1) and change the number of shims (2) to adjust the oil pressure. * Loosen the bolts of cover (I) gradually, lowering the tension of springs (3) and li + Ir
20-116 0
1.
9JFOO447
(41. Standard thickness of shims: 2.0 mm Pressure changed with 1 shim (t = 0.5 mm): 42.17 Pa (0.43 kg/cm*) The set pressure is heightened by increasing the shims, and lowered by decreasing the shims.
WA1 200-3
POWER TRAIN
TESTING AND ADJUSTING
FLUSHING PROCEDURE FOR HYDRAULIC CIRCUIT OF TORQUE CONVERTER AND TRANSMISSION *
Metal chips, etc. in the hydraulic circuit of the torque converter and transmission shorten the lives of the torque converter and transmission and can cause an internal breakage. Accordingly, flush the hydraulic circuit to remove the metal chips, etc. from them.
1.
Flush the 1) When sion, 2) When
2.
3.
circuit in the following cases. metal chips are sent to the circuit because of a damage of torque or hydraulic equipment. torque converter or transmission is overhauled or repaired.
Install the flushing elements. 1) Drain the oil from the filters. 2) Remove the 2 transmission oil filters, then install 2 flushing * Clean the inside of the case and removed parts. Refill transmission case with oil. Add new oil through the oil filler to the specified level. through the system. Then, check the oil level again.
l
Transmission
G
converter,
transmis-
elements.
Run the engine
to circulate
the oil
case: Approx. 350 t
4.
Flush the circuit according to the following procedure. 1) Start the engine, then run it at low idling without operating the gear shift lever or directional lever for about 20 minutes. -)r Heighten the engine speed to about 1,500 rpm at intervals. Jr If the engine water temperature gauge does not rise to the green range because of low ambient temperature, continue the warm-up operation further. 2) Perform actual work or travel for at least 20 minutes. Sr Use the all gear speeds (Forward, reverse, and 1st - 3rd gears). 3) Run the engine at low idling for about 20 minutes similarly to 4-I) above.
5.
Replace the flushing elements. 1) Replace the flushing elements with the standard elements similarly to 2-I) above. If the flushing elements are used for long hours, they are clogged. Accordingly, replace them with the standard ones. 2) Supply oil and check the oil level again.
A
6.
Replace the transmission last-chance filter. 1) Turn part A of last-chance filter case (I) with a wrench * If there is dirt in the filter case, clean it. Remove element (2) and install a new element. 2) 3) Fit new O-ring (3) to the rim of the case. * Apply a little quantity of grease to the periphery of the O-ring. 4) Install the case. w Case mounting bolt: 58.8 - 73.55 Nm 16 - 7 kgm1
to remove
be sure to
the case.
9JFOO458
WA1 200-3
20-117 0
TESTING
POWER TRAIN
AND ADJUSTING
HOW TO MOVE MACHINE WHEN TRANSMISSION VALVE IS BROKEN *
If the machine cannot be moved because of a trouble of the transmission valve parts (electric system, solenoid valve, spool, etc.), it can be moved again by installing fixed valve assembly (tool Nl). AInstallation of fixed valve assembly (tool Nl) to ECMV is a measure to move the machine from a dangerous work site to a safety place when it cannot be moved at any gear speed because of a transmission valve trouble. Use this method only when the transmission valve has a trouble. AWhen moving the machine, observe the procedure and take care of safety. A Lower the work equipment to the ground, apply the parking brake, and put blocks under the wheels to prevent the machine from moving. When working, stop the engine.
A
A
Take care not to get burned perature is high.
when
1.
Open the transmission
2.
Remove the valve cover. Ir Clean around ECMV thoroughly soil and dirt.
3.
the oil tem-
top cover.
and remove
Disconnect wiring connectors (I) - (14) (CN-T3, T4, T5, T6, T7, T8, Tll, T12, T13, T14, T20, T21, T22, T23). * For the precautions for removal of the wiring connectors, see DISASSEMBLY AND ASSEMBLY, “Removing transmission control valve assembly”.
20-118 0
WA1 200-3
TESTING
4.
POWER TRAIN
AND ADJUSTING
2 ECMV solenoids (15) Remove the following according to the moving direction of the maor reverse), then install fixed chine (Forward valve assembly (tool Nl). . When moving forward: Remove the F solenoid and 2nd solenoid. . When moving in reverse: Remove the R solenoid and 2nd solenoid. * If a wrong solenoid is removed, the transmission may be broken. Be careful. * Install plate N with the projected side directed to ECMV. Check that the O-ring is fitted to the fitting face. * Take care that soil and dirt will not enter the removed solenoids and valves.
TWWO2612
TWW02613
1) Assembly i) ii)
of fixed valve assembly Assemble spring (17) to cover Assemble the following spacers 415-1120, stamped mark R, 1, Spacer
(tool Nl) (16). (18) (7922)
(18) to use
TWW02614
Fixed valve assembly (tool Nl) the following parts, but they are on the WA1200-3. (Spacer, with 3rd, 792-415-1130 (Spacer, with 4th, 792-415-1140
includes not used H stamp) L stamp)
iii) Assemble valve (19). iv) Assemble O-ring on ECMV matching sursolenoid to the face and proportional fixed valve cover.
I WA1 200-3
i9
17 TWW02615
POWER TRAIN
TESTING AND ADJUSTING
2)
Using tool N2, install fixed valve assembly (20) to the ECMV. w Fixed valve assembly mounting bolt: 13.2 f 1.5 Nm Il.35 f 0.15 kgml
5.
Press the left brake pedal securely.
6.
Start the engine
7.
Release the brake pedal gradually to start the machine. A Put blocks under the wheels to prevent the machine from moving. If the engine is started, the transmission is engaged immediately and the machine starts. Accordingly, when starting the engine, check the travel direction and safety around the machine, and be sure to press the brake pedal.
and release the parking
brake.
A
20-119-l 0
WA1 200-3
TESTING AND ADJUSTING
STEERING SYSTEM
STEERING SYSTEM TESTING AND ADJUSTING STEERING OIL PRESSURE Measuring •
Hydraulic oil temperature: 45 – 55°C
¤ Lock
the front frame and rear frame with the safety bar.
1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3. Display the items of “Steering oil pressure” (4/4 of PM-CLINIC MENU screen). 4. Run the engine and turn the joystick lever to the “left” or “right”, and measure the oil pressure when the relief valve operates. 5. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the oil pressure is reset. Adjusting
¤ If
the relief pressure is not normal, adjust the steering relief valve according to the following procedure. ¤ When adjusting, stop the engine. 1. Loosen locknut (3) and turn adjustment screw (4) to adjust the relief pressure. fl Pressure changed with adjustment screw Pressure changed by 1 turn: Approx. 3.5 MPa {Approx. 35.7 kg/cm2} fl If the adjustment screw is tightened, the set pressure is heightened. If the former is loosened, the latter is lowered. fl When the relief pressure cannot be measured accurately, do not adjust it.
20-120 20-120 1 (8)
WA1200-3
TESTING
STEERING
AND ADJUSTING
SYSTEM
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE Measuring Hydraulic
oil temperature:
45 - 55°C
Lock the front frame and rear frame with the safety bar. the oil filler cap to release the residual ALoosen pressure from the hydraulic tank. a
1.
Disconnect drive shaft (I 1 between transmission and center support from the transmission.
2.
Disconnect drive shaft (2) between transmission and rear axle from the transmission.
3.
Disconnect diverter valve pilot hose (3). Replace elbow (4) with an oil passage shut-off elbow (See the next page), then install hose (3). (By this work, the oil pressure applied to the pilot port of the diverter valve is shut off and the emergency steering system can operate.)
4.
Remove oil pressure pickup plug (5) (PT l/8) between the diverter valve and steering valve, then install nipple C2 and oil pressure gauge Cl (39.2 MPa (400 kg/cm21).
5.
Start the engine and shift the gear to FORWARD (or REVERSE) 3rd. Heighten the travel speed to 24 km/h and turn the steering wheel to the right or left. Measure the oil pressure when the relief valve operates.
WA1 200-3
/
I
9JFOO448
STEERING SYSTEM
TESTING AND ADJUSTING
Adjusting
A
When adjusting,
1.
Remove
2.
Loosen locknut (7) and turn adjustment screw (8) to adjust the pressure. * Pressure changed with adjustment screw Pressure changed by 1 turn: Approx. 3.5 MPa {Approx. 35.7 kg/cm21 t If the adjustment screw is tightened, the set pressure is heightened. If the former is loosened, the latter is lowered. * When the relief pressure cannot be measured accurately, do not adjust it.
*
stop the engine.
cap nut (6) of the relief valve.
Preparation of oil pressure shut-off elbow Prepare elbow (07236-10210) and drive a pin having diameter of 5 mm into the drilled hole and weld it to shut off the oil passage.
TKWOllt8
WeI
20-122 0
WA1 200-3
STEERING SYSTEM
TESTING AND ADJUSTING
BLEEDING AIR FROM STEERING CIRCUIT Ir
If the steering valve or the steering cylinder is removed and installed, bleed air from its circuit according to the following procedure.
1.
Run the engine utes.
2.
Running chine to + Stop each
at low idling for about
5 min-
the engine at low speed, steer the mathe right and left 4 - 5 times. the piston rod about 100 mm before stroke end, and never relief the oil. perform
the
3.
Running the engine at full speed, operation in 2 above.
4.
Running the engine at low speed, move the piston rod to the stroke end to relief the oil.
WA1 200-3
9JFOO396
20- 123 0
STEERING SYSTEM
TESTING AND ADJUSTING
ADJUSTING STEERING STOPPER BOLT 1.
Running the engine at low speed, steer the machine and measure clearance a between frame end stopper (2) of front frame (I 1 and rear frame (3). If clearance a is out of the standard range, adjust it according to the following procedure. * Clearance a: 37 - 40 mm 1) Loosen locknut (4) and adjust clearance a to the standard range with steering angle adjustment bolt (5). the engine at low speed and operARun ate the joystick steering lever slowly. care not to catch your body, arm, ATake etc. between the front frame and rear frame. Adjust the stopper bolts on both sides * by the above method. 2)
9JFOO397
I
I\
Start the engine and check that the clearance between frame end stopper (2) of front frame (1) and rear frame (3) is normal when the machine stops turning.
9JFOO399
20-124 0
WA1 200-3
TESTING
BRAKE SYSTEM
AND ADJUSTING
BRAKE SYSTEM TESTING DROP OF WHEEL BRAKE OIL PRESSURE Put blocks under the wheels A the machine from moving.
I!
securely to prevent
1.
Testing wheel brake oil pressure 1) Remove bleeder screw (I), then install oil pressure gauge 139.22 MPa I400 kg/cm211 of tool I, joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw to bleed air from the brake circuit. For details, see BLEEDING AIR FROM EACH PART. 3) Press the left brake pedal and measure the brake oil pressure.
2.
Measuring drop of brake piston pressure 1) Remove bleeder screw (I), then install oil pressure gauge i39.22 MPa 1400 kg/cm211 of tool I, joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw to bleed air from the brake circuit. For details, see BLEEDING AIR FROM EACH PART. 3) Stop the engine, then press the left brake pedal so that the brake oil pressure becomes 15.5 MPa 1158 kg/cm21 and leave it for 5 minutes. Then, measure the pressure drop. * Take care not to move the brake pedal for 5 minutes. * After finishing the above work, bleed air from the brake circuit again.
WA1 200-3
?
20- 125 0
BRAKE SYSTEM
TESTING AND ADJUSTING
TESTING WHEEL BRAKE FUNCTION * . l . .
Test the wheel brake function under following condition. Road surface: Flat, level, straight, paved, and dried road Speed: Initial braking speed of 20 km/h Tire inflation pressure: Specified pressure (588 kPa (6 kg/cm211 Delay in pressing pedal: 0.1 set
1.
Start the engine and drive the machine with the directional lever in F (Forward) and the gear shift lever in 3rd.
2.
Keep the travel speed at 20 km/h, then press the brake pedal with the specified force. * Set the run-up path and the point to start measurement in advance. Keep the travel speed at 20 km/h on the run-up path and press the brake pedal when the machine passes the point to start measurement. * Perform this test with the transmission cut-off switch turned ON.
3.
Measure the distance between the point to start measurement and the stopping point of the machine. Ir Perform the above measurement 3 times, then obtain the average.
+ Stoooino
Point effect
Point
I
Stoooine
distance
--
where braking started
Point where operator foot on brake Pedal looeration Point1
Run-up
Put
path
TWW02433
20- 126 0
WA1 200-3
TESTING AND ADJUSTING
BRAKE SYSTEM
MEASURING WEAR OF WHEEL BRAKE DISC ¤ Stop the machine on a level place, and put blocks under the wheels to prevent the machine from moving. fl Brake oil pressure: 15.49 ± 1.37 MPa {158 ± 14 kg/cm2} 1. Remove cap (1). 2. Press the brake pedal to the stroke end.
3. Using slide calipers M, measure depth a from the end of shaft (2) to guide (3). fl Keep pressing the brake pedal during measurement. Wear limit: a = Max. 7.0 mm fl After the disc has been worn to near the wear limit, test it frequently, regardless of the maintenance period.
WA1200-3
20-127 20-127 1 (8)
TESTING AND ADJUSTING
BRAKE SYSTEM
TESTING AND ADJUSTING CHARGE CUT-IN AND CUT-OUT PRESSURE OF ACCUMULATOR Measuring • Brake oil temperature: 45 – 55°C ¤ While the engine is stopped, press the brake pedal at least 100 times to release the pressure from the accumulator circuit. 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3. Display the items of “F brake” or “R brake” (4/4 of PM-CLINIC MENU screen). 4. Measure the charge cut-in pressure of the accumulator. Run the engine at low speed, check that the oil pressure rises, then when the rise in the oil pressure becomes slow, measure the oil pressure (read the front brake pressure or rear brake pressure on the CGC monitor). 5. Measure the charge cut-out pressure of the accumulator. After the cut-in of the accumulator, the oil pressure starts lowering. At this time, measure the oil pressure. 6. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the oil pressure is reset. Adjusting Charge cut-out and cut-in pressure of accumulator fl If the charge cut-out pressure of the accumulator is adjusted, the valve area ratio cut-in pressure is changed. Accordingly, a cut-in pressure adjustment screw is not installed. 1. Loosen locknut (5) of cut-out valve (4) and turn adjustment screw (6) to adjust the cut-out pressure. fl If the adjustment screw is • turned to the right, the pressure is heightened. • turned to the left, the pressure is lowered. fl Pressure changed by 1 turn of adjustment screw: 5.59 MPa {57 kg/cm2} 3 Locknut: 9.8 – 11.8 Nm {1 – 1.2 kgm} fl After adjusting, check the cut-in and cut-out pressure of the accumulator again according to the above testing procedure.
20-128 20-128 1 (8)
WA1200-3
TESTING AND ADJUSTING
BRAKE SYSTEM
TESTING PARKING BRAKE PERFORMANCE *
Test the parking brake function under following condition.
. .
Tire inflation pressure: Specified pressure Road surface: Flat, paved, dry road having gradient of l/5 (11” 20’) Machine: Operating state
. 1.
Start the engine and drive straight up a slope having gradient of l/5.
2.
Press the brake pedal and set the directional lever in neutral, then stop the engine.
3.
Turn on the parking brake switch and release the brake pedal gradually. At this time, the machine must stop. j, Test the parking brake on an uphill road and a downhill road.
TWW02434
TWW02435
WA1 200-3
20-129 0
BRAKE SYSTEM
TESTING AND ADJUSTING
TESTING WEAR OF PARKING BRAKE DISC *
When the parking brake does not work sufficiently, check the parking brake disc for wear according to the following procedure. the work equipment to the ground and ALower put blocks under the wheels to prevent the machine from moving. AWhen 1.
checking the wear, stop the engine.
Drain oil from the transmission case. &
Transmission case: Approx. 350 e
2.
Remove 1 of 2 plugs (I).
3.
Measure depth a from end of cage (2) to the piston with slide calipers M. Standard depth: a = 41.2 mm max.
l
4.
M
If depth a is larger than the standard value, remove parking brake (4) and measure disc thickness W. For details, see DISASSEMBLY AND ASSEMBLY, Removing parking brake disc. Standard thickness: W = 3.2 + 0.1 mm l
5.
If the thickness of the parking brake disc is below the standard value, replace the disc.
20- 130 0
WA 1200-3
TESTING AND ADJUSTING
BRAKE SYSTEM
HOW TO RESET PARKING BRAKE MANUALLY *
The parking brake is controlled hydraulically. If it cannot be reset because of a trouble in the transmission, emergency reset solenoid valve, etc., it can be reset manually to move the machine.
Manual resetting of the parking brake is a measA ure to move the machine from a dangerous work site to a safety place. Use this method only in
an emergency A
A 1.
Lower the work equipment to the ground and put blocks under the wheels to prevent the machine from moving. When resetting the parking brake, stop the engine. Drain oil from the transmission case. &
Transmission case: Approx. 350 I?
2.
Remove 2 plugs (I).
3.
Remove 2 cage mounting bolts (21, then screw them in the slug holes alternatelv. * Remove 2 bolts (2) in the diagonal positions, together with the washers. * Tighten bolts (2) to pull piston (3) and reset the parking brake. * Tighten the 2 bolts evenly little by little. * If the bolts are tightened about -(3 + l/4) turns farther after they and washers touch the seat, the brake is reset.
9JFOO452
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.
WA1 200-3
20431 0
BRAKE SYSTEM
TESTING AND ADJUSTING
MEASURING PARKING BRAKE OIL PRESSURE Measuring *
A
parking
brake inlet pressure
Torque converter oil temperature: 60 - 80°C Put blocks under the wheels to prevent the machine from moving.
1.
Remove oil pressure pickup plug (PT l/8) (I), and install oil pressure gauge Cl (5.88 MPa 160 kg/cm21).
2.
Turn the parking
3.
Run the engine oil pressure.
brake switch OFF. at high idling and measure
the
A-A
Measuring pressure f
Torque
A chine
parking
brake solenoid
inlet
converter
oil temperature:
60 - 80°C
9JFOO413
Put blocks under the wheels to prevent the ma-
A 1.
2.
3.
from moving. While the engine is stopped, press the brake pedal at least 100 times to release the pressure from the accumulator circuit.
Turn the starting switch to the “ON” position and the parking brake switch to “OFF” position to reset the brake. Disconnect hose (21, and install the adapter and oil pressure gauge Cl (5.88 MPa {SO kg/cm211 of tool Cl. Run the engine at high idling and measure the oil pressure.
20-132 0
i
9JFOO414
WA1 200-3
TESTING AND ADJUSTING
HYDRAULIC EQUIPMENT
HYDRAULIC EQUIPMENT TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE •
Hydraulic oil temperature: 45 – 55°C
Measuring 1. Measuring work equipment relief pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3) Display the items of “Work equipment relief pressure” (4/4 of PM-CLINIC MENU screen). 4) Start the engine and raise the boom, then run the engine at full speed and dump the bucket. When the relief valve operates, measure the oil pressure. 2. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the oil pressure is reset.
WA1200-3
20-133 20-133 1 (8)
HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING
Adjusting 1.
Adjusting work equipment relief valve adjusting the oil pressure, stop the &hen engine. I) Loosen locknut (3) of work equipment relief valve (21, then turn adjustment screw (4) to adjust the oil pressure. * If the adjustment screw is . turned to the right, the pressure is heightened. . turned to the left, the pressure is lowered. * Pressure changed by 1 turn of adjustment screw: 1.02 MPa (10.39 kg/cm21 * After adjusting, measure the work equipment relief pressure again according the procedure described above.
2
3
20-134 0
.21 '004 QJF
4
9JFOO417
WA1 200-3
TESTING AND ADJUSTING
HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING PPC OIL PRESSURE •
Hydraulic oil temperature: 45 – 55°C the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. ¤ Operate the work equipment control lever 2 – 3 times to release the pressure from the PPC accumulator circuit.
¤ Loosen
Measuring 1. Measuring PPC relief pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the “PM-CLINIC MENU” screen. 3) Display the items of “PPC relief pressure” (4/4 of PM-CLINIC MENU screen). 4) Run the engine at full speed and measure the oil pressure. 5) If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. fl If the PAUSE button is pressed again, holding of the oil pressure is reset.
2. Measuring PPC valve output pressure 1) Remove the work equipment valve cover. 2) Remove oil pressure pickup plugs (PT 1/8) (1) – (4) from each circuit, then install nipples C2 and oil pressure gauges C1 (5.9 MPa {60 kg/cm2}). fl 1. For raising boom 2. For lowering boom 3. For dumping bucket 4. For digging with bucket 3) Start the engine and operate each circuit to the stroke end, then run the engine at full speed and operate each circuit. When the relief valve operates, measure the oil pressure.
WA1200-3
20-135 20-135 1 (8)
TESTING AND ADJUSTING
HYDRAULIC EQUIPMENT
Adjusting 1. Adjusting PPC relief valve
¤ When
adjusting the oil pressure, stop the engine.
1) Open the transmission top cover. 2) Loosen locknut (6) of PPC relief valve (5), then turn adjustment screw (7) to adjust the oil pressure. fl If the adjustment screw is • turned to the right, the pressure is heightened. • turned to the left, the pressure is lowered. fl Pressure changed by 1 turn of adjustment screw: 1.02 MPa {10.39 kg/cm2}
ADJUSTING PPC VALVE LINKAGE 1. Remove the underside cover of the work equipment control lever. 2. Adjust distance a from nut (1) of the PPC valve linkage to the floor top. • Distance a (Target value): 54 mm 3. Loosen nuts (2) and (3), then adjust the installed height of trunnion (5) to eliminate the play of lever (4). 4. After adjusting, tighten nuts (2) and (3).
20-136 20-136 1 (8)
WA1200-3
TESTING AND ADJUSTING
HYDRAULIC EQUIPMENT
BLEEDING AIR FROM EACH PART Bleeding
air from wheel
I\
i i !!!
I!
brake circuit
Sr If any brake circuit hose is disconnected for removal and installation of the brake valve, axle, etc., bleed air from the circuit according to the following procedure. A~pply the parking brake put and blocks under the wheels to prevent the machine from moving. Awhile the engine is running, never bleed air from the slack adjuster, since the drive shaft is rotating. 1.
Start the engine and heighten the pressure in the accumulator. (The pressure is heightened in about 30 set, if the engine runs at high idling.)
2.
Start the engine. Insert one end of a vinyl hose in bleeder (I), and put the other end in a container.
3.
Press the brake pedal and loosen the bleeder screw to bleed the air. Tighten the bleeder screw, then release the brake pedal slowly. Sr This work shall be done by two persons. One person shall press the brake pedal, and the other shall bleed air through the bleeder screw. * Use the left brake pedal. It Keep the brake oil tank full.
4.
Repeat this operation until any bubble does not come out any more through the vinyl hose. Then, press the pedal fully and tighten the bleeder screw while the oil is flowing out.
5.
Similarly to the above procedure, bleed air from the slack adjuster on the opposite side and bleeder (3) of each wheel. * If the pressure in the accumulator lowers, start the engine to heighten it. * After bleeding the air, run the engine at low idling and check the oil level in the brake oil tank, then supply oil, if necessary. * After bleeding the air, perform “Testing wheel brake performance”.
WA1 200-3
20- 137 0
TESTING
HYDRAULIC
AND ADJUSTING
EQUIPMENT
Bleeding air from piston pump *
If the hydraulic oil is replaced or the piston pump is replaced or the piston pump piping is removed, bleed air to prevent seizure of the pump according to the following procedure.
6.
Check that the hydraulic its top level.
7.
Loosen plugs (I), (21, (3), and (4) of the suction tubes of the piston pump.
8.
Loosen the adapter on the block side of case drain hose (5) of the piston pump.
9.
Oil flows out of plugs (I), (21, (31, (41, and hose (5) in order. After the all air is bled, tighten the
tank is filled with oil to
plugs and hose adapter. *
Since the oil level in the hydraulic tank is higher than (I), (21, (31, (41, and (5) above, oil can be bled easily.
20- 138 0
WA1 200-3
HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING
Bleeding
air from work
equipment
circuit
*
If the work equipment control valve or the work cylinder is removed and installed, equipment bleed air according to the following procedure.
1.
Run the engine
2.
Running the engine at low speed, raise and lower the boom 4 - 5 times repeatedly. Ir Stop the piston rod about 100 mm before each stroke end, and never relief the oil.
idle for about 5 minutes.
perform
9JFOO425
the
3.
Running the engine at full speed, operation of 2 above.
4.
Running the engine at low speed, operate the piston rod to the stroke end to relief the oil.
5.
Repeat the operations bucket cylinder.
of 2 and 3 above for the
-
WA1 200-3
9JFOO426
20-139 0
TESTING
HYDRAULIC
AND ADJUSTING
EQUIPMENT
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT Releasing residual pressure from piping between a hydraulic cylinder and control valve *
When disconnecting the piping between a hydraulic cylinder and the control valve, release the pressure from the circuit according to the following procedure.
1.
Stop the engine.
2.
Loosen the oil filler cap gradually to release the pressure from the tank.
3.
Operate the control lever. * After the control lever is operated 2 - 3 times, the pressure in the accumulator is lost.
4.
Run the engine at low idling for about 5 seconds, then stop it and operate the control lever. * Repeat the operations of 3) and 4) above 2 3 times to release the residual pressure completely.
Releasing residual pressure accumulator circuit *
from brake
When disconnecting the piping between cumulator and accumulator check valve tween the accumulator and brake valve, the pressure from the circuit according following procedure.
the acor berelease to the
1. Stop the engine.
2.
Press the brake pedal at least 100 times to release the pressure from the brake accumulator circuit.
Releasing residual pressure accumulator circuit *
*
from PPC
When disconnecting the piping between the PPC accumulator and PPC valve, release the pressure from the circuit according to the following procedure. Operate the control lever 2 - 3 times to release the pressure from the circuit.
20- 140 a
WA1 200-3
TESTING AND ADJUSTING
WORK EQUIPMENT ADJUSTING EQUIPMENT *
WORK EQUIPMENT SYSTEM
SYSTEM
WORK LEVER LINKAGE
If the operating effort or stroke of a work equipment control lever is out of the standard range, or if the work equipment control lever, PPC valve assembly, or boom/bucket solenoid is removed, adjust the operating effort and stroke of the control lever according to the following procedure.
When adjusting, stop the engine. A f Check that the operating effort of the work ment control
lever is in the standard
equiprange.
1. Remove the side cover of the work equipment control levers. 2.
Operate boom lever (I) and adjust the length of rod (4) so that cam follower (2) for the boom lever will be put in the detents on both ends of cam (3) evenly and clearance a will be 0.2 - 1 Tm&stance
b between pins of rod (4): 337 mm (Reference
value)
1i? /
9JFOO427
I-
3.
Operate bucket lever (5) and adjust the length of rod (8) so that cam follower (6) for the bucket lever will be put in the detents on both ends of cam (7) evenly and clearance c will be 0.2 - 1 mm. * Distance b between pins of rod (4): 337 mm (Reference value)
48
lr)l
9JFOO428
I WA1 200-3
9JFOO429
20-141 0
WORK EQUIPMENT SYSTEM
TESTING AND ADJUSTING
4.
procedure to set boom Perform the following kick-out solenoid (9) and bucket positioner solenoid (10) in the pull state (to turn them on) (See the illustration on the previous page). 1) Remove relay (L45) (117 and (L48) (12) in the operator’s cab. L45: Boom kick-out relay + L48: Bucket positioner relay 2) Connect a T-adapter to short @ and @ of relay 45 (Female) to each other, and short @ and @ of relay 48 (Female) to each other. -k Check that each solenoid is in pull state
m---9;FOO430
of 12 mm.
5.
I
Move boom kick-out solenoid (9) so that clearance d between boom lever cam (3) and cam follower (2) will be 0 - 0.5 mm when the solenoid is in the pull state. When adjusting, keep the boom lever in neu*
7
3 00
tral.
0
go +
6.
solenoid (IO) so that Move bucket positioner clearance e between bucket lever cam (7) and cam follower (6) will be 0 - 0.5 mm when the solenoid is in the pull state.
2
q
d
6
e
% 9JFOO431
7.
If the boom lever canceling force and the bucket lever canceling force are not 19.6 N (2 kg) and 9.8 N (1 kg) respectively, adjust them by changing installing holes d (at 4 places) of spring (13). Ir When the machine is shipped, the spring is installed to the second installing hole from the top.
8.
operate the bucket lever and After adjusting, boom lever and check that they are held in TILT, DUMP, and FLOAT positions.
I
20-142 0
9JFOO437
WA1 200-3
TESTING AND ADJUSTING
ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH Testing 1. Run the engine and operate the bucket to have proximity switch (1) operate. Stop the engine and measure clearance a between the proximity switch and angle (2). fl Standard clearance: a = 3 – 5 mm 2. Run the engine at medium speed (about 1500 rpm) and have the proximity switch operate and lower the bucket to the ground. At this time, check that the bucket angle is directed down by 0 – 1°.
Adjusting 1. If clearance a is not within the standard value, adjust as follows. 2. Lower the bucket completely to the ground on a horizontal ground surface. 3. Adjust proximity switch (1) so that clearance b from the switch detection surface to the tip of protector (3) is the standard value, then tighten nut (4) to hold it in position. • Standard clearance: b = 0.5 – 1.0 mm 3 Mounting nut: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} 4. Angle (2) moves to the side in relationship to the switch detection surface, so adjust the clearance so that it is a = 3 – 5 mm at all surfaces that it passes. 5. Run the engine at a mid-range speed (1500 rpm), and adjust mounting bracket (5) of the proximity switch so that the bucket angle is directed down by 0 – 1 degrees when the bucket is lowered to the ground and the positioner is actuated. fl Set the nominal position of the bracket so that c = 139 mm standard. fl The relationship between the bucket angle and the length of the cylinder when the bucket is at the horizontal position above the ground is 12 mm/1°. 6. The variation caused by the engine speed when the bucket is actuated must be within 4° when the bucket is just above the ground. fl If it cannot be adjusted correctly, repeat Steps 1 to 4 again.
WA1200-3
20-143 20-143 1 6
TESTING AND ADJUSTING
ELECTRICAL EQUIPMENT
TESTING AND ADJUSTING BOOM POTENTIOMETER fl After installing the boom, adjust the boom proximity switch. 1. Remove bolts (1) and cover (2). 2. Raise the boom to the stroke end of the boom cylinder, then stop the engine. 3. Loosen 2 screws (3). 4. Insert a T-adapter between the front harness and potentiometer. Turn the starting switch to the ON position and turn the potentiometer to the “right” or “left” slowly so that the voltage between terminals No. 2 and 3 of CN-F04 will be 4.3 ± 0.1 V. 5. After adjusting the potentiometer, tighten screws (3) temporarily and turn the starting switch to OFF position, then turn it to the ON position again. 6. Start the engine and lower the boom, then raise it to the top. Check again that the voltage is in the range of 4 above. fl If the voltage is in the range of 4 above, tighten screws (3) securely, then install cover (2) and bolts (1). fl If the voltage is out of the range of 4 above, adjust it again according to 4.
20-144 20-144 1 6
WA1200-3
TESTING AND ADJUSTING
ELECTRICAL EQUIPMENT
ADJUSTING BOOM HORIZONTAL DETECTION SWITCH fl Adjusting in lateral direction 1. Lower the bucket completely to the ground on a horizontal ground surface. 2. Adjust proximity switch (1) so that clearance d from the switch detection surface to cover (2) is the standard value, then tighten nut (3). • Standard clearance: d = 3 – 5 mm 3 Mounting nut: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} 3. Cover (2) moves in relationship to the switch detection surface, so adjust the clearance so that it is standard value d at all surfaces that it passes.
fl Adjusting boom in rotating direction 4. Set the boom to the horizontal position. 5. Loosen 2 lock bolts (5) of the switch mounting bracket. 6. When the boom is horizontal, use the oblong hole of bracket (4) to adjust the position so that cover (2) covers half the detection surface of proximity switch (1). fl See Fig. Y. 7. After completing the adjustment, tighten lock bolts (5).
WA1200-3
20-144-1 6
TESTING AND ADJUSTING
ELECTRICAL EQUIPMENT
PROCEDURE FOR SETTING INITIAL VALUE FOR REMOTE BOOM POSITIONER (METHOD OF INPUTTING BASE POINT) fl Carry out this setting after adjusting the boom potentiometer. 1. Operate the boom cylinder to the end of its stroke to raise. 2. Switch the CGC screen to the positioner screen. 3. Check both the UPPER stop position set display and LOWER stop position set display to make sure that they are not at the stop condition. fl Check that UPPER stop position set indicator (5) and LOWER stop position set indicator (6) are both OFF. 4. Press UPPER stop position set button (1) and LOWER stop position set button (2) within 10 seconds at least two times each. fl The buttons can be pressed in any order. 5. If the mounting position of the potentiometer is correct, UPPER stop position set display (3), LOWER stop position set display (4), UPPER stop position set indicator (5), and LOWER stop position set indicator (6) light up for 2.5 seconds and the buzzer sounds.
20-144-2 (8)
WA1200-3
ELECTRICAL EQUIPMENT
TESTING AND ADJUSTING
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP Proximitv
switch
actuation
Dilot IamD (Red1
fctuation
.
The proximity switch has a pilot lamp to indicate its operating condition. Use it for adjustment.
*
Condition of proximity switch actuation pilot lamp When the detector is at (near) the detecting face of the proximity switch: Lamp is turned on. When the detector is apart from the detecting face of the proximity switch: Lamp is turned off.
. .
Proximity switch actuation Pilot lamp
Detector
positior
Lights
I
When detector is detectian surface
nn
lamp
TEWDOl66
out
Goes
UP
positioned at of Proximity
Pilot
I
switch
When detector has detection surface
moved away of Proximity
~--r--L_
__-_____-
I
_-______j
j
j
.-_-___A j
j
II
Bucket positioner
I
from switch
+__-._-__-
I
l-l_-__
Detector
Proximiiu
switch
=7=---T Proximiiv
Deteitor
Proximity
switch
switch \
\
Reading of load-meter
Detector
TWW02436
WA1 200-3
1
20- 145 0
TESTING
ELECTRICAL
AND ADJUSTING
EQUIPMENT
INITIAL LEARNING METHOD OF TRANSMISSION CONTROLLER Ir
1.
2.
The transmission controller has a learning function to correct itself so that the gear shift feeling will be kept constant even if the transmission clutch is worn. If the transmission controller is overhauled or transferred to another machine, the control command values which the transmission controller have learned from the former transmission are used. As a result, gear shift shocks or abnormal sounds may be made. As the machine is operated, the transmission controller learns the condition of the new transmission and corrects the command values properly. If you wish to reset the current data and have the transmission controller learns the new data immediately, however, “reset the collected control data” and “perform initial learning” according to the following procedure. How to reset collected control data * The all control data collected in the past can be reset to the initial values by the following procedure. I) Check that the starting switch is at the OFF position. 2) Remove the right cover of the work equipment control lever box. wiring connector (CN-CSB) 3) Disconnect and connect a T-adapter P. 4) Turn the starting switch to the ON position. * Do not start the engine. 5) Short @ and @ of T-adapter P to each other, then open them again. How to perform initial learning * When correcting the initial control data of each clutch in the controller to proper values, perform the following procedure after “resetting the collected control data” as explained above. * Start the engine and perform the following gear shifting operation to stabilize the fill time of each clutch. 1) Perform one cycle of the following gear shifting operation; “N” + “Fl” + “F2” ~ “F3” ~ “F2” ~ UN” --) MR.,” --j “N”_
20-146 0
2)
3)
When performing the above operation, run the engine at low idling and turn the transmission cut-off switch off, and turn the manual shift switch on. Keep the gear at each gear speed for the following time. Hold in “F3” for “5 seconds”, and in the other gear speeds for “3 seconds”. Heighten the torque converter oil temperature to the second segment from the bottom (Torque converter may be stalled for this purpose), then lower the engine speed to low idling. * The target transmission oil temperature is 40 - 50°C. There will be no troubles even if the torque converter oil temperature lowers to the first segment during the following gear shifting operation. Perform following cycles @ and @ 2 times each; @ “N” + “Fl” + “F2” + “F3”. @ “F3” ~ “F2” ~ “N” ~ “R,” ~ “N”.
*
4) 5)
When performing the above operation, run the engine at low idling and turn the transmission cut-off switch off, and turn the manual shift switch on. * Keep the gear at each gear speed for the following time. . Hold in “F3” for “5 seconds”, and in the other gear speeds for “3 seconds”. * If the engine is stopped before performing the operations of 2) and 31, start with I) again. Raise the engine speed to 1,000 rpm, and repeat the operations of 2 and 3). Raise the engine speed to 1,500 rpm, and repeat the operations of 2 and 3). (Reference) The above gear shifting operations can be performed with the brake turned “ON”, and it is not necessary to drive the machine.
WA1 200-3
TESTING
ELECTRICAL
AND ADJUSTING
EQUIPMENT
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) Monitor Panel (rear)
The speedometer of the main monitor is common to various models, and different models input different travel speed signals. Accordingly, the speedometer needs to be adjusted for each model. The speedometer is normally used as the tachometer.
l
Ir
Adjusting
procedure TWW01722
.
Turn off the power and remove the main monitor, then adjust the adjustment section of the rear side of the speedometer.
1.
Adjusting for each model I) Remove the rubber caps of DIP switches 1, 2, and 3 (SWI, SW2, and SW3) on the rear side of the main monitor. 2) There are rotary switches under the rubber caps. Adjust these rotary switches with a flat-head screwdriver according to the following table. Ir To change the tachometer to the speedometer, set switch 3 to “0”.
:I
>dswitch
TWW01723
DIP
SW
1.2.3 DIP
SW
4
ON
piigq -
-
OFF
Switch posisiton
TWW02437
3)
4)
Remove the cap of DIP switch 4 (SW41 on the rear side of the main monitor, and set the inside ON-OFF switches according to the table at right. After adjusting, fit the rubber caps securely, then install the main monitor.
(Reference)
Correction
Position of switch Correction ratio (%I
WA1 200-3
ratio of switch
(2)
3
ON
4
ON
01234567 +14
+I2
+lO
+8
+6
+4
+2
0
20-147 a
TESTING AND ADJUSTING
ELECTRICAL EQUIPMENT
ADJUSTING STEERING LEVER ANGLE AND FRAME ANGLE SENSORS 1.
Set the machine angle (measuring
2.
Set steering position.
3.
Run the engine
4.
Slide the armrest to the auxiliary position (the backmost position). * If the armrest is set to this position, the console switch is turned “ON”.
5.
Turn steering position.
6.
About 1 second after, pips come out and adjustment is completed. * Do not operate the steering lever during the operations of 1) - 6). * If the sensors do not operate normally, check the installing direction of potentiometers (4) and (5) again, then calibrate again. . (4) Frame angle sensor (Potentiometer) . (5) Lever angle sensor (Potentiometer)
body and lever (1) at a right with eye).
lock lever (2) to the LOCK (lower)
at low idling. 9JFOO398
lock lever (2) to the FREE (upper)
Z
9JFOO437 1
9JFOO438
9JFOO439
20-l 48 0
WA1 200-3
ELECTRICAL EQUIPMENT
TESTING AND ADJUSTING
PROCEDURE FOR CHECKING DIODE .
.
1.
Use the following procedure to check the diode as individual part and the wiring harness including the diode. Use a digital tester with a range for measuring diodes. Put the red (+) end of the test pin in contact with the anode (PI of the diode, and the black (-1 end in contact with the cathode (N). * There is a mark showing the direction of continuity on the surface of the diode.
*
If a normal tester is switched to the diode range, the voltage of the internal battery is displayed. The value indicates the following. . No change: No continuity l Changes: There is continuity (normal) (Note) l Value is 0 or near 0: Short circuit inside diode
Note:
In the case of silicon diodes, a value between 450 and 600 is displayed.
TLPO0663
l---z-Diode
included
in
wiring
harness
TLP00664
J BLPO1357
WA1 200-3
20-149 0
GREASING SYSTEM
TESTING AND ADJUSTING
METHOD OF ADJUSTING AUTO-GREASE INJECTOR DISCHARGE AMOUNT 1. The injector is actuated by pressure from the pump and sends the set amount of grease to the bearing.
2.
3.
To check if the injector is working properly, observe the movement of indicator pin @ at the head. If the operation is normal, the pin will first be pulled in, and when the pump sto@s and the pressure is removed, the pin will return to its original position to complete the resetting for the next greasing. To adjust the injector discharge amount, turn adjustment screw @ at the head. 1) To reduce the discharge amount, loosen locknut @ and turn adjustment screw @ clockwise to gradually decrease the discharge amount. When the screw cannot be tightened any further (the position where it contacts the stopper), the discharge amount is the minimum. screw is turned counter2) If the adjustment clockwise 10 turns from the fully tightened position (minimum discharge amount), the setting will be maximum discharge amount. Maximum discharge amount: 1.3 cc/ST * After adjusting the injector discharge amount as shown above, be sure to tighten locknut
K 0
SJWOll33
@ again.
4.
It is possible
to overhaul or repair the injector, but if the injector fails, it is better to replace the injector with a new injector assembly. . Loosen locknut @ and turn adjustment screw @to adjust the amount of grease discharged each time.
Discharge Screwed in clockwise contact stopper Loosened clockwise
l
*
10 turns counterfrom above position
0.3 cc (minimum)
1.30 cc (maximum
One turn between the maximum and minimum positions changes the discharge by 0.13 cc. After adjusting the screw, be sure to tighten the locknut.
20- 150 0
to
per time
LlJWO1134
WA1 200-3
GREASING SYSTEM
TESTING AND ADJUSTING
METHOD OF SETTING AUTO-GREASE TIMER . .
.
The timer is installed to control the greasing interval for the auto-greasing system. The timer is installed in box @ at the rear of the operator’s seat. The timer can be adjusted to the desired greasing interval according to the following table by turning the blue dial. Note that there is a tolerance of approx. +15%. (Both the operation and rest periods) Example:
When
timer
is set to 11.25 minutes
11.25 minutes
11.25 minutes
11.25 minutes
stop
stop
stop Operation
1.
Adjustment of greasing interval Timer box @ is in the position diagram on the right.
.
2.
shown
in the
Power supply for timer Even after the starting switch is turned off, both the rest time and operating time are stored in this circuit board by the capacitor (Super Cap) for about five days, and the next operation starts under the condition when the power was turned off the previous time. However, if the power is kept turned off for more than five days, the data are deleted from memory.
Dial
(red)
/
Method of adjusting interval time (Blue dial) Open the door at the bottom rear of the cab, then open the lid of the timer box. Turn the dial shown in the diagram on the right to adjust the rest time and operating time. To adjust the rest time, turn blue rotary switch @ in the diagram on the right according to the following table.
AW43740B
WA1 200-3
GREASING SYSTEM
TESTING AND ADJUSTING
Position of switch Greasing interval (min) Position of switch Greasing interval (min) I)
3.
1
2
3
4
5
6
7
8
9
3.75
7.5
11.25
15
18.75
22.5
28.25
30
33.75
A
B
C
D
E
F
37.5
41.25
45
48.75
52.5
56.25
Set the blue dial to position 3 after the autogreasing system is installed.
Method of adjusting operating time (Red dial) To adjust the operating time, turn red rotary switch @ in the diagram on the right according to the following table. (Normally, fix this dial to position 2 (15 seconds).)
D i a I (b I ue)
AW437415
1
2
3
4
5
6
7
8
9
7.5
15
22.5
30
37.5
45
58.5
60
67.5
Position of switch
A
B
C
D
E
F
Operatingtime of pumpkiec)
75
82.5
90
97.5
105
112.5
Position of switch Operatingtime of pump(set)
I) 2)
Set the red dial to position 2 (for normal operation). When greasing is finished and the greasing pump is balanced, the greasing pump stops even if within the specified operating time (15 set).
20-152 0
WA1 200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
VHMS CONTROLLER BASIC PRECAUTIONS 1. Handling machine, safety, inspection and maintenance For details of safety items, operation, inspection, and maintenance of the machine, see the Operation and Maintenance Manual for the machine. 2. Handling monitoring system Always obey the following precautions when handling the monitoring system. 1) When disassembling, repairing, or modifying the machine or system, follow the instructions in the manual. 2) Do not touch the system (equipment) when operating the machine. 3) Do not damage or get the wiring harnesses, connectors, or sensors of the system (equipment) caught or pulled by force. This may cause short circuits or disconnections that will lead to failure or fire on the machine or system (equipment). 4) Do not get water, dirt, or oil on the system (equipment) 3. Permanent power source for VHMS (battery direct power source) 1) Meaning and need of permanent power source The VHMS has the function of checking and collecting data on the condition of the machine from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Therefore, its power supply is different from many of the electronic equipment and electrical parts.
WA1200-3
For the system to provide the above functions, it is necessary to have a power supply that is connected directly to the battery and always supplies electricity (permanent power source) in addition to the power source (switch power source) that is cut when the starting switch is turned OFF or the engine is stopped. Because this switch power source and permanent power source are provided, the period needed for collecting data is clearly known and it becomes possible to store this data in the internal memory. In other words, the VHMS uses the permanent power source to save to memory the data accumulated from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Then the VHMS controller itself turns off the permanent power source. 2) Precautions when turning the permanent power source OFF When the starting switch is turned OFF, the power supply is maintained for at least 3 minutes (the VHMS system shutdown time: the time taken for the VHMS system to save the data to memory and switch off), and then the permanent power source is turned OFF. If the VHMS system shut-down time is shorter than 3 minutes, the accumulated data may be damaged. a. When removing VHMS from permanent power source When removing the VHMS from the permanent power source (for example, when carrying out repairs), check that the monitor display (7-segment LED in the diagram below) of the VHMS controller is out.
20-153 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
b. When installing battery isolator or other battery shut-down device i) Basic connections It is a basic assumption that the engine stop switch is a type that will not shut off the permanent power source when the engine is stopped. ii) When safety regulations for user make it impossible to avoid shutting down all electric power • Install a battery isolator so that the permanent power source is kept in the specified condition for at least 3 minutes after the starting switch is turned OFF before the permanent power source is shut down. • If there is no timer, wait for at least 3 minutes before turning off the permanent power source. • If the above shut-down time is shorter than 3 minutes, the accumulated data may be damaged. 4. Precautions when VHMS power source is ON • For the first few seconds after the power is switched ON, the VHMS controller carries out the initial check (LEDs flash). Do not carry out any of the following operations until the initial check is completed. • Operation of manual snapshot switch • Downloading from PC (Check that the LEDs are displaying the aggregate numerals in turn before operating.)
20-154 (8)
WA1200-3
TESTING AND ADJUSTING
5. Precautions when replacing VHMS and transmission controller 1) Before starting replacement a. Download VHMS data When the VHMS controller is replaced, the data collected up to that point is lost, so be sure to download the accumulated data before starting the replacement operation. Next, send the accumulated data to web care. For details of the method of downloading, see the separate instruction manual for the technical analysis tool box. b. Specified method of shutting down VHMS power source i) Use the starting switch to turn the normal power source OFF ii) Maintain the permanent power source in the specified condition for at least 3 minutes. iii) Turn the permanent power source (battery direct) OFF. 2) Method of replacement, action after replacement When replacing the VHMS controller, be careful not to subject the VHMS controller or wiring harnesses to any excessive force or impact, and carry out the initial setup. For details, see the separate instruction manual for the technical analysis tool box.
WA1200-3
VHMS CONTROLLER
6. Handling communications controller (ORB ··· Orbcomm) 1) The ORB controller must be used. If the ORB controller is not used, it is impossible to carry out the request to open communications before starting to use. If the control power is turned on before completing the request, the transmission will be unauthorized and there will be problems with the communications system. If there are any problems or any part is unclear, please contact Komatsu or the person responsible for operation. 2) Finally, turn on the ORB power ON (connect the connector). After the VHMS controller confirmation is completed, connect the ORB controller connector (ORBA, ORB-B).
20-155 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
SETTING UP VHMS CONTROLLER
•
1. Setting up VHMS controller • In the following cases, always carry out the setup. 1) When making the initial installation of the VHMS system 2) When replacing or overhauling the following components • VHMS controller • Engine • Transmission 3) When the ORBCOMM communication system (optional) is installed • When carrying out the setup, the following are needed 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) • For details of the setup method, see the instruction manual for the technical analysis tool box (for service)
•
The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. Or contact Komatsu
2. Setting items • VHMS: For details of the setup method, see the instruction manual for the technical analysis tool box (for service). 1) Calendar (date, time, time difference from GMT, summer time (daylight saving time)) 2) Machine model, Serial No., variation code 3) Engine model, Serial No. 4) Transmission serial No. 5) Setting of integration of load meter • Starting ORBCOMM station 1) Communication method (Stop/Start, Interval, Transmission time) 2) Country code of communication controller (GCC)
3. Setup flow (outline) Procedure
Method (specific content, points to remember, etc.)
Turn starting switch ON (starting switch ON) • Check for generation of errors • Start setup tool
Check that no error is generated by the VHMS controller or other controller If there is any error, repair or correct to return condition to normal
2
Setting up VHMS
• Calendar (date, time, time difference from GMT, summer time (daylight saving time)) • Machine model, Serial No., variation code • Engine model, Serial No. • Transmission Serial No.
3
Starting switch OFF (starting switch OFF)
• Saving settings
4
Starting switch ON (starting switch ON)
• Checking VHMS functions
5
Start engine Test (quick PM) Start engine switch OFF
• Performing test (quick PM) • Downloding • Checking data (content of data)
6
Setting up load meter
• Time of start of data collection • Data collection unit (day)
7
Starting switch ON (starting switch ON) • Check for errors • Start setup tool
• Checking operation of Orbcomm • Setting up communications (need for comminications file, comminications frequency, GCC code)
8
Starting switch OFF (starting switch OFF)
• Setup completion report, content of setup (data), sending checksheet • Sending download data
1
20-156 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
1. Checking operation, actuation fl Check the functions of the VHMS system as follows. Start
Turn starting switch to [ON] position
Display Normal
Engine, transmission controllers show past errors, then give [00] display (no error exists)
VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists)
No display
Display Normal
No display
Turn starting switch [OFF], then check connection of wiring harnesses again
Turn starting switch again to [ON] position
Display Normal
Engine, transmission controllers show past errors, then give [00] display (no error exists) No display Abnormality in machine system • See machine shop manual
VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists)
Display Normal
No display Possible abnormality in VHMS controller
5. Collection of data fl If there is no abnormality in the system, the machine will operate and the operation data for the machine will automatically be saved by the VHMS controller.
WA1200-3
20-157 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
COLLECTING AND TRANSMITTING VHMS CONTROLLER DATA 1. Collecting data 1) Downloading to PC (personal computer) • PC (Personal computer) • VHMS analysis tool (Software) (799-608-3211) • Download cable (799-608-3220) Download the collected data to a personal computer and transmit them to the file server in the computer center by e-mail (Internet). Only a part of the data which must be collected in real time is transmitted by satellite communication. For even a machine equipped with the ORBCOMM, the data must be downloaded to a personal computer periodically. fl For downloading and transmission of the data, see “Instruction manual of analysis tool (for service)”. 2) Automatic transmission by communication satellite (Machine with ORBCOMM specification) • Detected errors and specified data are automatically transmitted to the file server in the computer center via the communication satellite.
2. Setup flow (Outline) Procedure
Method (specific content, points to remember, etc.)
1
Turn starting switch ON (starting switch ON) • Check for generation of errors • Start setup tool
Check that no error is generated by the VHMS controller or other controller If there is any error, repair or correct to return condition to normal
2
Setting up communication
• Checking data of satellite communication and setting of communication frequency • Setting GCC code
3
Starting switch OFF (Key switch OFF)
• Saving settings • Setup completion report
3. Executing quick PM fl See TESTING AND ADJUSTING, Executing PM Clinic with manual snap shot. • Before downloading data to the PC, execute the quick PM (equivalent to PM clinic) to collect the data under the normal operating condition and those under the conditions of stall of the torque converter, high idling operation, etc.
20-158 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
4. Method of downloading data to PC (personal computer) ¤ Stop the vehicle on level ground and lock the tires with chocks for safety. ¤ When turning the starting switch ON, check that the parking brake is turned ON and the gearshift lever is in the N position. ¤ When starting the engine, sound the horn and check that there is not a person around the vehicle. fl For the operating method of the personal computer, see “Instruction manual of analysis tool (for service)”. • Prepare the PC and wiring harness for downloading. 1) Install the download cable to the connector of the vehicle. 2) Connect either end of the download wiring harness to the PC. 3) Turn the starting switch of the vehicle ON. Check that the VHMS is in operation, and then start downloading to the PC. fl To check that the VHMS is in operation, check that the VHMS controller has started and the LED rotates and then displays the integrated numbers in order (See the following figure). 4) When downloading is completed, the download PC displays “complete”. 5) Turn the starting switch of the vehicle OFF, and then turn the PC OFF. Remove the download cable and return the connector cap.
WA1200-3
20-159 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
Items of trend data Table 1: Trend analysis data No.
Item
Content
Unit
Data source
1
SMR
Service meter
h
2
Calendar
Calendar
y/m/d h:m:s VHMS
3
Engine speed. Max.
Engine speed (Max.)
rpm
Engine controller
4
Blow-by press. Max.
Blow-by pressure (Max.)
kPa
Engine controller
5
Boost press. Max.
Boost pressure (Max.)
kPa
Engine controller
6
Eng. oil temp. Max.
Engine oil temperature (Max.)
deg C
Engine controller
7
Coolant temp. Max.
Engine coolant temperature (Max.)
deg C
Engine controller
8
Coolant temp. Min.
Engine coolant temperature (Min.)
deg C
Engine controller
9
Eng. oil press. Max.
Engine oil pressure (Max.)
MPa
Engine controller
MPa
Engine controller
11 Eng. oil press. @Hi Idle Min
Engine oil pressure at high idling (Min.) MPa
Engine controller
12 Exh. temp. Max. (LF)
Exhaust temperature at left front (Max.) deg C
Engine controller
13 Exh. temp. Max. (LR)
Exhaust temperature at left rear (Max.)
deg C
Engine controller
14 Exh. temp. Max. (RF)
Exhaust temperature at right front (Max.) deg C
Engine controller
15 Exh. temp. Max. (RR)
Exhaust temperature at right rear (Max.)
deg C
Engine controller
16 Fuel rate Ave.
Fuel consumption (Average)
Liter/h
Engine controller
17 PPC press. Max.
PPC pump pressure (Max.)
kg/cm2
VHMS
18 Hyd. Oil press. Max.
Loader pump pressure (Max.)
kg/cm2
VHMS
19 Hyd. Oil press. Ave.
Loader pump pressure (Average)
kg/cm2
VHMS
20 S/T pump press. Max.
Steering pump pressure (Max.)
kg/cm2
VHMS
21 S/T pump press. Ave.
Steering pump pressure (Average)
kg/cm2
VHMS
22 Hyd. Oil temp. Max.
Hydraulic oil temperature (Max.)
deg C
VHMS
23 Hyd. Oil temp. Ave.
Hydraulic oil temperature (Average)
deg C
VHMS
24 Hyd. Oil temp. Min.
Hydraulic oil temperature (Min.)
deg C
VHMS
25 Ambient temp. Max.
Atmospheric temperature (Max.)
deg C
VHMS
26 Ambient temp. Ave.
Atmospheric temperature (Average)
deg C
VHMS
27 Ambient temp. Min.
Atmospheric temperature (Min.)
deg C
VHMS
28 T/C in press. Max.
Torque converter input pressure (Max.)
kg/cm2
VHMS
29 T/C out press. Max.
Torque converter output pressure (Max.)
kg/cm2
VHMS
30 T/M main press. Max.
Transmission main pressure (Max.)
kg/cm2
VHMS
31 T/M lube press. Max
Transmission lubricating oil pressure (Max.) kg/cm2
VHMS
32 TM M/C oil press. Max
Modulated clutch oil pressure (Max.)
kg/cm2
VHMS
33 T/C oil temp. Max
Torque converter oil temperature (Max.)
deg C
VHMS
34 F. brake press. Max.
Front brake charge pressure (Max.)
kg/cm2
VHMS
35 R. brake press. Max.
Rear brake charge pressure (Max.)
kg/cm2
VHMS
36 Atmos. Press. Ave.
Atmospheric pressure (Average)
hPa
Engine controller
10 Eng. oil press. @Lo Idle Min Engine oil pressure at low idling (Min.)
20-160 (8)
Remarks
VHMS
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
Table 2: Transmission trend data No.
Item
Content
Unit
Data source
1
SMR
Service meter
h
2
Calendar
Calendar
y/m/d h:m:s VHMS
Transmission fill-up time
msec.
Transmission controller
Torque converter using time at each oil temperature
sec.
VHMS
Remarks
VHMS
Trig.Time F Ave. (fill time) Trig.Time R Ave. (fill time) 3
Trig.Time 1st (fill time)
(Every 200 h)
Trig.Time 2nd (fill time) Trig.Time 3rd (fill time) T/C oil temp. 120°C 4
T/C oil temp. 130°C T/C oil temp. 140°C
Table 3.1: Monitoring items of automatic snap shot (Trigger items) No.
Content
Error code
No.
Content
Error code
1
Lowering of engine oil pressure
C143
21 High exhaust temperature (L #7)
C647
2
Rise of engine coolant temperature
C151
22 High exhaust temperature (L #8)
C648
3
Rise of intake air temperature at left front C155
23 High exhaust temperature (R #1)
C651
4
Rise of intake air temperature at left rear C158
24 High exhaust temperature (R #2)
C652
5
Rise of intake air temperature at right front C162
25 High exhaust temperature (R #3)
C653
6
Rise of intake air temperature at right rear C165
26 High exhaust temperature (R #4)
C654
7
Rise of engine oil temperature
C214
27 High exhaust temperature (R #5)
C655
8
Lowering of engine coolant pressure
C233
28 High exhaust temperature (R #6)
C656
9
Engine overspeed
C234
29 High exhaust temperature (R #7)
C657
10 Lowering of engine coolant level
C235
30 High exhaust temperature (R #8)
C658
11 Lowering of engine oil level
C253
31 Sharp rise of left front inlet temperature C783
12 Abnormal rise of fuel temperature
C261
32 Sharp rise of left rear inlet temperature
13 Excessive lowering of engine oil level
C471
33 Sharp rise of right front inlet temperature C2158
14 High blow-by pressure
C555
34 Sharp rise of right rear inlet temperature C2159
15 High exhaust temperature (L #1)
C641
35 High torque converter oil temperature
B@CENS
16 High exhaust temperature (L #2)
C642
36 High hydraulic oil temperature
B@HANS
17 High exhaust temperature (L #3)
C643
37 Malfunction of modulated clutch
DBDOKT
18 High exhaust temperature (L #4)
C644
38 Malfunction of transmission
1500LO
19 High exhaust temperature (L #5)
C645
39 Lowering of left brake charge pressure
2G42ZG
20 High exhaust temperature (L #6)
C646
40 Lowering of right brake charge pressurea 2G43ZG
WA1200-3
C2157
20-161 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
Table 3.2: Data items of manual snap shot No.
Item
Content
Unit
Data source
1
Time
Date and time
sec.
VHMS
2
Eng. speed
Engine speed
rpm
Engine controller
3
Fuel inject
Fuel injection rate
mm3/st
Engine controller
4
Rail press.
Fuel rail pressure
kg/cm2
Engine controller
5
Cont. out-sig
Controller output signal
V
Engine controller
6
Blowby press.
Blow-by pressure
mmAq
Engine controller
7
Boost press.
Engine boost pressure
kg/cm2
Engine controller
8
Eng. oil temp.
Engine oil temperature
deg C
Engine controller
Engine oil pressure
kg/cm2
Engine controller
10 Eng. cool. temp.
Engine coolant temperature
deg C
Engine controller
11 Exh. temp. 1278L
Exhaust temperature (Cylinders 1, 2, 7, and 8L)
deg C
Engine controller
12 Exh. temp. 3456L
Exhaust temperature (Cylinders 3, 4, 5, and 6L)
deg C
Engine controller
13 Exh. temp. 1278R
Exhaust temperature (Cylinders 1, 2, 7, and 8R) deg C
Engine controller
14 Exh. temp. 3456R
Exhaust temperature (Cylinders 3, 4, 5, and 6R) deg C
Engine controller
15 PPC oil press.
PPC pump oil pressure
kg/cm2
VHMS
16 Hyd. oil press.
Loader pump oil pressure
kg/cm2
VHMS
17 S/T pump press.
Steering pump oil pressure
kg/cm2
VHMS
18 Hyd. oil temp.
Hydraulic oil temperature
deg C
VHMS
19 Boom raise sw.
Boom RAISE switch
D
Work equipment controller
20 Boom lower sw.
Boom LOWER switch
D
Work equipment controller
21 Bucket tilt sw.
Bucket TILT switch
D
Work equipment controller
22 Bucket dump sw.
Bucket DUMP switch
D
Work equipment controller
23 Ambient temp.
Atmospheric temperature
deg C
VHMS
24 M/C out speed
Modulated clutch output speed
rpm
M/C controller
25 T/C oil temp
Torque converter oil temperature
deg C
VHMS
26 Short indicator
Gear speed (position)
–
Transmission controller
27 M/C slip rate
Modulated clutch slip rate
%
VHMS
28 F. brake press.
Front brake charge pressure
kg/cm2
VHMS
Rear brake charge pressure
kg/cm2
VHMS
9
Eng. oil press.
29 R. brake press.
20-162 (8)
Remarks
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
TESTING AND MAINTAINING VHMS CONTROLLER 1. Testing time: Testing and maintaining time of vehicle Test the system at the maintaining time of the vehicle. 2. Testing items fl Test and check each item. If it is abnormal, take a proper remedy. 1) At check before starting (Ask the customer to perform the following check) i) Check that the sensors are installed normally. (Check the fitting parts for looseness, damage, and dirt.) ii) Check the wiring harnesses, cables, and connectors for disconnection and damage. iii) Check the sensor fitting parts for oil leakage and gas leakage. 2) At 1000-hour maintenance i) Communication antenna (if installed) • Check the antenna fitting parts for looseness and play. • Check the antenna for flaw, looseness, and play. • If the antenna is abnormal, replace it. 3) At irregular maintenance i) If a downloaded value is abnormal, check each sensor. 3. Remedy If any part is abnormal, repair, replace, or re-install (retighten) it.
WA1200-3
20-163 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
SETUP PROCEDURE FOR VHMS CONTROLLER fl Setup tools for VHMS controller Symbol
Q
Part No.
Part name
1
799-608-3211
VHMS analysis tool
2
799-608-3220
Wiring harness
3
Commercially Notebook personal computer available (OS: Windows98/2000)
1. Check of machine information, engine information, and controller information fl This step is a work on the whole machine. Check and record the machine information, engine information, VHMS controller information, and ORBCOMM controller information. Information to be checked No.
21T-06-64590
Coupling assembly (Attached tool)
21T-06-64392
Wiring harness (Attached tool)
4
fl Before starting operation after completion of local assembly or before resuming operation after storage for a long period, set up the VHMS controller according to the following procedure. fl Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the setup procedure. fl For the method of installing the VHMS Setup Program to the personal computer, refer to the Operation Manual contained in the package of service kit Q1. fl When using the VHMS controller for the first time or after replacing it, set it up with a personal computer. • Note that the contents of the VHMS controller cannot be changed with the service menu of the machine control monitor (CGC). fl The setup procedure covers both “ORBCOMM Specification” and “ORBCOMMLESS Specification”. In case of “ORBCOMMLESS” Specification”, omit the procedures necessary for “ORBCOMM Specification” only. fl During the setup work, make necessary confirmations for each work according to the “VHMS Setup Work Checklist”.
20-164 (8)
Information
Remarks
1
Machine model
2
Machine serial No.
3
Current service meter reading
4
Engine serial No.
5
Transmission serial No.
6
VHMS controller serial No. (*1)
7
ORBCOMM terminal serial No. [For only ORBCOMM specification] (*2)
(*1) (*2)
By 0.1 h
The VHMS controller is under the operator’s seat. The ORBCOMM controller is at the right rear of the operator’s seat.
WA1200-3
TESTING AND ADJUSTING
2. Check of operation of ORBCOMM controller (For only ORBCOMM specification) fl This step is a work performed in the operator’s cab. 1) Check that the starting switch is in the OFF position. 2) Check the green LED of the ORBCOMM controller and confirm that the controller is in operation. fl Power is constantly supplied to the ORBCOMM controller. Accordingly, if the green LED is lighting up while the starting switch is turned OFF, the controller is operating normally.
WA1200-3
VHMS CONTROLLER
3. Connection of personal computer fl This step is a work performed in the operator’s cab. 1) Check that the starting switch is in the OFF position. ¤ Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Q3 and the download connector DL1 by wiring harness Q2. fl Connect the personal computer to the RS232C terminal.
20-165 (8)
TESTING AND ADJUSTING
4. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. fl Power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
VHMS CONTROLLER
5. Startup of VHMS setting tool 1) Turn the personal computer ON and start the OS. 2) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool.
3) Press the Next button. 4) Input the 10-digit service ID to [Service ID]. fl Service ID: Part No. of VHMS controller • Input 0 to the position at the right end. fl The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 5) Select [Data clear and Set up] in the [Select Function] box. 6) Press the [OK] button to go to the Set up screen.
20-166 (8)
WA1200-3
TESTING AND ADJUSTING
6. Setup of VHMS controller [Machine information] 1) The [Machine information] tab is displayed first in the [Data clear and Set up] menu, and the screen data are read automatically. 2) The default initial screen appears. (Initial screen set at the delivery time) 3) Check all the data.
4) If the information in the [Date/Time] box is not correct, change it according to the following procedure: i) Press the [Edit] button (1) in the [Date/Time] box to display the correction screen. ii) The pull-down menu appears in the [TimeZone] box. Press the [▼] button to scroll the screen and select the correct information.
WA1200-3
VHMS CONTROLLER
iii) Check the current time. If it is wrong, correct it. • Input the correct time directly in the corresponding box. iv) Correct the information and press the [OK] button.
5) If the information in the [Machine information] box is not correct, change it according to the following procedure: i) Press the [Edit] button (2) in the [Machine information] box to display the correction screen. ii) When changing the variation code, press the [▼] button in the pull-down menu to select the code to be changed. • STD: Standard boom • HL: High lift boom • EHL: Extra high lift boom iii) When changing the Serial No., Engine Serial No. 1, or Engine Serial No. 2, input the correct No. directly in the corresponding box. • Engine Serial No. 1: Engine serial No. • Engine Serial No. 2: Transmission serial No. iv) Correct the information and press the [OK] button.
20-167 (8)
TESTING AND ADJUSTING
6) If the information in the [SMR] box is not correct, change it according to the following procedure: i) Press the [Alt] and [S] buttons to display the correction screen. (Press both keys simultaneously.) ii) Input the correct information directly and press the [OK] button. (You can input the value to the 1st decimal place.) iii) The confirmation screen appears again. Press the [Y] button.
7) After checking and changing all the data of [Machine information], press [Apply] button (3) to settle the setting. fl If [Apply] button (3) is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
20-168 (8)
VHMS CONTROLLER
8) After checking and changing all the data of [Machine information], press [Exit] button (4) to finish [VHMS Setting Tool]. 7. Check of saving operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is turned OFF. fl When the starting switch is turned OFF, the VHMS controller records and updates the data. fl The power is still held for several seconds to save the data after the starting switch is turned OFF. Accordingly, check that the 7-segment LED of the controller is turned OFF. 8. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. fl Power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
WA1200-3
TESTING AND ADJUSTING
9. Startup of VHMS setting tool 1) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool. 2) Input the 10-digit service ID to [Service ID]. fl Service ID: Part No. of VHMS controller • Input 0 to the position at the right end. fl The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 3) Select [Set up] in the [Select Function] box. 4) Press the [OK] button to go to the Set up screen.
VHMS CONTROLLER
10. Setting of PLM data 1) Open the [PLM] tab and go to the setting screen. In the default mode (which was set when delivered), collection of the data is started at 0:00 AM to collect the data of 1 day. 2) Press the [Edit] button (5) to go to the screen for setting the collection start time and collection unit (day).
3) Select an item to be changed (Start time or Interval) and set it with (▲▼) buttons (6). You may input a value directly.
4) Press [OK] button (7).
WA1200-3
20-169 (8)
TESTING AND ADJUSTING
11. Setting of ORBCOMM communication [For ORBCOMM specification only] • Open the [Communication Setting] tab. • Check all the data.
1) To change the setting of [SHORT FAULT HISTORY], follow the procedure below. i) Select [SHORT FAULT HISTORY] on the screen and press the [Edit] button (5) at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the setting and then press the [OK] button. fl When setting up, select [Occurrence] in the [Timing] box, and set the function to [ON].
20-170 (8)
VHMS CONTROLLER
2) To change setting of [SHORT TREND ANALYSIS], follow the procedures below. i) Select [SHORT TREND ANALYSIS] on the screen and press the [Edit] button (5) at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the setting and then press the [OK] button. fl When setting up, select [20h] in the [SMR] box, and set the function to [ON].
iii) The confirmation screen appears again. If the setting is correct, press the [Y] button to finish setting. iv) After checking and changing all the data, press the [Exit] button at the right bottom of the screen to turn the software OFF.
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
3) To change the setting of [Satellite Setting], follow the procedure below. i) Press the [Edit] button (6) in the [Satellite Setting] block to display the setting screen. ii) Bring GCC Code to the applicable area and then press the [OK] button.
i)
When the data are cleared, the system asks you if you will download the current data file. Since the file is not necessary for setting up, press the [No] button.
GCC codes and applicable areas Code
Applicable area
1
USA
120
Italy
121
Malaysia
122
Korea
123
Brazil
130
Japan
ii) Check that OK is displayed at the left end and confirm that setting is finished normally, and then press the [Close] button.
4) After checking and changing all the data in [Communication Setting], press the [Apply] button (7) to settle the setting. fl If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
WA1200-3
20-171 (8)
TESTING AND ADJUSTING
iii) Press the [Apply] button. • Only the changed data are displayed. Check them and press [OK] button (9).
VHMS CONTROLLER
12. Check of saving operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is turned OFF. fl When the starting switch is turned OFF, the VHMS controller records and updates the data. fl The power is still held for several seconds to save the data after the starting switch is turned OFF. Accordingly, check that the 7-segment LED of the controller is turned OFF.
iv) The OK screen appears. Press [Close] button (10), and then press the [Exit] button to finish the VHMS Setting Tool and turn the starting switch OFF.
20-172 (8)
WA1200-3
TESTING AND ADJUSTING
13. Procedures for executing Quick Pm 1) Run the engine at low idling. 2) Set the safety lock lever in the FREE position. 3) Set the machine control monitor (CGC) to display the service menu selection screen. fl See “Functions and operations of machine control monitor (CGC)”. 4) Select [Snap shot].
VHMS CONTROLLER
6) Operate the switches and levers at each execution time according to the “Operating procedure for quick PM clinic” shown on the following parts. fl The execution times are displayed on the machine control monitor (CGC). ¤ Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the vehicle extremely during the work.
5) Continue the operation on the screen to start the snap shot. fl While the following screen is displayed, press the [START] button, and the check message is displayed. fl Before starting the snap shot, fully understand the operating procedure for the snap shot. • See STRUCTURE AND FUNCTION, CGC monitor.
WA1200-3
20-173 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
OPERATING PROCEDURE FOR QUICK PM CLINIC 1. 800 rpm Operating condition and order
Engine
Transmission shift switch (minute) Operating time (minute)
3. 2. Engine at Engine at low idling full throttle, bucket circuit relieved in tilt-back position
N
N
4. Engine at full throttle, steering circuit relieved
5. Engine at high idling
N
N
N
6. 7. Engine at Engine at full throt- low idling tle, torque converter circuit relieved F3
8. Engine at high idling
N
9. 10. Engine at Engine at full throt- low idling tle and stalled fully
N
F3
N
0.0
0.5
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
–5.5
–5.0
–2.0
–1.5
–1.0
–0.5
0.0
0.5
1.0
1.5
2.0
Snap shot trigger (Press START button) Only when personal computer is used 1-1 Engine speed
1/4
1-2 Engine oil pressure
1/4
1/4
1/4
1/4
1/4
fl
1/4
1-3 Blow-by pressure
2/4
1-4 Boost pressure
2/4
1-5 Atmospheric temperature
1/4
fl
2/4
2-1 Torque converter inlet pressure
3/4
2-2 Torque converter outlet pressure
3/4
3-1 Transmission main relief pressure
3/4
3-2 Transmission lubricating oil pressure
3/4
3-3 Transmission MOD oil pressure
3/4
4/4
4-1 Steering relief pressure 5-3 Brake charge cut-in (*1)
4/4
5-4 Brake charge cut-out (*1)
4/4
6-1 Work equipment relief pressure
4/4
6-2 PPC oil pressure
4/4
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is running at low idling, press the brake pedal at least 10 times to lower the brake accumulator circuit pressure to below the cut-in pressure. ¤ The error of the operating condition changing time must be ±5 seconds. 1/4 fl Value: Page No. of PM clinic on CGC fl: When a personal computer is not used, read each value.
20-174 (8)
WA1200-3
TESTING AND ADJUSTING
14. Downloading of set data 1) Set the starting switch to the ON position. 2) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. fl Input [User Name] and [Password]. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. fl Make sure that the downloading has completed before proceeding to the next step.
WA1200-3
VHMS CONTROLLER
15. Check of Downloaded Data fl This step is a work performed in the operator’s cab (on the personal computer). 1) Check the set data with the [View] function. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. fl Make sure that the [MFA0] code at the time when the snapshot was executed is displayed in [Fault History]. fl Make sure that the snap shot data have been recorded.
2) After checking the set data, turn the [VHMS Analysis Tool] OFF.
20-175 (8)
TESTING AND ADJUSTING
16. Disconnection of personal computer 1) Make sure that the starting switch is in the OFF position. ¤ Be sure to turn the starting switch OFF before connecting or disconnecting the personal computer. 2) Turn the OS of the personal computer OFF and switch off the personal computer. 3) Disconnect wiring harness Q2 from download connectors DL1.
VHMS CONTROLLER
17. Communication to Komatsu After completing steps 1 to 16 successfully, please send the check sheet and the VHMS data to VHMS/WebCARE Support Center of Komatsu, Tokyo. fl Since Komatsu has to arrange the setting for satellite communication on the receiving side, be sure to inform Komatsu of the completion of the setting. fl There are 2 types of the check sheets, 1 for the VHMS and the other for the ORBCOMM (optional). Send them by fax. fl Send the VHMS data by Notes (LAN) or E-mail (WAN). Contact VHMS/WebCARE Support Center by Phone: 03-5561-2765 (Country No.: 81) Fax: 03-5561-4766 (Country No.: 81) E-mail: [email protected]
20-176 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
To: VHMS/WebCARE Support Team (in KOMATSU, Tokyo)
Date of setting: Date of fax: DB/Branch name: Filled by:
VHMS Setup Work Check Sheet (For WA1200-3) Setting step
Check item
Result
Model name Serial No. 1
Check of machine information, engine information, and controller information
Current service meter reading (by 0.1 h) Engine serial No. Transmission serial No. VHMS controller serial No. ORBCOMM controller serial No.
2
Check of operation of ORBCOMM controller (For only ORBCOMM specification)
Is green LED lighting?
yes
no
3
Connection of personal computer
Is connection made securely?
yes
no
4
Check of operation of VHMS controller
Is 7-segment LED operating normally?
yes
no
5
Starting of VHMS setting tool
Is setting tool set in “Data clear and set up”?
yes
no
Is Date (mm/dd/yyyy) set? Date/Time [Local Time] 6
Setting up of VHMS controller
Is Time set? Is time zone set?
h
GMT+
Is DST (Summer Time) set? SMR
Is SMR (h) set? Is Variation code set?
Machine information
Is engine serial No. set?
Code Serial No.
Is transmission serial No. set?
Serial No.
7
Check of saving operation of VHMS controller
Were Apply button and Exit button pressed in order?
yes
no
Turn starting switch OFF → Wait for 3 min → Turn starting switch ON
yes
no
8
Check of operation of VHMS controller
Is 7-segment LED operating normally?
yes
no
9
Starting of VHMS setting tool
Is setting tool set in [Set up]?
yes
no
10
Setting of PLM data
Setting of PLM
Is PLM Start Time set?
Short Fault History
Is Send set?
ON
OFF
Short Trend Analysis
Is Send set?
ON
OFF
Short Load Meter
Is Send set?
ON
OFF
GCC
Is GCC set?
11
Setting of ORBCOMM communication [For only ORBCOMM specification]
Is Interval (day) set?
Is Number (Default: 10) set? Is Interval (Default: 180) set? Is SMR set?
12
Check of saving operation of VHMS controller
Were Apply button and Exit button pressed in order?
yes
no
Turn starting switch OFF → Wait for 3 min → Turn starting switch ON
yes
no
13
Execution of quick Pm clinic
Was snap shot operated according to correct procedure?
yes
no
14
Downloading of VHMS data
Is downloading completed?
yes
no
Are all files downloaded?
yes
no
Is there [MFAO] error code in fault 0.csv?
yes
no
Is there snap shot file?
yes
no
Is personal computer disconnected normally?
yes
no
Was check sheet sent by fax?
yes
no
Was downloading sent by E-mail?
yes
no
15
Check of downloaded data
16
Disconnection of personal computer
17
Communication to KOMATSU
When was download time (by wristwatch)?
Where to make contact: VHMS/WebCARE Support Team (in KOMATSU, Tokyo) • PHONE: 03-5561-2765 (Country No: 81) • FAX: 03-5561-4766 (Country No: 81) • E-mail: [email protected]
WA1200-3
20-177 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
SETTING PROCEDURE FOR REPLACED VHMS CONTROLLER fl Setting tools for replaced VHMS controller Symbol
Part No.
Part name
1
799-608-3211
VHMS analysis tool
2
799-608-3220
Wiring harness
3
Commercially Notebook personal computer available (OS: Windows98/2000)
Q
fl When the VHMS controller needs to be replaced, set it before removing it and set the newly installed VHMS controller according to the following procedure. fl Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the setup procedure. fl For the method of installing the VHMS Setup Program to the personal computer, refer to the Operation Manual contained in the package of VHMS analysis tool Q1. fl When using the VHMS controller for the first time or after replacing it, set it up with a personal computer. • The contents of the VHMS controller can be changed with the service menu of the machine control monitor (CGC), too. fl The setup procedure covers both “ORBCOMM Specification” and “ORBCOMMLESS Specification”. In case of “ORBCOMMLESS” Specification”, omit the procedures necessary for “ORBCOMM Specification” only. fl During the setup work, make necessary confirmations for each work according to the “Setting Work Checklist for replaced VHMS”.
20-178 (8)
Work before replacing VHMS controller fl Perform steps 1 - 4 on the currently installed VHMS controller. 1. Connection of personal computer fl This step is a work performed in the operator’s cab. 1) Check that the starting switch is in the OFF position. ¤ Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Q3 and the download connector DL1 by wiring harness Q2. fl Connect the personal computer to the RS232C terminal.
WA1200-3
TESTING AND ADJUSTING
2. Check of operation of VHMS controller fl This step is a work performed in the operator’s cab. 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. fl The switch power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
VHMS CONTROLLER
3. Downloading of set data fl This step is a work performed in the operator’s cab (on the personal computer). 1) Set the starting switch to the ON position. 2) Turn the personal computer ON and start the OS. 3) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. fl Input [User Name] and [Password]. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
4) Use the [Download] function to download the data currently recorded in the VHMS controller to the personal computer. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. fl Make sure that the downloading has completed before proceeding to the next step.
5) Turn the VHMS analysis tool OFF.
WA1200-3
20-179 (8)
TESTING AND ADJUSTING
4. Check of set information fl This step is a work performed in the operator’s cab (on the personal computer). fl Check the setting of [Communication Setting] for only [ORBCOMM specification]. 1) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool. 2) Input the 10-digit service ID to [Service ID]. fl Service ID: Part No. of VHMS controller • Input 0 to the position at the right end. fl The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 3) Select [Set up] in the [Select Function] box. 4) Press the [OK] button to go to the Set up screen.
VHMS CONTROLLER
5) Open the [Machine Information] tab and check and record all the information. fl The [Machine information] tab is displayed first in the [Set up] menu.
6) Open the [Communication Setting] tab and check and record all information.
7) After checking and recording all the information, press [Exit] button (1) at the right bottom of the screen to turn the [VHMS Setting Tool] OFF. 8) Turn the OS of the personal computer OFF and switch off the personal computer. 9) Set the starting switch in the OFF position. ¤ When the VHMS controller is replaced, the personal computer may be kept connected. Be sure to turn the personal computer and starting switch OFF, however.
20-180 (8)
WA1200-3
TESTING AND ADJUSTING
Work after replacing VHMS controller fl Perform steps 5 – 17 on the newly installed VHMS controller. 5. Check of operation of ORBCOMM controller [For only ORBCOMM specification] 1) Check that the starting switch is in the OFF position. 2) Check the green LED of the ORBCOMM controller and confirm that the controller is in operation. fl Power is constantly supplied to the ORBCOMM controller. Accordingly, if the green LED is lighting up while the starting switch is turned OFF, the controller is operating normally.
WA1200-3
VHMS CONTROLLER
6. Check of connection of personal computer fl If the personal computer has been disconnected during the above work, connect it again, referring to “1. Connection of personal computer”. 1) Check that the starting switch is in the OFF position. ¤ Be sure to check the connection of the personal computer while starting switch is in the OFF position. 2) Check that the personal computer and download connector DL1 are connected securely by wiring harness Q2.
20-181 (8)
TESTING AND ADJUSTING
7. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. fl The switch power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
20-182 (8)
VHMS CONTROLLER
8. Startup of VHMS setting tool fl This step is a work performed in the operator’s cab (on the personal computer). 1) Turn the personal computer ON and start the OS. 2) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool. 3) Input the 10-digit service ID to [Service ID]. fl Service ID: Part No. of VHMS controller • Input 0 to the position at the right end. fl The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 4) Select [Data clear and Set up] in the [Select Function] box. 5) Press the [OK] button to go to the setting screen.
WA1200-3
TESTING AND ADJUSTING
9. Re-setting of VHMS controller fl This step is a work performed in the operator’s cab (on the personal computer). [Machine Information] 1) Open the [Machine Information] tab. fl The [Machine Information] tab is displayed first in the [Data clear and Set up] menu. 2) Change all the data to the latest data or the data recorded before the replacement.
3) Collect the [Date/Time] information, if necessary, according to the following procedure. fl Set the [Date/Time] data, except the [Time Zone], to the accurate data at the time of correction. i) Press the [Edit] button at the right lower part of the [Date/Time] box to display the correction screen. ii) Correct the information and press the [OK] button.
WA1200-3
VHMS CONTROLLER
4) Collect the [SMR] information, if necessary, according to the following procedure. fl Press the [Alt] and [S] buttons to display the correction screen. (Press both keys simultaneously.) fl Be sure to set the service meter to the value recorded before the replacement + 0.1 h. fl If the service meter is set wrongly, the data on the WebCARE database cannot be controlled. Accordingly, set it accurately. Delete the value in the [SMR(h)] box and input a new value.
5) Collect the [Machine Information] information, if necessary, according to the following procedure. i) Press the [Edit] button at the right lower part of the [Machine Information] box to display the correction screen. ii) Change the current information to the information recorded before the replacement and press the [OK] button.
20-183 (8)
TESTING AND ADJUSTING
6) After checking and changing all the data in [Machine Information], press [Apply] button to settle the setting. fl If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
VHMS CONTROLLER
10. Check of saving operation of VHMS controller • Turn the starting switch OFF and wait for 3 minutes, and then turn the starting switch ON again. 11. Startup of VHMS setting tool 1) Click the icon of [Setting Tool] on the personal computer screen to start the VHMS setting tool. 2) Input the 10-digit service ID to [Service ID]. fl Service ID: Part No. of VHMS controller • Input 0 to the position at the right end. 3) Select [Set up] in the [Select Function] box. 4) Press the [OK] button to go to the setting screen.
7) Press the [Exit] button to finish [VHMS Setting Tool].
20-184 (8)
WA1200-3
TESTING AND ADJUSTING
12. Setting of payload meter (PLM) 1) Open the [PLM] tab and go to the setting screen. • Change all the data to the data recorded before the replacement. 2) Press [Edit] button (5) to go to the screen for setting the collection start time and collection unit (day).
3) Select an item to be changed (Start time or Interval) and set it with (▲▼) buttons (6). • You may input a value directly.
VHMS CONTROLLER
13. Setting of ORBCOMM communication [For ORBCOMM specification only] 1) Open the [Communication Setting] tab. 2) Change all the data to the data recorded before the replacement.
3) To change the setting of [SHORT FAULT HISTORY], follow the procedure below. i) Select [SHORT FAULT HISTORY] on the screen and press [Edit] button (5) at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the current setting to the setting recorded before the replacement and then press the [OK] button.
4) Press [OK] button (7).
WA1200-3
20-185 (8)
TESTING AND ADJUSTING
4) To change setting of [SHORT TREND ANALYSIS], follow the procedures below. i) Select [SHORT TREND ANALYSIS] on the screen and press the [Edit] button at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the current setting to the setting recorded before the replacement and then press the [OK] button.
5) After checking and changing all the data in [Communication Setting], press [Apply] button (7) to settle the setting. fl If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
VHMS CONTROLLER
14. Check of saving operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is turned OFF. fl When the starting switch is turned OFF, the VHMS controller records and updates the data. fl The power is still held for several seconds to save the data after the starting switch is turned OFF. Accordingly, check that the 7-segment LED of the controller is turned OFF. 15. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. fl The switch power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
6) Press the [Exit] button to finish [VHMS Setting Tool].
20-186 (8)
WA1200-3
TESTING AND ADJUSTING
16. Procedures for executing Quick PM-clinic 1) Run the engine at low idling. 2) Set the safety lock lever in the FREE position. 3) Set the machine control monitor (CGC) to display the service menu selection screen. fl See “Functions and operations of machine control monitor (CGC)”. 4) Select [Snap shot].
VHMS CONTROLLER
6) Operate the switches and levers at each execution time according to the “Operating procedure for quick PM clinic” shown on the following parts. fl The execution times are displayed on the machine control monitor (CGC). ¤ Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the vehicle extremely during the work.
5) Continue the operation on the screen to start the snap shot. fl While the following screen is displayed, press the [START] button, and the check message is displayed. fl Before starting the snap shot, fully understand the operating procedure for the snap shot.
WA1200-3
20-187 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
OPERATING PROCEDURE FOR QUICK PM CLINIC 1. 800 rpm Operating condition and order
Engine
Transmission shift switch (minute) Operating time (minute)
3. 2. Engine at Engine at low idling full throttle, bucket circuit relieved in tilt-back position
N
N
4. Engine at full throttle, steering circuit relieved
5. Engine at high idling
N
N
N
6. 7. Engine at Engine at full throt- low idling tle, torque converter circuit relieved F3
8. Engine at high idling
N
9. 10. Engine at Engine at full throt- low idling tle and stalled fully
N
F3
N
0.0
0.5
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
–5.5
–5.0
–2.0
–1.5
–1.0
–0.5
0.0
0.5
1.0
1.5
2.0
Snap shot trigger (Press START button) Only when personal computer is used 1-1 Engine speed
1/4
1-2 Engine oil pressure
1/4
1/4
1/4
1/4
fl
1/4
1-3 Blow-by pressure
2/4
1-4 Boost pressure
2/4
1-5 Atmospheric temperature
1/4
1/4
fl
2/4
2-1 Torque converter inlet pressure
3/4
2-2 Torque converter outlet pressure
3/4
3-1 Transmission main relief pressure
3/4
3-2 Transmission lubricating oil pressure
3/4
3-3 Transmission MOD oil pressure
3/4
4/4
4-1 Steering relief pressure 5-3 Brake charge cut-in (*1)
4/4
5-4 Brake charge cut-out (*1)
4/4
6-1 Work equipment relief pressure
4/4
6-2 PPC oil pressure
4/4
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is running at low idling, press the brake pedal at least 10 times to lower the brake accumulator circuit pressure to below the cut-in pressure. ¤ The error of the operating condition changing time must be ±5 seconds. 1/4 fl Value: Page No. of PM clinic on CGC fl: When a personal computer is not used, read each value.
20-188 (8)
WA1200-3
TESTING AND ADJUSTING
17. Downloading of set data 1) Set the starting switch to the ON position. 2) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. fl Input [User Name] and [Password]. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. fl Make sure that the downloading has completed before proceeding to the next step.
WA1200-3
VHMS CONTROLLER
18. Check of Downloaded Data fl This step is a work performed in the operator’s cab (on the personal computer). 1) Check the set data with the [View] function. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. fl Make sure that the [MFA0] code at the time when the snapshot was executed is displayed in [Fault History]. fl Make sure that the snap shot data have been recorded.
2) After checking the set data, turn the [VHMS Analysis Tool] OFF.
20-189 (8)
TESTING AND ADJUSTING
19. Disconnection of personal computer 1) Make sure that the starting switch is in the OFF position. ¤ Be sure to turn the starting switch OFF before connecting or disconnecting the personal computer. 2) Turn the OS of the personal computer OFF and switch off the personal computer. 3) Disconnect wiring harness Q2 from download connectors DL1.
VHMS CONTROLLER
20. Communication to Komatsu After completing steps 1 to 15 successfully, please send the check sheet and the VHMS data to VHMS/WebCARE Support Center of Komatsu, Tokyo. fl There are 2 types of the check sheets, 1 for the VHMS and the other for the ORBCOMM (optional). Send them by fax. fl Send the VHMS data (before and after the replacement) by Notes (LAN) or Email (WAN). Contact VHMS/WebCARE Support Center by Phone: 03-5561-2765 (Country No.: 81) Fax: 03-5561-4766 (Country No.: 81) E-mail: [email protected]
20-190 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
To: VHMS/WebCARE Support Team (in KOMATSU, Tokyo)
Check Sheet for setting replaced VHMS (For WA1200-3)
Date of setting: Date of fax: DB/Branch name: Filled by: Check item
Setting step
Result
1. Connection of personal computer
Is connection made securely?
yes
no
2. Check of operation of VHMS controller
Is 7-segment LED operating normally?
yes
no
3. Downloading of VHMS data
Is downloading completed?
yes
no
4. Check of set information Date/Time [Local Time]
Date(mm/dd/yyyy) Time Time zone DST(Summer Time)
GMT+
SMR
Machine
Engine Short Fault History Short Trend Analysis Short Load Meter PLM
Product Type Machine Model Type Variation code Serial No. Engine Model Serial No.1 Serial No.2 Send Number Send Interval Send SMR Start time Interval
ON
OFF
ON
OFF
ON
OFF
Repacemant of VHMS
Is starting switch turned OFF?
yes
no
5. Check of operation of ORBCOMM controller (For only ORBCOMM specification)
Is green LED lighting?
yes yes
no no
6. Check of connection of personal computer
Is connection made securely?
yes
no
7. Check of operation of VHMS controller
Is 7-segment LED operating normally?
yes
no
8. Start of VHMS setting tool
Is setting tool set in [Set up]?
yes
no
9. Re-setting of VHMS controller
Date/Time [Local Time] SMR Machine Engine
yes yes yes yes
no no no no
10. Writing of set data
Were Apply button and Exit button pressed in order? Turn starting switch OFF → Wait for 3 min → Turn starting switch ON
yes yes
no no
11. Start of VHMS setting tool
Is setting tool set in [Set up]?
yes
no
12. Setting of PLM data
Setting of PLM
Is setting matched to record before replacement?
yes
no
13. Setting of ORBCOMM communication [For only ORBCOMM specification]
Short Fault History Short Trend Analysis Short Load Meter GCC
Is setting matched to record before replacement? Is setting matched to record before replacement? Is setting matched to record before replacement? Is setting matched to record before replacement?
yes yes yes yes
no no no no
14. Check of saving operation of VHMS controller
Were Apply button and Exit button pressed in order? Turn starting switch OFF → Wait for 3 min → Turn starting switch ON
yes yes
no no
15. Check of operation of VHMS controller
Is 7-segment LED operating normally?
yes
no
16. Execution of quick Pm clinic
Was snap shot operated according to correct procedure?
yes
no
17. Downloading of VHMS data
Is downloading completed?
yes
no
18. Check of downloaded data
Are all files downloaded? When was download time (by wristwatch)? Is there [MFAO] error code in fault 0.csv? Is there snap shot file?
yes yes yes yes
no no no no
19. Disconnection of personal computer
Is personal computer disconnected normally?
yes
no
20. Communication to KOMATSU
Was check sheet sent by fax? Was downloading sent by E-mail?
yes yes
no no
Is setting matched to record before replacement? Is 0.1 h added to record before replacement for new setting? Is setting matched to record before replacement? Is setting matched to record before replacement?
Where to make contact: VHMS/WebCARE Support Team (in KOMATSU, Tokyo) • PHONE: 03-5561-2765 (Country No: 81) • FAX: 03-5561-4766 (Country No: 81) • E-mail: [email protected]
WA1200-3
20-191 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
OUTLINE OF MEASUREMENT PROCEDURE FOR PM CLINIC There are the following 3 types of measurement procedure for PM clinic of WA1200-3. fl Basically, apply measurement procedure 1 or 2. 1. Measurement procedure by machine control monitor (CGC) Read the data on the PM clinic screen with “PM clinic function” (1) of the machine control monitor (CGC).
2. Measurement procedure by stopwatch, scale, etc. Measure each data with a stopwatch, scale, etc.
3. Measurement procedure by downloading data in VHMS controller Connect a personal computer to the VHMS controller and execute the quick PM clinic with the machine control monitor (CGC), and then download the PM clinic data to the personal computer. fl The following tools are necessary to this measurement procedure. Symbol
Q
Part No.
Part name
1
799-608-3211
VHMS analysis tool
2
799-608-3220
Wiring harness
3
Commercially available
Notebook personal computer (OS: Windows98/2000)
21T-06-64590
Coupling assembly (Attached tool)
21T-06-64392
Wiring harness (Attached tool)
4
20-192 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
PREPARATION FOR MEASUREMENT FOR PM CLINIC ¤ Stop
the vehicle on level ground and lock the tires with chocks for safety.
1. Check safety around the vehicle and start the engine. 2. Set the machine control monitor (CGC) to display the service menu selection screen, and then select the “PM clinic” menu and display “PM clinic (1/4, 4/4)” screen. fl For the operating method, see STRUCTURE AND FUNCTION, CGC monitor. 3. Warm up the engine to increase the engine coolant temperature and hydraulic oil temperature. • Engine coolant temperature: Min. 40°C • Hydraulic oil temperature: Min. 40°C 4. Lower the work equipment to the ground and stop the engine.
WA1200-3
20-193 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
MEASUREMENT PROCEDURE BY CGC MONITOR 1. Start of engine 1) Check that the CGC monitor is not displaying the abnormality screen. 2) Prepare the PM clinic sheet. Check safety around the vehicle, sound the horn, and start the engine. 3) Turn the steering lock switch in the OFF position. 4) Set the safety lock lever in the FREE position. 2. Check of indication of engine coolant temperature gauge and torque converter oil temperature gauge 1) Set the CGC monitor to display the monitor screen. 2) Check the indication of the engine coolant temperature gauge and torque converter oil temperature gauge.
3. Change of display of machine control monitor (CGC) Set the CGC monitor to display the service menu and select the “PM clinic” menu. fl For the operating method, see STRUCTURE AND FUNCTION, CGC monitor.
4. Measuring with “PM clinic (1/4)” 1) Display “PM clinic (1/4)”. 2) Measure the engine speed, engine oil pressure, engine oil temperature, and engine coolant temperature. fl For the measurement conditions, see the check sheet.
20-194 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
5. Measuring with “PM clinic (2/4)” 1) Display “PM clinic (2/4)”. 2) Measure the engine speed, blow-by pressure, boost pressure, exhaust temperature, atmospheric temperature, and fuel rail pressure. fl For the measurement conditions, see the check sheet.
6. Measuring with “PM clinic (3/4)” 1) Display “PM clinic (3/4)”. 2) Measure the torque converter oil temperature, torque converter inlet pressure, torque converter outlet pressure, transmission main pressure, transmission lubricating oil pressure, and transmission modulation pressure. fl For the measurement conditions, see the check sheet.
7. Measuring with “PM clinic (4/4)” 1) Display “PM clinic (4/4)”. 2) Measure the hydraulic oil temperature, PPC oil pressure, hydraulic oil pressure, steering pump oil pressure, front brake oil pressure, and rear brake oil pressure. fl For the measurement conditions, see the check sheet.
8. Measuring work equipment speed and hydraulic drift Using a stopwatch, scale, etc., measure the work equipment speed and hydraulic drift.
WA1200-3
20-195 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
MEASUREMENT PROCEDURE BY DOWNLOADING DATA IN VHMS CONTROLLER 1. Connection of personal computer 1) Check that the starting switch is in the OFF position. ¤ Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Q3 and the download connector DL1 by wiring harness Q2. fl Connect the personal computer to the RS232C terminal. 2. Start of engine 1) Check that the CGC monitor is not displaying the abnormality screen. 2) Prepare the PM clinic sheet. Check safety around the vehicle, sound the horn, and start the engine. 3) Turn the steering lock switch in the OFF position. 4) Set the safety lock lever in the FREE position.
3. Change of display of machine control monitor (CGC) 1) Set the CGC monitor to display the service menu selection screen. fl See STRUCTURE AND FUNCTION, CGC monitor. 2) Select “Snap shot”.
4. Execution of snap shot 1) Continue the operation on the screen to start the snap shot. fl While the following screen is displayed, press the [START] button, and the check message is displayed. fl Before starting the snap shot, fully understand the operating procedure for the snap shot.
20-196 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
2) Operate the switches and levers at each execution time according to the “Operating procedure for quick PM clinic” shown on the following parts. fl The execution times are displayed on the CGC monitor. ¤ Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the vehicle extremely during the work.
WA1200-3
20-197 (8)
TESTING AND ADJUSTING
VHMS CONTROLLER
OPERATING PROCEDURE FOR QUICK PM CLINIC 1. 800 rpm Operating condition and order
Engine
Transmission shift switch (minute) Operating time (minute)
3. 2. Engine at Engine at low idling full throttle, bucket circuit relieved in tilt-back position
N
N
4. Engine at full throttle, steering circuit relieved
5. Engine at high idling
N
N
N
6. 7. Engine at Engine at full throt- low idling tle, torque converter circuit relieved F3
8. Engine at high idling
N
9. 10. Engine at Engine at full throt- low idling tle and stalled fully
N
F3
N
0.0
0.5
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
–5.5
–5.0
–2.0
–1.5
–1.0
–0.5
0.0
0.5
1.0
1.5
2.0
Snap shot trigger (Press START button) Only when personal computer is used 1-1 Engine speed
1/4
1-2 Engine oil pressure
1/4
1/4
1/4
1/4
fl
1/4
1-3 Blow-by pressure
2/4
1-4 Boost pressure
2/4
1-5 Atmospheric temperature
1/4
1/4
fl
2/4
2-1 Torque converter inlet pressure
3/4
2-2 Torque converter outlet pressure
3/4
3-1 Transmission main relief pressure
3/4
3-2 Transmission lubricating oil pressure
3/4
3-3 Transmission MOD oil pressure
3/4
4/4
4-1 Steering relief pressure 5-3 Brake charge cut-in (*1)
4/4
5-4 Brake charge cut-out (*1)
4/4
6-1 Work equipment relief pressure
4/4
6-2 PPC oil pressure
4/4
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is running at low idling, press the brake pedal at least 10 times to lower the brake accumulator circuit pressure to below the cut-in pressure. ¤ The error of the operating condition changing time must be ±5 seconds. 1/4 fl Value: Page No. of PM clinic on CGC fl: When a personal computer is not used, read each value.
20-198 (8)
WA1200-3
TESTING AND ADJUSTING
VHMS CONTROLLER
5. Downloading of snap shot data 1) Turn the personal computer ON and start the OS. 2) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. fl Input [User Name] and [Password]. fl For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. fl For the operation procedures and method of analyzing the data, refer to the Operation Manual for VHMS Analysis Tool.
WA1200-3
20-199 (8)
Pm clinic check sheet WA1200-3 Basic information User name
Date of delivery
Address
Year: Month: Day:
User No.
Chassis serial No.
Engine serial No.
Specifications Tire, front/rear 55.5/80-57-68PR(L5) 65 /65-57-62PR(L5)
Bucket m3 (cu.yd) 20.9 (25.9)
Type of work Construction Construction, civil engineering Road Others
Quarry, mining Coal Gold Limestone Others
Type of soil Specific gravity
t/m3
Rock Soft Ordinary Hard
Gravel Sand Clay Coal
Contents of work V-shape loading Cross drive loading Load and carry
Remarks
Specified operating time Shifts/day
Hours/shift hours Distributor/Dealer name
20-199-1 (8)
WA1200-3
Pm clinic service
WA1200-3 (CUMMINS) QSK60
hour inspection Work direction No.
Date of execution
Chassis serial No. Engine serial No.
Service meter
Inspector
Interview with operator and walk-around inspection
Accepted Rejected
Is there any abnormality before starting inspection?
Max. level of coolant temperature Blue Red
Max. torque converter oil temperature Blue Red
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
(During work)
(During work)
1–1 Engine speed
Engine
1
Condition
Unit
Engine: Low idling Engine: Full throttle rpm
m
Standard value of new machine
Service limit value
600 – 700
575 – 725
Measurement result
Accepted Rejected
1850 – 2050 1750 – 2150 1890 – 2090 1790 – 2150 1545 – 1945 1445 – 2045 Max. 3.29 {Max. 330}
0.34 – 0.48 {3.5 – 4.9}
Min. 0.34 {Min. 3.5}
Min. 0.71 {Min. 1.76}
Min. 0.137 {Min. 1.4}
Torque converter: Stalled
150.5 – 180.5 kPa {mmHg} {1180 – 1406}
Min. 130 {Min. 1000}
Engine: Full throttle Torque converter oil temperature: 60 – 80 °C Transmission: Neutral
MPa {kg/cm2}
0.95 – 1.15 {9.7 – 11.7}
0.95 – 1.15 {9.7 – 11.7}
0.78 – 0.98 {8.0 – 10.0}
0.78 – 0.98 {8.0 – 10.0}
MPa {kg/cm2}
1–4 Boost pressure
T/C
Max. 1.25 {Max. 127}
1–3 Torque converter: Stalled Engine lubricating oil pressure Engine speed: 800 rpm (SAE15W-40)
2–1 Torque converter inlet pressure 2–2 Torque converter outlet pressure
3
3–1 Main relief pressure
Transmission
°C
Altitude
Full stalled kPa {mmAq}
3–2 Lubricating oil pressure
Min.
Hydraulic equipment: Stalled
Torque converter: Stalled
2
°C
2000 – 2100 1950 – 2150
Torque converter: Stalled
1–2 Blow-by pressure
Max.
After starting engine
Inspection item Item
Ambient temperature
2.45 – 2.84 2.45 – 2.84 {25.0 – 29.0} {25.0 – 29.0} Directional switch: Neutral
3–3 Modulated clutch oil pressure Directional switch: 3–4 1st clutch Neutral modulating pressure Gear speed: 1st Directional switch: 3–5 2nd clutch Neutral modulating pressure Gear speed: 2nd Directional switch: 3–6 3rd clutch Neutral modulating pressure Gear speed: 3rd
0.05 – 0.15 {0.5 – 1.5}
0.05 – 0.15 {0.5 – 1.5}
Engine: 2.30 – 2.60 2.30 – 2.60 Full throttle {23.5 – 26.5} {23.5 – 26.5} MPa Oil 2 temperature: {kg/cm } 2.10 – 2.40 2.10 – 2.40 {21.5 – 24.5} {21.5 – 24.5} 60 – 80°C 2.30 – 2.60 2.30 – 2.60 {23.5 – 26.5} {23.5 – 26.5} 2.30 – 2.60 2.30 – 2.60 {23.5 – 26.5} {23.5 – 26.5}
1/2
WA1200-3
20-199-2 (8)
Pm clinic service Item
T/C
4 4 Steering relief pressure Steering Right lock (Left lock) wheel to operating Left lock (Right lock) time
Brake
5 5–1 Parking brake 5–2 Wheel brake
Condition Engine: Full throttle Oil temperature: 45 – 55°C Engine: Low idling
Unit
Standard value of new machine
Oil temperature:
Sec.
Engine: Full throttle 45 – 55°C
Flat ground, F3, engine at full throttle
Max. 6.5
Max. 7.5
Max. 5.6
Max. 6.5
0.0
Max. 0.7
Front left
0.0
Max. 0.7
0.0
Max. 0.7
0.0
Max. 0.7
17.6 – 18.2 {180 – 186}
17.6 – 19.1 {180 – 195}
20.6 – 22.1 {210 – 225}
20.6 – 23.5 {210 – 240}
—
—
31.1 – 32.3 {317 – 330}
31.1 – 32.3 {317 – 330}
3.72 – 4.70 {38 – 40}
3.23 – 5.19 {33 – 53}
Raise
12.0 – 13.0
Max. 14.0
Lower
4.5 – 5.5
Max. 7.0
3.4 – 4.0
Max. 5.0
2.7 – 3.3
2.7 – 3.3
mm
Rear left Charge cut-in pressure Charge cut-out pressure
Engine: Low idling MPa Oil 2 temperature: {kg/cm } 45 – 55°C
Hydraulic equipment
6 Hydraulic oil temperature
°C
6–1 Work equipment valve relief pressure
Oil temperature: 45 – 55°C Engine: Full throttle Bucket: Relieved in tilt position
6–2 PPC oil pressure
Oil temperature: 45 – 55°C Engine: Full throttle
6–3 Lift arm speed
6–4 Bucket speed
Engine: Full throttle
Accepted Rejected
Vehicle is stopped
Front right
Wear of brake disc
Measurement result
31.07 – 32.34 30.09 – 32.34 MPa {377 – 330} {kg/cm2} {317 – 330}
Rear right 5–3 Accumulator charge pressure (Front)
Service limit value
MPa {kg/cm2}
Full stroke Tilt back
Sec.
Full stroke Dump
Set lift arm and bucket in measuring positions and stop engine. Hydraulic drift
Lift arm and bucket: Horizontal
Bucket hinge pin Bucket edge
mm /15min
Max. 250
Max. 250
Max. 100
Max. 100
Final drive
Replace plug with spare. Front right final drive Visual check of final drive drain plug
Engine: Stopped
Front left final drive Rear right final drive
There must not be abnormally many metal chips.
Rear left final drive
Memo: Enter phenomena and information you noticed during today’s check.
2/2
20-199-3 (8)
WA1200-3
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES 1. Display on CGC monitor 1) Outline The VHMS controller sends various types of information via CAN (network) to the CGC monitor. The “Failure history” in that information can be displayed on the service menu selection screen. 2) Display of failure history Press failure history display button (1) in the service menu to display the “Failure history screen”. The “codes”, “contents”, “failure occurrence times”, and “failure reset times” are displayed in order from the oldest one. If a failure is not reset, its “failure set time” is not displayed. The total number of the failure histories is displayed in part (2), the failure history No. in (3), the 6digit error code in (4), the failure occurrence time in (5), failure reset time in (6), and number of times of failure occurrence in (7). 3) Function of each button i) Page selector buttons (8) and (9): • These buttons are used to turn over the currently displayed page forward or in reverse ii) UP/DOWN buttons (10) and (11): • These buttons are used to scroll the currently displayed part up or down. ii) Failure history No. button (3): • If this button is pressed, the corresponding history is not displayed any more. fl Even if the history is not displayed any more, it is still saved in the controller. iv) Service menu display button (12): • If this button is pressed, the “Service menu” screen appears.
WA1200-3
20-199-4 (8)
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
2. Display on main monitor 1) Outline Various control systems are checked and the results are displayed in the speedometer display section of the main monitor. The contents of each displayed troubleshooting result are the remedy code, error code, and elapsed time after failure are displayed. Communications between the main monitor and various controllers are made by means of serial signals through the network circuit. (Parallel signals are used specially for only the engine controller.)
Example) When error code “CALL” is displayed
2) Remedy code A remedy code notifies an abnormality directly to the operator and shows an action to take such as stopping the vehicle immediately. There are 3 types of the remedy code (displayed in part “a”), which are E00, E01 + CALL (E01 and CALL are displayed alternately), and CALL. If an emergency failure occurs, the corresponding remedy code is displayed in the speedometer display section. 3) Error code and elapsed time after failure Each failure detected by various controllers is displayed by a code. This code shows which system of which controller has a failure. Then, the operator troubleshoots the indicated controller. 4) Saving of error code Each error code is saved in the transmission controller. i) Up to “9 error codes” can be saved. ii) The following items are saved. • Error code (Part “b”) • Elapsed time after failure (Up to 1,000 hours) (Part “c”) iii) The error codes are saved in the order of time of occurrence. The same code as one that was saved before is not saved. iv) After 7 error codes are saved, if a new failure occurs, the oldest error code is deleted and the error code of the new failure is saved. fl The saved error codes and the elapsed times can be displayed by operating the setting switch of the main monitor.
20-199-5 (8)
Example) When error code “41” occurred 27 hours before
WA1200-3
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
5) Switch operation procedures and operations main monitor Switch operation
Operation of main monitor
Display of failure history mode i) Stop the engine. • ii) Turn the starting switch ON. iii) Hold switch (1) (the 2nd switch from the top on the left side) and headlamp switch (2) for 5 seconds. •
Display of next error code iv) Press headlamp switch (2).
•
•
Clearing of error code v) Hold rear lamp switch (3) for 2 seconds.
Returning from failure history display mode vi) Hold switch (1) and headlamp switch (2) for 5 seconds or start the engine.
WA1200-3
•
•
•
The error code and remedy code are displayed in the speedometer display section and the elapsed time after failure is displayed in the remedy code section. If there is not a failure, “CC” is displayed in the speedometer display section and “0000” is displayed in the remedy code display section.
The error codes and elapsed times are displayed in order (from the newest one). The failures which have not been repaired flash and those which have been repaired light up. The displayed error code and elapsed time are cleared. The error code of a failure which has not been repaired is not cleared.
The main monitor starts the normal display.
20-199-6 (8)
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
fl “Controller” is omitted from each component name.
Monitoring items table Signal name Real-time monitor Engine 1/2 Engine speed 1/2 Coolant temperature 1/2 Engine oil temperature 1/2 Fuel rail pressure 1/2 Engine oil level 2/2 Exhaust temperature table Transmission controller 1/4 Transmission direction signal F 1/4 Transmission direction signal N 1/4 Transmission direction signal R 1/4 Shift-up switch 1/4 Shift-down switch 2/4 Engine speed 2/4 Fill signal F 2/4 Fill signal R 2/4 Fill signal 1st 2/4 Fill signal 2nd 2/4 Fill signal 3rd 3/4 Engine speed 3/4 Solenoid F 3/4 Solenoid R 3/4 Solenoid 1st 3/4 Solenoid 2nd 3/4 Solenoid 3rd 4/4 Engine speed 4/4 Auto-shift signal
Unit
1rpm 1°C 1°C 1kPa (ON/OFF) 1°C
VHMS CENSE CENSE CENSE CENSE CENSE
(ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm 1mA 1mA 1mA 1mA 1mA 1rpm (ON/OFF)
T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M T/M VHMS T/M
4/4
Manual shift signal
(ON/OFF)
T/M
4/4
Transmission cut-off signal
(ON/OFF)
T/M
4/4 Kick-down switch signal Modulated clutch controller 1/6 Transmission cut-off signal 1/6 Drive force control dial signal 1/6 Travel speed control dial signal 1/6 Travel speed 1/6 Travel speed set
(ON/OFF)
T/M
(ON/OFF) 0.1V 0.1V 0.1km/h 0.1km/h
T/M MOD/C MOD/C MOD/C MOD/C VHMS MOD/C MOD/C MOD/C
2/6 2/6 2/6 2/6
Engine speed Modulation output Travel speed Modulated clutch slip rate
1rpm 1rpm 0.1km/h 1%
2/6 2/6 3/6 3/6 3/6 3/6 3/6 3/6 4/6 4/6 4/6 4/6 4/6
Modulated clutch solenoid Modulated clutch fill signal Engine speed Boom RAISE signal Boom LOWER signal Bucket TILT signal Bucket DUMP signal NC solenoid output signal Engine speed Wheel (Tire) speed Travel speed Modulated clutch solenoid Drive force
1mA (ON/OFF) 1rpm (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm 1rpm 0.1km/h 1mA 1ton
20-199-7 (8)
Component name
Remarks
Each time momentary switch is turned ON, AUTO and MANUAL are selected alternately. Value recognized by controller is displayed. Each time momentary switch is turned ON, AUTO and MANUAL are selected alternately. Value recognized by controller is displayed. Condition for cutting off: Left brake pedal is pressed while cut-off switch (main monitor) is effective.
Travel speed control dial signal converted into value in km/h
MOD/C slip rate = (MOD/C output speed)/(Engine speed x 74/58) x 100(%)
MOD/C MOD/C VHMS Work equipment Work equipment MOD/C MOD/C MOD/C VHMS MOD/C MOD/C MOD/C MOD/C
WA1200-3
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
Signal name 4/6 Tire slip signal 5/6 Boom RAISE signal 5/6 Bucket TILT signal 5/6 Fill signal F 5/6 Fill signal 1st 5/6 Tire slip signal 6/6 Engine speed 6/6 Right brake proximity switch 6/6 Acceleration signal 6/6 Engine control signal 6/6 Set/Acceleration (Idle-up) 6/6 RESUME/Deceleration (Idle-down) Remote positioner controller 1/1 Boom angle signal 1/1 Boom RAISE signal 1/1 Boom LOWER signal 1/1 Detent signal 1/1 RAISE set signal 1/1 LOWER set signal Load meter 1/1 Boom bottom pressure
Unit (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm (ON/OFF) 0.1V 0.1V (ON/OFF) (ON/OFF)
Component name Main monitor Work equipment MOD/C T/M T/M Main monitor VHMS MOD/C MOD/C MOD/C MOD/C MOD/C
0.1V (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF)
Work equipment Work equipment Work equipment Work equipment VHMS VHMS
1MPa
VHMS
1/1 Measured pressure 1/1 Calibration pressure 1/1 No-load pressure 1/1 Measured weight Joystick steering 1/2 Joystick ON/OFF signal 1/2 Steering lever potentiometer 1/2 Articulation angle 1/2 Joystick solenoid output 1/2 Steering lock 2/2 Transmission direction signal F 2/2 Transmission direction signal N 2/2 Transmission direction signal R 2/2 Steering signal output PM clinic 1/4 Engine speed 1/4 Engine oil pressure 1/4 Engine oil temperature 1/4 Engine coolant temperature 2/4 Engine speed 2/4 Blow-by pressure 2/4 Boost pressure 2/4 Exhaust temperature 2/4 Atmospheric temperature 2/4 Fuel rail pressure 3/4 Torque converter oil temperature 3/4 Torque converter inlet pressure 3/4 Torque converter outlet pressure 3/4 Torque converter main pressure 3/4 Transmission lubricating oil pressure 3/4 Transmission modulation pressure 4/4 Hydraulic oil temperature 4/4 PPC oil pressure 4/4 Hydraulic oil pressure 4/4 Steering pump pressure 4/4 Front brake pressure 4/4 Rear brake pressure
1MPa 1MPa 1MPa 1TON
VHMS VHMS VHMS VHMS
WA1200-3
(ON/OFF) 0.1V 0.1V 1mA (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm kPa °C °C rpm Pa kPa °C °C kPa °C MPa MPa MPa MPa MPa °C MPa MPa MPa MPa MPa
Work Work Work Work Work T/M T/M T/M Work
Remarks
Positioner screen switch of CGC Positioner screen switch of CGC Differential pressure = Bottom pressure – Head pressure Measured trigger pressure Calibration pressure Calibration pressure default value Measured trigger load
equipment equipment equipment equipment equipment
equipment
VHMS Quantum CENSE Quantum VHMS Quantum Quantum CENSE VHMS Quantum VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS
20-199-8 (8)
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
Table of CGC display items related to alarm 1. The check lamp output is driven with the VHMS. 2. The flashing synchronization signal of the caution lamp output of the main monitor is driven with the ON/OFF output of the VHMS. Possibility of outputting of an alarm is sent from the VHMS to the main monitor by S-NET. 3. The check lamp and caution lamp are independent from each other. (If 2 abnormalities occur, both lamps flash.) Detecting condition 1 No.
Item
Indication range
Detail of indication range
Condition for alarming Detecting Detecting condition 2 condition 3 While Abnormality Before engine is engine is detecting started running time
1
Engine oil level
Below low level
H: Abnormal L: Abnormal
2
Engine oil pressure
Below specified pressure
See CUMMINS Maintenance Manual.
3
Engine coolant temperature
Above 105°C
Above 105°C
5 6
Fuel level
–––
2
When condition at left is not satisfied
–––
fi
2
When condition at left is not satisfied
fi
10
When condition at left is not satisfied
Below specified level Below 1 segment of gauge (11%)
fi fi
–––
10
When condition at left is not satisfied
Below specified level Below 1 segment of gauge (11%)
–––
10
When condition at left is not satisfied
fi fi fi
fi fi fi fi
2
When condition at left is not satisfied
2
When condition at left is not satisfied
10
When condition at left is not satisfied
Below 150 For 60 sec after engine is started.
–––
fi
–––
When condition at left is not satisfied
Below 150 kg/cm2 At 60 sec after engine is started.
–––
fi
5
When condition at left is not satisfied
Below 150 kg/cm2 For 60 sec after engine is started.
–––
fi
–––
When condition at left is not satisfied
Below 150 kg/cm2 At 60 sec after engine is started.
–––
fi
5
When condition at left is not satisfied
fi
fi
10
When condition at left is not satisfied
Below specified level OPEN = 24 V (When oil level is insufficient)
fi
–––
10
When condition at left is not satisfied
Below specified level OPEN = 24 V (When oil level is insufficient)
–––
fi
10
When condition at left is not satisfied
Above 120°C
8
Torque converter oil temperature
Above 130°C
Above 130°C
9
Hydraulic oil temperature
Above 105°C
Above 105°C
oil 10 Brake pressure (F) 11 (Cut-in/Cut-out pressure) oil 13 Brake pressure (R) 14 (Cut-in/Cut-out pressure)
kg/cm2
Below 150 kg/cm2
Below 150
kg/cm2
16 Battery fluid level (1) Below low level
OPEN (When fluid level is insufficient) = 6-V cell is below 2 V
17 Battery fluid level (2) Below low level
OPEN (When fluid level is insufficient) = 6-V cell is below 2 V
18 Battery fluid level (3) Below low level
OPEN (When fluid level is insufficient) = 6-V cell is below 2 V
19 20 21 22
Brake oil level Coolant level
Resetting condition
fi
Temperature is above 120°C but alarm for above 130°C is not detected.
7
Resetting condition 1
Below low level
OPEN = 24 V (When coolant level is insufficient)
fi
–––
2
When condition at left is not satisfied
Below low level
OPEN = 24 V (When coolant level is insufficient)
–––
When condition at left is not satisfied
–––
fi fi
30
OPEN = 24 V (When clogged) and torque converter oil temperature is above 50°C
2
When condition at left is not satisfied
–––
fi
2
When condition at left is not satisfied
23 Transmission filter Above specified differential pressure pressure 24 Clogging of air cleaner (1)
Above specified negative pressure
25 Clogging of air cleaner (2)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When condition at left is not satisfied
26 Clogging of air cleaner (3)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When condition at left is not satisfied
27 Clogging of air cleaner (4)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When condition at left is not satisfied
Below 9.3 V (while engine is running) (Condition for judging rotation of engine: Terminal R voltage is above 9.3 V or engine speed is above 600 rpm)
–––
fi
2
When condition at left is not satisfied
terminal When charging is 28 Alternator R voltage abnormal
20-199-9 (8)
OPEN = 24 V (When clogged)
WA1200-3
TESTING AND ADJUSTING
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
Alarm output Main monitor output
Massage display (CGC) Sensor Constant Real-time monitor, Saving of Error detecting display PM clinic No. failure history component (Reference) (Reference) Saved: fi
Alarm display on CGC
Screen color
Cancel switch
Check lamp
Caution lamp
Buzzer
Abnormal
Yellow
Installed
Flashing
–––
–––
901
fi
CENSE
–––
fi
Abnormal
Red
Not installed
–––
Flashing
ON
902
fi
CENSE
–––
fi
Abnormal
Red
Installed
–––
Flashing
ON
904
fi
CENS
Gauge
fi
Insufficient
Yellow
Installed
Flashing
–––
–––
905
x
Insufficient
Yellow
Installed
–––
Flashing
–––
906
x
Abnormal
Red
Installed
–––
Flashing
–––
907
fi
Abnormal
Red
Installed
–––
Flashing
ON
908
Abnormal
Red
Installed
–––
Flashing
–––
911
fi
Pressure is being increased
Yellow
Installed
–––
Flashing
–––
912
x
Abnormal
Red
Not installed
–––
Flashing
ON
913
fi
Pressure is being increased
Yellow
Installed
–––
Flashing
–––
912
x
Abnormal
Red
Abnormal
VHMS
Gauge
–––
Gauge
–––
Gauge
–––
fi fi fi
–––
fi
–––
fi
–––
fi
–––
fi
–––
–––
–––
–––
VHMS Gauge VHMS
Remarks
VHMS
VHMS
Yellow
Not installed
Installed
–––
Flashing
Flashing
–––
ON
–––
915
fi
916
fi
917
fi
918 Abnormal
Yellow
Installed
Flashing
–––
–––
925
Abnormal
Red
Not installed
–––
Flashing
ON
926
Abnormal
Yellow
Installed
Flashing
–––
–––
927
Abnormal
Red
Not installed
–––
Flashing
ON
928
Abnormal
Yellow
Installed
Flashing
–––
–––
931
fi fi fi fi fi fi
Abnormal
Yellow
Installed
Flashing
–––
–––
932
fi
Abnormal
Yellow
Installed
Flashing
–––
–––
933
fi
VHMS
VHSM VHSM VHMS
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
VHMS Abnormal
Yellow
Installed
Flashing
–––
–––
934
fi
–––
–––
Abnormal
Yellow
Installed
Flashing
–––
–––
935
fi
–––
–––
Abnormal
Yellow
Installed
Flashing
–––
–––
937
fi
–––
–––
WA1200-3
VHMS
20-199-10 (8)
TESTING AND ADJUSTING
ERROR CODES TABLE
ERROR CODES TABLE fl The main monitor displays a diagnosis code (excluding codes related to VHMS) and a remedy code. fl The CGC monitor displays a 6-digit error code. • Obtain a diagnosis code from the displayed error code and this table, and then see the corresponding troubleshooting section.
Work equipment controller
Modulated clutch controller
Transmission controller
Com- Diagponent nosis code 10 11 12 13 14 15 16 18 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 39 70 72 73 74 75 76 77 78 80 81 82 83 84 85 43 44 45 49 51 52 55 56 57 58 59 61 62 63
Remedy code
E11 CALL CALL CALL CALL CALL CALL CALL CALL CALL E01 CALL CALL CALL CALL CALL E00 E00 CALL E01 CALL E01 CALL E01 E01 + CALL CALL E00 CALL E00 E00 E00 E00 E00 CALL CALL CALL E01 + CALL CALL
E00 E01 E01 E01 E01
+ CALL + CALL + CALL + CALL E00 E01 + CALL
20-199-11 (8)
Failed system
Error code displayed on CGC
Former error code
Short circuit, disconnection, or short circuit with power source in backup lamp relay output signal system Disconnection in modulated clutch outlet speed signal sensor system Short circuit, disconnection, or short circuit with power source in F ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in R ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in 1st ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in 2nd ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in 3rd ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid signal system Short circuit or disconnection in joystick steering FNR switch system Short circuit or disconnection in joystick steering shift-up/shift-down switch system Disconnection in travel speed signal sensor system Short circuit or disconnection in engine rotation sensor system Abnormality in memory Short circuit in transmission oil temperature sensor system Grounding fault in F. fill switch system Grounding fault in R. fill switch system Grounding fault in 1st fill switch system Grounding fault in 2nd fill switch system Grounding fault in 3rd fill switch system Grounding fault in F/R fill switch system Disconnection in 1st, 2n, or 3rd fill switch system Disconnection or short circuit with power source in F bypass solenoid signal system Grounding fault in F bypass solenoid signal system Disconnection or short circuit with power source in R bypass solenoid signal system Grounding fault in R bypass solenoid signal system Disconnection or short circuit with power source in 1st bypass solenoid signal system Grounding fault in 1st bypass solenoid signal system Disconnection in boom RAISE/LOWER, bucket TILT/DUMP pressure switch system Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system Grounding fault in F/R ECMV fill switch system Disconnection in 1st, 2nd, or 3rd fill switch system Grounding fault in 1st, 2nd, or 3rd fill switch system Grounding fault in RPM-SET IDLE-UP/RESUME IDLE-DOWN system Grounding fault, disconnection, or short circuit in drive force control dial system Grounding fault, disconnection, or short circuit in travel speed control dial system Grounding fault, disconnection, or short circuit in wheel rotation sensor system Grounding fault, disconnection, or short circuit in modulated clutch outlet rotation signal sensor system Short circuit, disconnection, or grounding fault in engine rotation sensor system Short circuit, disconnection, or grounding fault in travel speed sensor system Short circuit, disconnection, or grounding fault in neutral-cut solenoid system Short circuit, disconnection, or grounding fault in modulated clutch ECMV solenoid system Disconnection, short circuit, or grounding fault in dumping solenoid system Short circuit with power source on hot side of dumping solenoid Short circuit with power source on return side of dumping solenoid Disconnection or grounding fault in boom lever kick-out solenoid system Disconnection in boom RAISE/LOWER pressure switch system Disconnection, grounding fault, or short circuit in boom angle sensor system Short circuit or disconnection in travel speed sensor system Disconnection, grounding fault, or short circuit in joystick caution buzzer relay system Disconnection, grounding fault, or short circuit in steering lever angle sensor system Deviation of potentiometer signal of steering lever angle sensor/frame angle sensor system Disconnection, grounding fault, or short circuit in frame angle sensor system Disconnection or grounding fault in steering lever lock switch system Disconnection, grounding fault, or short circuit in joystick neutral interlock relay system Disconnection, grounding fault, or short circuit in joystick basic pressure control EPC solenoid system
D160KZ DLFAKA DXH8KZ DXH7KZ DXH4KZ DXH5KZ DXH6KZ DWJ2KZ DDF2KZ DDF3KZ DLT3KZ DLE2KZ DAQ0KT DGF1KB DDTQKB DDTNKB DDTKKB DDTLKB DDTMKB DDTDKA DDT8KA DW23KZ DW23KB DW24KZ DW24KB DW25KZ DW25KB DDNJL4 DK10L5 DDTDKB dDT8KA DDT8KB DDA7LD DDD8KX DDD7KX DLF6L8 DLT2KZ dLE2KZ dLT3KZ DWNAKZ DXHPKZ DXHNKZ DXHNKY DXHNKB DW72KZ DDNGL4 DKA0KX DLt3KZ D100KZ DK5FLX DKD0KZ DKD0KX DDQ2L6 D191KZ DXF0KZ
E010 E011 E012 E013 E014 E015 E016 E018 E020 E021 E022 E023 E024 E025 E026 E027 E028 E029 E030 E032 E033 E034 E035 E036 E037 E038 E039 E070 E072 E073 E074 E075 E076 E077 E078 E080 E081 E082 E083 E084 E085 E043 E044 E045 E049 E051 E052 E055 E056 E057 E058 E059 E061 E062 E063
WA1200-3
TESTING AND ADJUSTING
ERROR CODES TABLE
fl Error codes related to engine controller (marked with *) are also displayed on the CGC.
VHMS controller
Com- Diagponent nosis code V-1 V-2 V-4 V-5 V-6 V-7 V-8 V-9 V-10 V-11 V-12 V-13 V-14 V-15 V-16 V-17 V-18 V-19 V-20 V-21 V-22 V-23 V-24 V-25 V-101 V-102 V-103 V-104 V-105 V-107 V-108 V-109 V-110 V-111 V-113 V-114 V-115 V-116 V-117 V-118 V-119 V-120 V-121 V-122 V-123 V-124 V-125 V-126 V-127 V-128 V-129 V-130
WA1200-3
Remedy code
Failed system Engine oil level below LOW level Engine oil pressure below specified pressure Engine coolant temperature above 105°C Fuel level below specified level (While engine is stopped) Fuel level below specified level (While engine is running) Torque converter oil temperature above 120°C Torque converter oil temperature above 130°C Hydraulic oil temperature above 105°C Lowering of front or rear brake oil Lowering of front brake oil pressure Lowering of rear brake oil pressure Disconnection or grounding fault in battery fluid level sensor “1” system Disconnection or grounding fault in battery fluid level sensor “2” system Disconnection or grounding fault in battery fluid level sensor “3” system Brake oil level below specified level (Before engine is started) Brake oil level below specified level (while engine is running) Coolant level below LOW level (Before engine is started) Coolant level below LOW level (While engine is running) Clogging of transmission oil filter Clogging of air cleaner “1” Clogging of air cleaner “2” Clogging of air cleaner “3” Clogging of air cleaner “4” Charge trouble of alternator Disconnection or short circuit with power source in NSW power supply system Grounding fault of 24 V in sensor power supply Grounding fault of 12 V in sensor power supply Grounding fault of 5 V in sensor power supply Wrong connection of connector Failure in communication with CGC or controller Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and transmission controller) Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and modulated clutch controller) Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and work equipment controller) Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and main monitor) Short circuit with power source in buzzer output system Short circuit with power source in check lamp system Short circuit with power source in flashing synchronization signal system Disconnection or grounding fault in boom bottom pressure sensor Disconnection or grounding fault in boom head pressure sensor Disconnection or grounding fault in rear brake oil pressure sensor system Disconnection or grounding fault in work equipment relieve pressure sensor system Disconnection or grounding fault in front brake oil pressure sensor system Disconnection or grounding fault in transmission main relief pressure sensor system Disconnection or grounding fault in steering relief pressure sensor system Disconnection or grounding fault in torque converter outlet oil pressure sensor system Disconnection or grounding fault in transmission modulation oil pressure sensor system Disconnection, grounding fault, or short circuit with power source in transmission lubricating oil pressure sensor system Grounding fault in torque converter oil temperature sensor system Grounding fault or short circuit with power source in hydraulic oil temperature sensor system Disconnection, grounding fault, or short circuit with power source in atmospheric temperature sensor system Disconnection or grounding fault in PPC relief pressure sensor system Disconnection or grounding fault in torque converter inlet oil pressure sensor
Error code displayed on CGC
Former error code
C253 (*) C143 (*) C151 (*) B@BFZK b@BFZK B@CENS b@CENS B@HANS 2G41MB 2G42ZG 2G43ZG B@GAZK B@GBZK B@GCZK B@G5ZK b@G5ZK B@BCZK b@BCZK 15BONX AA1ANX AA1BNX AA1CNX AA1DNX AB00MA DBB0KK DBB6KP DBB7KP DBB5KP DBB0KQ DBBRKR
E901 E902 E904 E905 E906 E907 E908 E911 E912 E913 E915 E916 E917 E918 E925 E926 E927 E928 E931 E932 E933 E934 E935 E937 E811 E812 E813 E814 E818 E824
DAQSKR
E825
DBCSKR
E826
DB9SKR
E827
DAF0KR
E828
DVO0KB D5ZPKB D5ZQKB DHPCKX DHPDKX DHU3KX DH24KX DHU2KX DHT3KX DHT8KX DH20KX DHT9KX
E841 E843 E844 E861 E862 E863 E864 E865 E866 E867 E868 E871
DHTAKX
E872
DGT1KX DGT2KX DGE5KX DHT4KX DHT5KX
E874 E875 E877 E878 E884
20-199-12 (8)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING A
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A
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.
If the radiator cap is removed when the engine is hot, hot water A the engine to cool down before starting troubleshooting.
may spurt out and cause burns, so wait for
A
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A
When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
A 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, and important point is of course to understand the structure and function. 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.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any 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 manhours, parts, or oil or grease, and at the same time, 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. Points to ask user or operator I) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.
20-202 0
4) 5)
4.
5.
6.
Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure 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. + When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
WA1 200-3
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
ber of machine
1)
Look at the table of troubleshooting the shop manual
and prepare
tools in
the necessary
2)
locations
of failure
*
Pinpoint
1)
Before
21
See the Troubleshooting
toots. * .
(carry out
T-adapter Hydraulic
pressure
gauge
kii, etc.
Look in the parts book and prepare essary
replacement
parts.
the necstarting
manual,
-
Drive
select
Section
and
of the shop
a troubleshooting
flowchart
machine
to confirm
and operate
the condition
locate
troubleshooting,
the
and judge
if there
is really
a
Step 4
-
Was there
anything
strange
chine before the failure -
Did the failure
the ma-
occur suddenly?
Had any repairs been carried
WA1 200-3
about
occurred? out before the
20-203 0
POINTS TO REMEMBER WHEN CARRYING OUT MAlmNANCE
TROUBLESHOOTING
POINTS TO REMEMBER 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 gear oil and hydraulic oil). 1.
1)
POINTS TO REMEMBER ELECTRIC EQUIPMENT
WHEN
Handling
and connectors
wiring
harnesses
HANDLING
Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors 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.
Main failures
occurring
in wiring
harness
Defective contact of connectors (defective contact between male and female) Problems with defective 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 oxidization of the contact surfaces.
Improper insertion
I Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper correction or breakage.
TEwoo192
Crimped portion
TEwGm93
20-204 0
WA1 200-3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Disconnections in wiring If the wiring is held 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 of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
TEwOOl94
High-pressure water entering 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. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil 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, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. f When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. * If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
WA1 200-3
I
TEWOO196
TEWW196
20-205 0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2)
Removing, installing, and drying connectors and wiring harnesses
0
Disconnecting connectors 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. * Never pull with one hand. When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. * If the connector is twisted up and down or to the left or right, the housing may break.
0
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. * If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206 0
WA1 200-3
TROUBLESHOOTING
0
Connecting
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
connectors
Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) 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 got 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, re* place the connector. Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 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. j, If the connector cannot be corrected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
WA1 200-3
20-207 0
TROUBLESHOOTING
l
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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. 6) Disconnect the connector and wipe off the water with a dry cloth. Ir If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
TEWW196
Dry the inside of the connector with a dryer. lf water gets inside the connector, use a dryer to dry the connector. + Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
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, blow it with contact restorer and reassemble.
20-208 0
T-adapter
WA1 200-3
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TROUBLESHOOTING
3)
Handling
control
box
The-control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
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) 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. -
2.
II
TEWC0206
electric circuits when troubleshooting I) Always turn the power OFF before disconnecting or connect connectors.
Points to remember
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Disconnect and connect the related connectors several times to check. * Always connect any disconnected connectors before going on to the next step. If the power is turned ON with the connectors still disconnected, unnecessary abnormality * displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. + If there is any change, there is probably defective contact in that circuit.
3)
WA1 200-3
20-209 0
TROUBLESHOOllNG
POINTS TO REMEMBER WHEN CARRYING OUT MAIMENANCE
3. 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 main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.
I
-
TEWOO207
31 Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
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.
TEwOO209
20-210 0
WA1 200-3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
51 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. (Drain the oil from the hydraulic tank; also 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 chanoing 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)
oil
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 ultrafine (about 3~11particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
WA1 200-3
20-211 0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING l-
Judgement standard
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 converte, Transmission hydraulic, hydraulic tank oil)
-
Clean, drain
5. Check brake oil level
-
Add oil
6. Check engine oil level
-
Add oil
7. Check coolant level
-
Add water
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
-
Tighten 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
-
Repair or replace
Item
17. Check battery voltage (engine stopped)
24 - 26 V
Replace
18. Check battery electrolyte level
-
Add or replace
19. Check for discolored, burnt, exposed wiring
-
Replace
20. Check for missing wiring clamps, hanging wiring
-
Repair
21. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)
-
Disconnect :onnector and dry
22. Check for blown, corroded fuses
-
Replace
23. Check alternator voltage (engine running at l/2 throttle or above) (If the battery charge is low, the voltage may be approx. 25V immediately after starting.) 24. Sound of actuation of battery relay (when starting switch is turned ON, OFF)
20-212 0
28.5 - 29.5 V
-
Replace
-
WA1 200-3
CONNECTOR
TROUBLESHOOTING
TYPES AND MOUNTING
LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS *
The Address column in the table below shows the address in the connector (Bdimensional
WA1 200-3
arrangement
drawing
drawing).
20-2 13 0
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
Mounting location
Address H-9
El0
DTl
2
Compressor magnet clutch
El1
DTl
2
Diode
l-3
El2
DTl
2
Intermediate connector
K-5
E13
Terminal
1
Engine ground
K-5
El4
DTl
3
PRE-LUB starter
l-2
El5
DTl
3
Safetv relav
H-2
ERI 1DTI ER3
1 6 1Intermediate connector
1 DTHD4l
ER4 I DTHD4l
LOCATIONS
1 L-2 1 1 GO2 1M
1 2 1Riaht working lame
I Kl
1 I intermediate connector
1 K-l 1 1 GO3 I M
1 2 I Rioht workino lamp
1 J-9 I
1 1Intermediate connector
1 K-1 1
GO4
DTl
3
Stairway lamp switch
K-4
ER5
DTHD4
1
Intermediate connector
K-1
GO4
Plug
1
Left backup buzzer
K-7
ER6
DT2
3
Intermediate connector
L-2
GO5
Plug
1
Left backup buzzer
K-7
ER7
DT2
4
Intermediate connector
L-2
GO6
DTl
3
Backup buzzer relay
K-7
ER8
DT2
3
Intermediate connector
L-2
GO6
DTl
2
Coolant level sensor
l-9
ETHl ;t&r
1
Ether injection solenoid
l-9
GO7
M
2
Left working lame
K-7
ETH2 DTl
2
Diode
ETH3
Imnnm,l ‘-pi”
FOl 1DTl
l-9
1 I Ether iniection solenoid
1 6 I Intermediate connector
I ~08
1 2 I Left working Iamp
I K-6 I
I
6 I Left combination lamp
1 K-7 I
1 I Right backup buzzer
I K-8 I
IM
I I-9 I I GO9 I M
I A-5 l l GlO l’-pi” l mnntirir
F02
DTl
6
Intermediate connector
A-4
Gil
l-pin conneuor
1
Right backup buzzer
K-8
F04
DT2
3
Boom angle sensor
A-6
G12
M
2
Left engine room lamp
J-8
F05
DT2
3
Proximity switch for load meter A-5
G13
M
2
Right engine room lamp
l-9
G14
M
2
Left rear side working lame
K-8
F06 I DT2
I
3 I Boom bottom Dresswe sensor I D-l I
F06 l X
l
3 1 Drive force control dial
I 3 1Travel speed control I Terminal I 1 I Horn (350 Hz)
F07 l X F07
dial
F08 1Terminal I I I Horn (350 Hz) FO9
Terminal 1
I d-l I I G15 I M
I
2 1Rioht rear side working iamo I H-9 I
1 d-l I I G16 1M
I
2 1Stairwav lame
I B-l I I GND I M
I
1 I Right front combination Iamp
I B-l I I GND I M
I
1 I Left front combination lamp1 C-l I
Horn (315 Hz)
A-5
F10
Terminal 1
Horn (315 Hz)
A-5
Fll
-
2
Working lamp (Optional)
B-l
F12
-
2
Working lamp (Optional)
A-2
F13
DT2
3
Bucket positioner
A-4
F14
DT2
3
Boom head oressure sensor A-3
~1 GRl
DTlA
12
I K-8 I I B-7 I
lntermedtate connector
HRl
lDT2
1 2 I NC (Neutral) solenoid
t G-9 l
I A-2 1 I HR2
I DT2
I
2 I Diode
I G-l 1
F20 I Terminal I 1 I Chassis ground
I D-8 I I HR3 I DT2
I
2 I Bucket TILT switch
I C-8 I
F21 I Terminal1 1 I Horn (add)
I C-1 I
HR4
DT2
2
Bucket DUMP switch
F15 I DT2
1
3 1 Wheel rotation sensor
C-8
F22
Terminal 1
Horn (add)
C-l
HR6
DTI
2
Rear brake level
E-l
F23
TeninaI
1
Horn (add)
A-5
HR8
DT2
2
Boom dump solenoid
B-7
F24
Terminal 1
Horn (add)
A-4
HR9
DT2
2
Boom dump solenoid
B-7
FL1
HD-2608614
Intermediate connector
A-9
HRlO
DTI
2
Front brake level
D-l
FL2
HD-25085 14
Intermediate connector
B-9
HRll
DT2
2
Boom lever detent switch
C-8
FRl
HD-86J8623
Intermediate connector
B-9
I HR12
FR2 I HP4W82l21 I Intermediate connector FSl
lL
20-214 0
I
2 I Fuse box
I DT2
I
2 I Boom RAISE switch
1 B-7 I
I B-8 I I HR13 I DT2
I
2 I Boom LOWER switch
I C-8 I
I h-7 I I HR14 I DT2
I
2 I Parkina brake solenoid
I F-l l
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
Connectar Type No.
~ HR17 l DT2 l
2 l Ememencv brake switch
~ HR18 1DT2 l
2 l Ememencv brake switch
HR19 1DT2 I 1 HSl
DT2
1 E-I 1
No. of pins
LOCATIONS
Address
Mounting location
JL9
DT2
6
Joint connector
a-2
JLlO
DT2B
8
Joint connector
a-2
JLII
DTI
6
Joint connector
a-l
6
Joint connector
a-l
6 I Joint connector
I a-1
/ E-I 1 JL12 DT2 2 I Emergencvoarking brakeresetsolenoid1 F-l 1 1 JL13 1DTI I 2
Hydraulicoil temperaturesensor A-6
JL14
DT2
6
Joint connector
a-l
HS2
DT2
3
Workequipment oil pressure sensor A-7
JL15
DT2
6
Joint connector
a-l
~ HS3
DT2
JL16
DT2
6
Joint connector
DT2
Steering oil pressure switch PPC oil pressure sensor
C-I
HS4
3 3
DTl DTl
8 6
Joint connector Joint connector
JL17 JL18
DT2 DT2
6 6
Joint connector Joint connector
a-l a-l
JBl JB2
G-9 V-9 v-9
JLI9
DT2
6
Joint connector
JEI
1DTl
JE2
DTl
JE3 JE4 JFl JF2
1 6 1Joint connector
I T-9 1 I JL20 l DT2 I
DTIB
6 8
Joint connector Joint connector
V-8 v-9
DTl
6
Joint connector
v-9
JL23
DTPB
DTI DTl
6
Joint connector
6
Joint connector
O-I N-l
JL24 JL25
DT2 DTI
6
Joint connector
M-4
JF3 DT2 JF4 I DTZB I
8 1Joint connector
JF5 1DTlBl
8 / Joint connector
JF6
DTI
6
JGl
DTlB
JG2
DTI
JG3 JG4 JG7
1 JL21 1DTIB I JL22 DT2B
6 I Joint connector
I a-l I a-l
8 l Joint connector 8 Joint connector
a-l
8 6
Joint connector Joint connector
a-l
6
Joint connector
C-l
JL26 DT2 6 Joint connector 6 Joint connector 1M-4 I JM4 DTI I M-3 I I JRI i DTIB 1 8 1Joint connector
Q-9
c-l C-I 1W-6 I w-5
Joint connector
M-4
8
Joint connector
w-7
JR3
DTI
6
Joint connector
T-2
6
Joint connector
w-7
JR4
DT2
6
Joint connector
T-2
DTlB
8
Joint connector
w-7
T-l
Joint connector
W-8
DT2 DTl
Joint connector
6
JR5 JR7
6
DTI
6
Joint connector
u-2
DTIB
8
Joint connector
W-8
JR8
DTlB
8
Joint connector
I W-8 I
JR9
DT2
6
Joint connector
Q-I R-I
I Joint
JG8 l DTI
I
6
JGN l DTl JGN I DTl
I I
6 l Joint connector 6 1Joint connector
connector
I JR2 I DTI
I
1M-2 I I JR10 I DT2 I I M-6 I I JRII I DT2 I JR12 DTI
JLl1
a-l a-l
DT2 1 6 1Joint connector
I z-2 I
l Q-I
6 I Joint connector 6 l Joint connector 6
l Q-9 Q-9 O-8
Joint connector
JR13 DTlB
8
Joint connector
JR14 DT2
6
Joint connector
N-7
JR15 DTl
6
Joint connector
O-8 N-7
JR16 DTl
6
Joint connector
JRA
6
Joint connector
DT2
JL2 I DT2 I
6 I Joint connector
1 Z-2 I I JSI
JL3 1DT2Bl JL4 DTI
8 \ Joint connector 6 Joint connector
JL5
DTlB
8
Joint connector
I z-2 I I JS2 I x I l-pin z-4 JS3 COllWCt0r l-pin z-4 JS4 connector
JL6
DTZB
8
Joint connector
z-4
JTI
DT2
JL7
DT2
6
Joint connector
z-2
JT2
DT2
JL8
DT2
6
Joint connector
z-2
JT3
DT2B
WA1 200-3
6 I Joint connector
T-9 I i-7
I SWP 1 12 I Jovstick lever switch
I i-5
3 I Potentiometer 1 Console switch
i-6
Console switch
i-5
6
Joint connector
w-5
6
Joint connector
w-6
8
Joint connector
w-5
I
20-Z
15
0
TROUBLESHOOTING
?O-216 0
CONNECTOR TYPES AND MOUNTING
LOCATIONS
WA1 200-3
TROUBLESHOOTING
Conlector No.
No. of pins
Type
L127 1Reiavl
CONNECTOR TYPES AND MOUNTING
Mounting
Address
location
5 1Steerina neutral
relav
1 n-8 1
L128 1DT2
1
2 1 Diode
I r-9 I
L129 I -
I
2 I Resistor
I r-9 I
1
L130 &$&,
Travel speed “ON/OFF” indicator u-2
L131 &$&),
1
Travel speed “ON/OFF” indicator
t-2
L132
Relay
5
Dust indicator
1 relay
m-9
L133
Relav
5
MT5 OPl QP2
Dust indicator
2 relav
n-9
L134 1Relavl
5 I Dust indicator
3 relav
I n-9
I
~135 I Relay1
5 I Dust indicator
4 relav
I n-8
1 0~5
L136 &F&r
1
Remote positioner RAlSEindicator n-8
L137 &$&,
1
Remotepositioner RAlSEindicator o-8
L138
g&
1
Remote positionerLOWER indicator
n-7
L139
COlXECtO~
l-P’”
1
RemotepositionerLOWERindicator
o-8
1
PRE-LUBE indicator
r-9 o-9 n-7
L140 &:&tor L141 &!$&,,
1
PRE-LUBE indicator
L142 I&&orl
1
Turn signal switch
I,i.2~l
I Turn
LOCATIONS
OP3 0~4
I 01 I ~2 I ROl
DT2
3
l-pin
1 COtNECtOf l-pin connector 1 z-tn. 1
Transmission modulating oilpressure sensor ab-6 Fuse box
v-7
Fuse box
v-7
Fuse box
v-7
I,2L,I
I
I Fuse box
I,Z’L,,I
I
I Fuse box
Iv-71
I T-9
IHD-~w I 21 I Enaine controller I 31 I Engine controller
sianal switch
n-7
~144 I&$!&,/
1 ( Turn signal switch
I n-7
L145 I&!$,,r/ ._. L146 mnnector ‘-p’”
1 1DC converter
) v-5
1
DC converter
(24 V/12 VI
v-6
R03
DT2
2
Diode
u-2
l-147
2
DC converter
(24 VI12 V)
v-5
R04
DT2
2
Diode
u-2
2-,--
Service meter ~~~
2
L143
1
KES
(24 V/12 VI
lH5~ I DT2
R02 ( DT2
I
2 l Torqueconverteroil fiiterdoggingsensorI S-l I
1
2 1Torqueconverter oil filtercloggingSensor1 S-l
s-9
R05
DTl
L152 I Relavl
5 I Alternator
sianal relav
I n-9
R06
Terminal 1
L160 I;;{$;rl
1
Alternator
indicator
I q-9
L161 l,Z~,,l
1 I Alternator
indicator
I o-9
L150
LRI
I
KES ~-
I
1~~95086131 I Intermediate
I
connector
I I
I T-9 I
Fuel level sensor
v-9
Slow blow fuse
W-8
I Slow blow fuse
IW-81
R08 \Terrninal I I I Slow blow fuse
IW-81
R07
ITerminalI
I
I N-9
I
R23 (DT2
I
2 1Diode
I a-9 I
LR7 I DTI
I
4 \ Intermediate
connector
1M-9
LR~ I DT2
I
3 I Intermediate
connector
I M-9
R25
DT2
2
Diode
LR9 I DT2
I
4 I Intermediate
connector
I M-9
R26
KES
2
Side windshield
1 R24 I KES I
2 I Rear windshield
washer
\ O-8 I Q-9
washer
P-8
MO1
MIC
21
Modulated
clutch controller
v-5
R27
DT2
2
Diode
Q-9
M02A
040
20
Modulated
clutch controller
v-5
R30
DTI
3
Left condenser
P-9
M02B
040
16
Modulated
clutch controller
v-4
R31
DTl
3
Right condenser
P-8
DT2/DTl 4 _
Intermediate
connector
u-9
MC1
X
3
Modulated clutchdirectcouplingswitch u-8
RAI
MC2
-
2
Resistor
n-8
RA2
M2/DTl
3
Intermediate
connector
1 R-9
MC3
-
2
Diode
s-9
RA3
DT2
6
Intermediate
connector
I x-3
I v-4
MC4 I-
I
2 I Diode
MT1
I
3 I Tranunission lubricating oil preswre~nwj
I DT2
WA1 200-3
z-9
I
RA4 I DTHDSI 1 I Intermediate
1 RA5 1DTI
1 4 I Intermediate
I
connector
I x-2 I
connector
1x-2 1
20-217 0
TROUBLESHOOTING
Connectar No.
No. of oins ,~
Type I
RA6
DTHD3
1
CONNECTOR TYPES AND MOUNTING LOCATIONS
Mounting location intermediate connector
Address
Connectar No.
Type
u-9
T20
DT2
2
DT2
2
‘R” (Reverse) bypasssolenoid ab-4
DT2
2
“F” (Forward) bypasssolenoid aa-
DT2
2
“R” (Reverse) drain solenoid
RA7
DTl
2
Battery fluid level sensor
W-3
T21
RA8
DTl
2
Battery fluid level sensor
R-9
T22
1 R-9 1
T23
1 R-9 1
T24
RA9 1DTl
1 2 1Batten, fluid level sensor
RAlO 1DTHD41 1 1Intermediate connector
I S-9
I Terminal 1 1 I Terminal
RAll
No. of pins
I 2 I Resistor
RES4 I-
I
2 I Resistor (120 Q)
SMALLI M
I
1 1 Left front combination lamp I P-l
(150 Q f 1 %I
I a-l
1st bypass solenoid
X-8
ab-4
1DT2 1 2 1Torqueconverter oil temperaturesensor 1 v-8
I
V2B IAMPO7OI12 RES3 I-
Add. ress
Mounting location
I
V3A
I AMP070 I 18
I VHMS
controller
I
r-l
I VHMS controller
I m-5 I
I Riaht
WORK21M
I
2
I
WORK21M
I
2 1Left headlamp
headlamp
I M-6
I M-5
2 I Steering lock switch
I t-1 I
WORK3 M
2
Right working lamp
M-6
SVl
I-
I
4 1Solenoid 1
I S-9 I
WORK3 M
2
Left working lamp
M-5
sv2
I-
I
4 I Solenoid 2
I s-9 I
I DT2
1 2 l2nd solenoid
I x-81
T6
1DTl
1 2 I2nd fill switch
1 x-8 I
Ti’
1DT2
2 I3rd solenoid
1 v-8
T8
IDTl
2 I3rd fill switch
I v-8
STL I DT2
T5
T9
DT2
2
Modulated clutch solenoid
TlO
DTl
2
Modulated clutch fill switch ab-6
ab-5
111
DT2
2
‘R” (Reverse) solenoid
aa-
T12
DTl
2
“R” (Reverse) fill switch
ab-3
1DT2 I I DTl I
2 1“F” (Forward) solenoid
T14
2 I “F” (Forward) fill switch
I z-2
T15
I DT2
2 I Speed sensor
1w-4 I
T13
I Modulatedclutchrotationsensorlab-
~16
I DT2
T17
I DT2
T18
DT2
1 2
Parking brake indicator switch
T19
DT2
1 2
Torque converter oil temperature sensor a b-5
20-218 0
I
2
2 I Engine rotation sensor
I I
I z-9 I y-l
WA1 200-Z
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM
FL2 FL1.
AR02
I
\
I
.
..._”
I
Rl8 F22
20-220 0
+
AR01
I
HR14
HRi9 BwWOl5Ol +
WA1 200-3
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
--ilS
9
c2
807
G16
G13
DIAGRAM
ETH2
.E03
GRl GR6
\
E05
El3
GO4
E07
E‘ll
\
El4
I 16
ERl ER6 ER7 ER8
AiOl AL02
BWWO1502
WA1 200-3
20-221 0
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
LRl LR2
11..
I
DIAGRAM
RAlO RA9 I_._ \ I._
+
JR1 1 1119 -..-R30 R3!
PHl
JM4
\\\
R3-
WORK1 WORK2 WORK3 JHD
JGN WORK3
WORK2 WORK1 JF6 JF3
Rll
/
JF2
/
JFl
/
TURN’
SMAlLL
Ri2 BWW01503 +
20-222 0
WA1 200-3
TROUBLESHOOTING
+ PRE SV2
JGR3
REl
CONNECTOR ARRANGEMENT DIAGRAM
01
JE4 R07
/
JG4
/JG7 ,JG3 ,JGl bJG2
‘JR2
\
RA’ RA3
‘JGRP
RAS RA4 RA12
\
RA13 si2
R01 R02 +
WA1 200-3
20-223 0
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
c2 C3B
DIAGRAM
+-
I
CO6
co4 \
\
6
JLb
JL6
20-224 0
WA1 ZOO-3
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
DIAGRAM
FS6 FS6 I
FS4
/
I
JS2 33
/
I
I
1
1
+
’
WA1 200-3
DLi A14
‘Al2
\
\
\
A16
'A10
YY\M\\\
‘A14
A\8B 1542 BWWO
20-225 0
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
L6iil:4L73L;L91
DIAGRAM
+
17;;z3/::: Lf 19 L133
Ll14 &
L69
L39
-1134
L69 I ‘~j;l?T
L92
I
L61 L99 L68 L67 L63 L62 L4i
LiO6
Li6 W
RESP
RES4
LO6
L26
Li6 I L96
20-226 0
I L97
,
WA1 XXI-3
TROUBLESHOOTING
CONNECTOR ARRANGEMENT
DIAGRAM
+ Ll03
L160
LO1
L128
Ll50
t en I. OP2.OP3 OP6
WA1 200-3
20-227 0
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
\
DIAGRAM
Ti2
Tl4
T18
/
Tl
20-228 0
WA1 200-3
CONNECTOR ARRANGEMENT
TROUBLESHOOTING
I8 I
c21
!!
c29
DIAGRAM
c20
A17 Al6 Cl3 !ll
c12
\
\\\
1
Cl7 Cl4 Cl6 Cl8
C23
C27
C24
.C26 .
‘cne
WA1 200-3
20-229 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS *
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. No. of pins
X type connector Female (male housing)
Male (female housing)
2
1
3
EElI 2
4 TEwoozz5
20-230 0
WA1 200-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
SWP type connector
Male (female
Female (male housing)
housing)
6
‘6 TFNc4l235
1
5
4
8
8
1
4
5
8
9
12 BlPOKl35
BLFWO34
1
4
8
11
3
i
io
?14 TEwooz39
11
8
4
1
14
4
16
WA1 200-3
TEwoo240
1
1
4
5
8
9
2
20-231 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
M type connector Female (male housing)
Male (female housing) 2
2 e7 1
BLFOCO38
3
TEwoo244
1
3
4
ElS 4
2 lEwoo246
TEwca245
1
4
4
1
6 cl 3’
8
‘6
TEWOO247
Qzl 8’
‘5 BLFWXO
20-232 0
BLPOOO41
WA1 200-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
NO.
of pins
T
8
S type connector
Ezl ‘8
10
(White
Female (male housing)
Male (female housing)
1 \
6 /
5
10
TEwKQ49
$3 Two0251
6
I
12 (White i
12
5
16 (White
is0
i
WA1 200-3
BEL00114
BEL00113
i6
BEL00115
16
7
BEL00116
20-233 0
TROUBLESHOOTING
No. of pins
CONNECTlON TABLE FOR CONNECTOR PIN NUMBERS
T
S type connector Male (female housing)
Female (male housing)
10 (Blue
10
i
BEL00117
1
6
5
12 ElFwx3
BELO
6
1
8
1
16
7
12 (Blue
1
16 (Blue
20-234 0
El
8
0
TEwoozs6
WA1 200-3
No. of pins
TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION
TROUBLESHOOTING
MIC connector Male (female housing)
Female (male housing)
5
9
13
8
13
H
BLFOOO4B
Bl.Pooo50
9
9
17
17
1 00
0
10
17
BLPmo52
21
WA1 200-3
20-235 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
AMP040 type connector Female (male housing)
Male (female housing)
a
4
8
12
6
8LFwos5
a
i
i
BLFUOOBB
16
16
20
20-236 0
ai
11
1 lEww234
WA1 200-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
l-
AMP070 type connector Male (female housing)
Female (male housing)
10
EWWOl601
BWWO1602
12
i 5
12
5
BWW01603
NW01604
14
aI 6
BWWO1605
EWWOl606
18
8
18
BWWO1607
18
8
8WWO1608
10
1
20
Y
20
EWWOl609
WA1 ZOO-3
BWWOl6lO
20-237 0
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
L type type connector Male (female housing)
I
2
Female (male housing)
I
ELI a
m
20-238 0
WA1 200-3
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
Automobile (KESI 1 connector Male (female housing)
Female (male housing)
1
WLOI
140
it3
2
3
BVLOI 141
BVLOl142
k 4
BLFQWW
1
8 Em
. f?3 I
5
\
8
BU%QQ?2
WA1 200-3
20-239 0
TROUBLESHOOTING
T 1
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Type Shell size code
HD30 series connector
Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
EWWO1612
18-8 (1)
Pin (female terminal)
Pin (male terminal)
NW01614
Pin (male terminal)
Pin (female terminal)
BWWO1616
18-14 (2)
Pin (female terminal)
Pin (male terminal)
BWWO1617
20-240 0
WA1 200-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
TYPE Shel size code
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
BWWO1820
18-2C (3)
Pin (female terminal)
Pin (male terminal)
BWWO1622
BWWO1621
Pin (male terminal)
Pin (female terminal)
fn\ 0 '00
IlO o '2
90
200
O
02'
,07
020
0'9
03 o 060'6 0405 0'7 ::O ,' 0 O'6 15
BWWO1623
18-21 (4)
Pin (female terminal)
BWWO1625
WA1 200-3
BWWO1624
Pin (male terminal)
BWWOl626
20-24 1 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
T
Type Shell size code
I
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
oT
0
ova oz oy 0
OS
f\
0”
ow
ox
BWWO1627
24-9 (5)
Pin (female terminal)
BWW01628
Pin (male terminal)
l-3 0 SOT
”
ooopooV
oy
ox
ow
BWWOI 629
Pin (male terminal)
BWWO1631
24-16 (6)
Pin (female terminal)
BWWOl633
20-242 0
lT OS .Z lwl l u
/OR X
y
BWW01830
Pin (female terminal)
BWWO1632
Pin (male terminal)
BWW01634
WA1 200-3
TROUBLESHOOTlNG
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Type Shell size code i
I
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
EWWO1636
24-21 (7)
Pin (female terminal)
BWWO1637
Pin (male terminal)
BWWO1639
24-23 (8)
Pin (female terminal)
Pin (male terminal)
BWWOI 636
Pin (female terminal)
BWWOl640
Pin (male terminal)
BWWO1642
WA1 200-3
20-243 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
T 1
Type Shell size code
HD30 series connector Body (Plug)
Body (Receptacle)
Pin (male terminal)
Pin (female terminal)
BWWO1644
24-31 (9)
Pin (female terminal)
Pin (male terminal)
BWWO I646
20-244 0
WA1 200-3
CONNECTIONTABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
[Number
T
is printed on each connector (Wire inserting end).]
DT series connector Body Plug)
2
2
Body (Receptacle)
fiE3 lzzil
I
BWWO1647
EWWO1649
6WWO1650
BWW01652
WA1 200-3
20-245 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. Of pins
[Number is printed on each connector (Wire insetting end).]
T
DT series connector Body (Plug)
Body (Receptacle)
6
BWWO1654
BWWOl653
a
@f!a!@ Em 08
I
4
BWWO1655
4
1
BWW01656
12
1
6 BWWO1657
20-246 0
I
BWWO1656
WA1 200-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
[Number is printed on each connector (Wire inserting end).]
T
DTM series connector Body (Receptacle)
Body (Plug)
2
B
ihdi 0
2
0
1
1
BWWOl659
WA1 200-3
m c3 2
BWW01660
20-247 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
1
DTHD series connector Body (Receptacle)
Body F’b)
0Q
0
4%
0
EWWO1661
20-248 0
BWWO1662
WA1 200-3
TROUBLESHOOTING
EXPLANATION
OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
(For details,
see section
STRUCTURE
AND FUNCTION)
TRANSMISSION CONTROL SYSTEM (Input
(Dutwt
sianals)
sionalsl
_I
ECMV 3rd Shift-down
c 0
ECHV R
Transmission cut-off switch
:....r:,...-
Auto/Manual
I
Backup
lamp relay
Transmission controller
psolenoid
Fill
switch
F
Fill
switch
R
Fill
switch
I
Fill
switch
2
Fill
switch
3
1
IstLE
wq?-
I
*7-
*7-
*F”----
-7-
Work
Transmission temPerature
1
WA1 200-3
ewipsent
oil
TXW02438
20-249 0
EXPLANATION
TROUBLESHOOTING
MODULATED
OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
CONTROL SYSTEM (Input
Klutuut
sionals)
sisnats)
I Drive control
force voltaoe
Travel control
speed voltaoe
Transmission
$---_H
cut-off
selector
snitch
NC solenoid
valve
outout I
Sneed
VHMS controller
settins
LE
(+12VI
Modulated clutch (MOD/C) controller
Sneed
set
ON/OFF
sional
a7
Modulated
clutch
1 Transmission -7
Transmission
I Transmission q Transmission q Transmission q
20-250 0
*7
O?
F
=7
ECMV fill
signal
F clutch
sisnal
R clutch
signal
1st
clutch
sinnal
2nd
clutch
sisnal
3rd
clutch
signal TXW02439
WA1 200-3
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
WORK
EQUIPMENT CONTROL SYSTEM lnout
@
signals
Boom anale
Output (1)
ootentioaeter
sianals
Boon lever
kick-out
solenoid
r @Boom
RAISE
witch
12) Boom PPC dumoino
+?!!I @Booa
lever
detent
R-IIxzI @ nettino
snitch
Q) ~:y;;:,m:j;;ner
raise
@
Remote positioner raise eta0 selector witch
@
Remote mritioner lower tten selector switch
Work eouionent controller
I
A: B: P: S:
Analog signal Dioital sional Pulse signal S-NET sional
(3)
Remote buzzer
(4)
Diselar of lower settino of remote positioner
(5)
Disolav of raise setting of remote positioner
(6)
Disolav of raise stop of remote positioner
(7)
Disolar of lower stop of remote Positioner
Positioner outout Main
twitch
solenoid
snitch
inout
check
monitor
TMS controller
@Remote Positioner function selector
l
@Steerins potentiometer calibration relet switcl
:8) EPC solenoid of steering
for main
control Pressure Steerino
lock velve To steerino
@Steering
rrn”?’ 5i1iy
lever
anal1
@Frame angle Potentiometer
@
!y;;;
caution
buzzer
’ 1 F
Steer ino lever lock switch
Startino
lever
u
Neutral relay
I
WA1 200-3
Nban
safetrl
.I loratickknob
tch
is
la N
20-251 0
TROUBLESHOOTlNG
EXPLANATIONOF FUNCTIONS OF ELECTRICCONTROL MECHANISM
MAINMONITORSYSTEM
_
Modulated controller
clutch
Network control sri tch
_[
.Uodel shional .Abnormalitr signal .Neutcal sional
[ When jcrstick
Transmission controller
Gear
I
t
I
..A
weed
cut-off
sritcb
cut-off
1
t
signal
Travel
speed
signal
;ygo;;f
coolant
signal
Joystick lever L switch
uorkino sional
lame
a
I
temoerature
monitor
signal
lame switch
steering
Service
meter
I
signal
FNR
Emersencv
indicator
-
Rear relay
I Turn
brake
aressure
weed
buzzer
c
tinnal
Ensine
Alarm
Parkino
c
Main
w
grease
signal
buzzer
Transmission switch sidnal
A
is used)
Alarm Transmitsion
Auto I
Network
,
I-
tire slip ON/OFF
+
INisht
Iishtinr
sisnaf
imi
operation
I
VHYS controller
Starting
switch
I
ON signal
WA1 200-3
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
VHMS CONTROL SYSTEM Monitoring
items for maintenance
Engine
speed
I Electromaonet
1
ic
Fuel 1
level
Toraue converter oil temperature .
a
Hydraulic tenperature .
g ~
Ataos~~
oil
Brake
fluid
level
temperature Coolant
Transmission differential
1
oil filter pressure
I
level
~;pa~;a
4;
air
cleaner %
F
Alternator
terminal
R
+24V Brake differential wemutt
+24V
Transmission oil preswr.2
+24vfTj+q
Tranmission oi I Prefmre
Steering
modulation
I
+24V
relief
-+24V
1
relief
i24V
Pressure
nb
+24V-
lubricatino
I
+24V outlet
+24V
I
I
Dressure
7h
I
I
I
I
I TXW02442
WA1 200-3
20-253 0
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
Functional items of load meter
INPUT
+24\
OUTPUl
I
+24\ +24V
L
+*4”m!i
VHMS controller
Subtotal
switch
-7
Cancel
switch
I
1
Mele;ase
disDlav
1 TXW02443
20-254 0
WA1 200-3
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 1. Display on CGC 1) Outline The VHMS controller transmits information of various types through CAN (network) to the CGC monitor, and the “Failure history information” in that information is displayed on the SERVICE MENU SELECT SCREEN of the CGC monitor.
2) Display of failure history If failure history button (1) on the service menu is pressed, the “FAILURE HISTORY SCREEN” appears. The “Code”, “Contents”, “Starting time of failure detection start time”, and “Finishing time of failure detection” of the failures are displayed in the order of time from the oldest one. If the failure still exists, the “finishing time of failure detection” is not displayed. The number of the all past failures is displayed in section (21, the failure No. in section (31, the failure code and its contents in section (41, and the time when the failure occurred in section 5. 31 Function of each button i) Service Menu button (6): . If this button is pressed, the “SERVICE MENU SCREEN” appears. ii) Page button (7): This button is used to turn over the page. iii) UP/DOWN button (8): This button is used to move the displayed part up and down. iv) Failure history No. button (3): . If this button is pressed, the history corresponding to it is not displayed. * Although the history is not displayed in this case, the data in the controller are saved.
SERVICE Real
Monitor
PM-Clinic Serial Memory
aintenance
Monitor
Failure
History
Snapshot
Trigger
,1 A’
No. set Clear
BWWOl551
2 3
4
5 7
l
WA1 200-3
Time
MENU SELECT
6
BWWO 1552
20-255 0
TROUBLESHOOTlNG
2.
Display on main monitor
1)
Outline
METHOD OF DISPLAYING ACTlON CODE AND FAILURE CODE
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 (a): EOO, E01 + CALL (EOI and CALL are displayed alternately), and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer display.
31 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.
41 Saving failure code The transmission controller writes the failure codes to memory. i) A total of 9 failure codes can be saved in memory. ii) The data that is saved to memory is as follows: (1) Failure code (b) (2) Time elapsed since failure (c) (up to 1000 hours) iii) 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. iv) If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved. * 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.
Examole: When action code CALL is displayed
I
SPEED
\ a
I
BWWO153
Example: When failure code “41” has occurred 27 hours before b /
SPEED
/\ c
BWWOl532
20-256 0
WA1 200-3
TROUBLESHOOTING
METHOD OF DISPLAYING ACTlON CODE AND FAILURE CODE
5) Switch operation procedure and actuation Switch operation
Actuation
Trouble data memory mode display Stop engine. ii) Turn starting switch ON. iii) Switch (I) (Second switch from the left top) and head lamp switch (2) simultaneously ant keep pressed for at least 5 seconds.
i)
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 100001.
Going to nest failure code iv) 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.
r
Clearing failure code Y) Keep rear lamp switch (3) pressed for at least 2 seconds.
Wtting
The failure code and elapsed time on the display are cleared. If the failure still exists, the failure code is not cleared.
trouble data
memory display mode 4
Switch (I) and head lamp switch (2) simultaneously and keep pressed for at least 5 seconds. Or start the engine.
WA1 200-3
The display returns to the normal display.
20-257 0
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
TROUBLESHOOTING
MONITORING Screen No.
ITEMS
LIST (CGC)
Name of signal
Unit
Component name
Remarks
REAL TIME MONITOR
T/M UP SHIFT SW 114
T/M DOWN SHIFT SWITCH
(ON/OFF)
T/M
(ON/OFF)
114 274
ENGINE SPEED
1 rpm
2l4
FILL SIGNAL F
(ON/OFF)
T/M
2/4
FILL SIGNAL R
(ON/OFF)
T/M
2l4
FILL SIGNAL 1st
(ON/OFF)
TIM
I 2l4
FILL SIGNAL 2nd
I
(ON/OFF)
) T/M
FILL SIGNAL 3rd
I
(ON/OFF)
I TIM
1 mA
1 T/M
SOLENOID 2nd SOLENOID 3rd ENGINE SPEED AUTO SHIFT SIGNAL
I I
1mA 1 rpm (ON/OFF)
VHMS
1 TIM VHMS T/M
Each time momentary switch is turned ON, state (AUTO/MANUAL) is changed. Value recognized by controller is displayed. Each time momentary switch is turned ON, state (AUTO/MANUAL) is changed. Value recognized by controller is displayed.
20-258 0
WA1 200-3
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
(MOD/C OUTPUT SPEEDJAENGINE SPEED
WA1 200-3
20-259 0
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
TROUBLESHOOTING
Screen No.
Name of signal
I 516 I BUCKET TILT SIGNAL
I 516 I
FILL SIGNAL F
Component name
Unit
I
I
(ON/OFF)
MOD/C
(ON/OFF)
I T/M
5/6
FILL SIGNAL 1st
(ON/OFF)
T/M
516
TIRE SLIP SIGNAL
(ON/OFF)
Main monitor
I 616 I ENGINE SPEED I 1 R.H. BRAKE PROXIMITY SWITCH 1 I 6/S I I 6/S I ACCELERATOR SIGNAL 1 CONTROLLER OUTPUT SIGNAd
1 rpm
I VHMS
(ON/OFF)
I MOD/C
0.1 v
I MOD/C
0.1 v
I MOD/C
6/S
SET/ACCEL, DECEL (IDLE UP)
---
616
RESUMEIACCEL, DECEL (IDLE DOWN)
- - -
- - -
0.1 v
Work equipment
(ON/OFF)
Work equipment
REMOlE
I
~~ ~~~
---
I I I
I
POSITIONER CONTROLLER BOOM ANGLE SIGNAL
l/l
I l/l
I
(ON/OFF)
516
616
Remarks
I BOOM
RAISE SIGNAL
I
l/7
BOOM LOWER SIGNAL
(ON/OFF)
Work equipment
l/l
DETENT SIGNAL
(ON/OFF)
Work equipment
l/l
UPPER SET SIGNAL
(ON/OFF)
VHMS
Positioner screen switch of CGC
111
LOWER SET SIGNAL
(ON/OFF)
VHMS
Positioner screen switch of CGC
LOAD METER
I I
BOOM BOTTOM PRESSURE
l/l
I I
MEASURED PRESSURE
l/l
I l/l
I CAL. PRESSURE
I I l/l
NO LOAD PRESSURE
lb
MEASURE LOAD
O.OlMPa 10.1 kg/cm? 1 VHMS
1 Di$?~;~?~~fafr;;~~
O.OlMPa (0.1 kg/cm21 VHMS
Measured trigger pressure
IO.OlMPa (0.1 kg/cm’!I I VHMS
I Calibration
pressure
O.OlMPa IO.1 kg/cm*]
VHMS
Default calibration pressure
1 TON
VHMS
Measured trigger load
JOYSTICK STEERING
l/2
J/S ON/OFF SIGNAL
l/2
S/T NEUTRAL SWITCH
I 712 I S/T LEVER POTENT10
I l/2
I ARTICULATE
ANGLE
II2
J/S SOLENOID OUTPUT
l/2
STEERING LOCK
20-260 0
_--
_--
(ON/OFF)
I
Work equipment
0.1 v
I Work equipment
v
Work equipment
1 mA
Work equipment
(ON/OFF)
Work equipment
0.1
WA1 200-3
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
TROUBLESHOOTING
Screen No.
Name of signal
2/2
T/M DIRECTION SIGNAL F
1 2/2
1 T/M DIRECTION SIGNAL N
1 Z/2
1 T/M DIRECTION SIGNAL R
l/2
Unit
Component name
(ON/OFF)
T/M
1
(ON/OFF)
I T/M
1
(ON/OFFIj (ON/OFF)
S/l N SIGNAL OUTPUT
I T/M
Remarks
I
I
I
I
Work equipment
PM CLINIC 114
ENGINE SPEED
114
COOLANT TEMP.
1°C
CENSE
114
T/C TEMP.
1°C
VHMS
1°C
j VHMS
I
I
1 CENSE
I
I
1O.OlMPa (0.1 kg/cm3 I CENSE
I
I
I I I
I I I
I
I
I l/4
I AMBIENT
TEMP.
1 rpm
I
VHMS
I 114 I BLOW-BY PRESSURE I l/4 I ENGINE OIL PRESSURE
I
1 2/4
I O.OlMPa (0.1 kg/cm3 I CENSE
1 BOOST PRESSURE
1 mmAq
2i4
EXH. GAS TEMPERATURE
1%
CENSE
2l4
T/C IN PRESSURE
O.OlMPa IO.1 kg/cm3
VHMS
2l4
T/C OUT PRESSURE
O.OlMPa IO.1 kg/cm3
VHMS
1 2/4
( T/M MAIN PRESSURE
1O.OlMPa (0.1 kg/cm3 1 VHMS
1 Z/4
1 T/M LUB. PRESSURE
I O.OlMPa 10.1 kg/cm3 I VHMS
I 314 I T/M MOD PRESSURE 314 -I- S/T PUMP PRESSURE
I O.OlMPa (0.1 kg/cm3 I VHMS I o.lMPa
11 kg/cm3
1 VHMS
314
F BRAKE OIL PRESSURE
O.lMPa 11 kg/cm3
VHMS
314
R BRAKE OIL PRESSURE
O.lMPa 11 kg/cm3
VHMS
314
HYD. OIL TEMP.
I 314 I HYD. OIL PRESSURE 414
PPC OIL PRESSURE
WA1 200-3
1°C
I
I
VHMS
I O.lMPa 11 kg/cm3
I VHMS
O.lMPa (1 kg/cm3
VHMS
20-261 0
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
TROUBLESHOOTING
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR 1. The check lamp output is driven with VHMS.
2.
3.
As the signal to synchronize flashing of the caution lamp output of the main monitor, the ON/OFF output of VHMS is used. Permission of the alarm output is given by S-NET and is sent from VHMS to main monitor. The check lamp and caution lamp are set independently (When two failures occur, both flash). 1
Al arming condiion
Detecting condiion 1 Item
UO.
1
2
Engine oil level
Engine oil pressure
Display range Below LOW level
Below specified pressure
Detail of display range H: Normal lz Abnormal (Engine speed in rpm, oil pressure in kPa) Below followina linear interpolation graph (0.0) (800, 138) ;;;3 $4r71 12200:345)
Above 102oC
Above 102°C but 1OEK alarm is not detected
Above 105°C
2
When left is not satisfied
0
2
When left is not satisfied
10
When left is not satisfied.
T-tx0
10
When left is not satisfied
10
When left is not satisfied
Belowspecifiedlevel Below 1 segment of gauge (11%)
*_--
0
10
When leit is not satisfied.
Above 12OOC
Above 120°C but 130°C alarm is not detected
Above 130°C
Above 130°C
Above 105oC
Above 10S°C
Below 14.7 MPa (150 kglcmq
Below 14.7 MPa (150 kg/cm3 and within 60 set after engine starts
--IO
0
10
When left is not satisfied.
0
0
10
When left is not satisfied.
0
0
10
When left is not satisfied.
__-
0
___
When left is not satisfied.
0
5
When left is not satistied.
-i-
Below 14.7 MPa (150 kg/cm? and atter 60 set after engine starts
---
Below 14.7 MPa I150 kg/cm9 and within 60 set after engine starts
___
0
___
When left is not satisfied.
Below 14.7 MPa f150 kg/cm3 and after 60 set after engine starts
-_-
0
5
When let?is not satisfied.
0
0
10
When leti is not satisfied.
0
___
10
When left is not satisfied.
0
10
___ =I=
When left is not satisfied.
2
When left is not satisfied.
0
2
When left is not satisfied.
--_
0
2
When left is not satisfied.
2
When left is not satisfied.
Batteryfluid level (3) Below LOW level
OPEN (Fluid level is low) = 6 V ceil is below 2 V
Belowspeciiiedlevel OPEN = 24 V (Fluid level is low) Belowsoecifiedlevel OPEN = 24 V (Fluid level is low)
l
t
-I--__-_ 0
Below LOW level
OPEN = 24 V (Coolant is insufficient)
Below LOW level
OPEN = 24 V (Coolant is insufficient)
Above specified pressure
OPEN = 24 V (Clogging) and torque converteroil temoeratureis above 50°C
Above specified negative pressure
OPEN = 24 V (When clogged)
__-
0
Above specified negative pressure
OPEN = 24 V (When clogged)
__-
0
When left is not satisfied.
Above specified negative pressure
OPEN = 24 V (When clogged)
___
0
When left is not satisfied.
above specified negative pressure
OPEN = 24 V (When clogged)
_-_
0
When left is not satistied.
Above 9.3 V (While engine is running) [Criterionwhile engine is running: Voltage of terminal R is above 9.3 V or engine speed > 600 mm)
---
0
When let?is not satisfied.
Voitageat alternator when charging is terminal R sbnormal
20-262 0
-__
__-
OPEN (Fluid level is low) = 6 V cell is below 2 V
.
___ 1 0
0
17 1Batteryfluid level(21 Below LOW level
,8
t-l-
Resettingcondition
0
OPEN (Fluid level is low) =6Vcellisbelow2V
4
Failure engine engine etectinf starts is runnin mekec
Above 105°C
Batteryfluid level(1) Below LOW level
Coolant level
mdilkmi Resettingcondition 1
m
Belowspecifiedlevel Below 1 segment of gauge (11%)
Below 14.7 MPa (150 kg/cm?
‘1
Letactinc
I
WA1 200-3
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
Alarm output w
T, ompent &ference) Clinic(Reference)
Abnormal
Not installed
Red
I
I
- - -
Flashing
CENSE
---
I
,
I
Abnormal
Yellow
Installed
0
- - -
Flashing
1
1
Gauge
0
CENSE VHMS
-__
1 966
)
X
0 Abnormal
Red
‘ressurizing Yellow Abnormal
Installed
- - -
Flashing
Installed
---
Flashing
1 Red 1Not installed1 - --
‘ressurizing Yellow
Installed
---
1913 1
0
Flashing
___
I 912 I
X
1915 1
0
Not installed
- - -
Flashing
Abnormal
Yellow
Installed
Flashing
- - -
Abnormal
Yellow
Installed
Flashina
- - -
Abnormal
Red
Not installed
- - -
Abnormal
Yellow
Installed
Flashing
- - -
Abnormal
Red
Not installed
- - -
Fiashina
ON
I installed ( Flashing 1 ---
Abnormal I Yellow
I installed I Flashing 1 - --
Gauge
---
Gauge
0
Gauge
0
---
0
---
0
___
0
-__
0
___
0
VHMS .
---
VHSM
Flashing
Abnormal I Yellow
---
VHMS
ON
Red
0
Gauge
VHMS
VHMS
1Flashing
Abnormal
Gauge
___
932
0
Abnormal
Yellow
Installed
Flashing
- --
___
933
0
Abnormal
Yellow
Installed
Flashing
---
___
934
0
-__
935
0
-__
937
0
---
___
---
-__
VHMS
Abnormal I Yellow
Abnormal
I Installed I Flashing 1 ---
1 Yellow 1 Installed 1Flashing / i:y
*
VHMS
+WA1 200-3
20-263 0
FAILURE CODES LIST
TROUBLESHOOTING
FAILURE CODES LIST * * *
Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only CGC monitor). For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor. In “Display of history”, EOOO + Contents of failure + Time when failure occurred + Time when failure is rest are displayed.
39 70 72
E01
1 EOl + CALL
a4 1 a5 ( CALL
20-264 0
1Short circuit with chassis ground in 1st bypass solenoid Disconnection
in boom
RAISE/LOWER,
bucket
TILT/DUMP
signal
system
pressure
switch
I system
Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system
Short circuit, disconnection, or short circuit with chassis ground in neutral cut solenoid system
I Short circuit. discunnsction,or short circuit with chassis gmund in modulated clutch ECMV solenoid system
1 E039 1 E070 / E072
( E084 1 E085
WA1 200-3
TROUBLESHOOTING
*
FAILURE CODES LIST
Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only CGC monitor). For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor. In “Display of history”, EOOO + Contents of failure + Time when failure occurred + Time when failure is rest are displayed.
* *
CGC monitor
)e,,ke Failure Action code code
44
E043
EOl + CALL Short circuit of hot side of dumoina solenoid with Dower source
45
g U
Real-time Displayof display history
Disconnection, short circuit, or short circuit with chassis ground in dumping solenoid
43
=g 2
Failed system
E044
Short circuit of return side of dumping solenoid with power source
E045
49
Disconnectionor short circuitwith chassisground in boom lever kick-outsolenoidsystem
E049
51
Disconnection in boom RAISE/LOWER pressure switch system
E051
52
Disconnection, short circuitwith chassisground or short circuitin boom angle sensorsystem
E052
2
55
: ‘3 B Y z
56
CALL
EOO
Short circuit or disconnection in travel sDeed sensor svstem
E055
Disconnection, shortcircuitwithchassisground or short circuit in joystick cautionbuzzerrelaysystem
E056
57
EOl t CALL Disconnection, shortcircuitwithchassis ground or short circuit in steering lever angle sensor system
EO57
58
EOlt CALL Deviationof potentiometer signal in steering lever angle sensor/frsmeangle sensor system
E058
59
EOl t CALL Disconnection, short circuitwith chassisgroundor short circuitin frame angle sensorsystem
E059
61
EOl t CALL Disconnection or short circuit with chassis ground in steering lever lock switch system
E061
62
EOO
Disconnection, shortcirceitwithchassis aroundor shortcinxitin iovstkkneutrelinterfcck relevsystem
E062
Disconnection, short circuit with chassis ground or short circuit in joystick main EOl t CALL pressure control EPC solenoid system
63
I
lE8ii
E812 1
1
E813 E814)
I I E821 l E824 1 E818
1 Disconnection or short circuit with Dower source in NSW Dower sutmlv svstem
E063
1
1 Short circuit with chassis ground in 24-V system of sensor power supply
1Short circuit with chassis around in 12-V svstem of sensor Dower SUDDIY
I
) Short circuit with chassis ground in 5-V system of sensor power supply
I
I Wrong connection of connector I Failure in controller (Failure in securino of memorv) 1Failure in communication with CGC and engine controller
I !
I 1 1 1 I I 1
E811
E813 E814 E818 E821
Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between transmission controllers)
E825
E826
Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between modulated clutch controllers)
E826
E827
Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between work eauioment controllers1
E827
I
IE8311
I Failure in controller (Handle error)
E841 E843
1 I
Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between main monitors)
I I
Short circuit of buzzer output with power source
1Short circuit of check lamp with power source
I l 1 I
E828 I E831 I E841 E843
E844
Short circuit of flash synchronizing signal with power source
E844
E861
Disconnection or short circuitwith chassisground in boom bottompressuresensorsystem
E861
E862
Disconnectionor short circuit with chassisaround in boom head oressure sensor svstem
) E864 1
Disconnectionor short circuitwith chassisground in rear brake oil pressuresensor system 1
E863
1Disconnection or shortcircuitwith chassisgroundin work equipment relief pressure sensor system 1
E862
) E863 1 E864
E865
Disconnection or short circuitwith chassisground in front brakeoil pressuresensorsystem
E865
E866
Disconnection or shortcircuitwithchassisgmundin transmission main relief pressure senscrsystem
E866
E867
Disconnectionor short circuitwith chassisaround in steerinarelief oressuresensorsystem
E867
E8681
Disconnectionor short circuit with chassis groundin torque converter outlet oil pressure sensor system
1 E866 1 E871
E871
I
1Disconnectionor short circuit with chassis around in transmission modulation oil pressure sensor system 1
lE8721 I
Disconnection, short circuit with chassis ground or short circuit with power source in transmission lubricating oil pressure sensor system
WA1 200-3
I
E824
E825
lE4
I
E812
20-265 0
TROUBLESHOOTING
* * *
FAILURE CODES LIST
Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only CGC monitor). For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor. In “Display of history”, EOOO + Contents of failure + Time when failure occurred + Time when failure is rest are displayed. CGC monitor 1 1 Real-time 1Displayof 1 1 display 1 history
1 Failed system E874
Short circuit with chassis ground in torque converter oil temperature sensor system
E874
E875
Shortcircuit withchassis ground or shortcircuit withpowersource in hydraulic oiltemperature senscr system
E875
ES77
Disconnection, short circuit with chassis ground or short circuit with power source in atmosoheric temoerature sensor svstem
E877
E878
Disconnectionor short circuit with chassisground in PPC relief pressure sensor system
ES78
5884
Diicnnectionor shortcircuitwithchassis groundin torqueconverterinletoil pressuresecscrsystem
E901
Enaine oil level below LOW level
1
E937
*
1
Charging trouble of alternator
For display of failure codes related to engine controller, see “Troubleshooting system (G-mode)“.
20-266 0
E884 DkhvofcautbnE901
~k$ayofratin( E937
for engine controller
WA1 200-3
TROUBLESHOOTING
METHOD OF USING JUDGEMENT
TABLE
METHOD OF USING JUDGEMENT TABLE This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-00, H-OO, etc.) matches the symptoms. The judgement table is designed so that it is easy to determine from the self-diagnostic display which troubleshooting table to go to. * The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system (M-00). (See troubleshooting of the machine monitor system) [Method of using judgement table1 A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check if an error code is displayed on the graphic display portion of the monitor panel. If an error code is displayed: Go to the troubleshooting code at the bottom of the judgement table (E-OO, etc.). If there is a problem but no error code is displayed: Go to the troubleshooting code on the right of the judgement table (H-001. For failure modes where no 0 mark is given, go directly to the troubleshooting code on the right of the judgement table.
l
l
l
l
WA1 200-3
20-267 0
METHOD OF USING TROUBLESHOOTINGCHARTS
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Troubleshooting
2.
Code No.
1
Component
G-00
Troubleshooting
of engine controller system
T-00
Troubleshooting
of transmission
MC-00
Troubleshooting
of modulated clutch controller system
J-00
Troubleshooting
of joystick steering controller system
w-00
1 Troubleshooting
of work equipment controller system
M-00
1 Troubleshooting
of main monitor system
v-00
Troubleshooting
of VHMS controller system
H-00
Troubleshooting
of hydraulic, mechanical system
controller system
Method of using troubleshooting table Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with f. The precautions marked * are not given in the I, but must always be followed when carrying out the check inside the I. Distinguishing conditions Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. Method of following troubleshooting chart * Check or measure the item inside In, and according to the answer follow either the YES line or the NO line to go to the next 0. (Note: The number written at the top right corner of the I 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. . Below the I there are the methods for inspection or measurement, and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow ttie NO line. . Below the I 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 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 Item 1). Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. 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.
20-268 0
WA1 200-3
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CHARTS
@ M-5
0* * *
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.
0
a) L.H. turn signal display does not light up a) Divided into sections a) and bl I b) R.H. turn signal display does not light up
@
Flow chart
a1 L.H. turn signal display does not light up
1 YES IS voltage between Lo6 (14)
DefBcdve cowact 0, d&connection in wirina
and chassis groundnormal? . Repeats0 V and NO M-30V. *Turn startingswitchON. . Turn LH. turn signalON.
hamessbetweenLO6” (female)(14) and L144 (male)(1)
Repairor
b) R.H. turn signal display does not light up ,
Repair or replace
M-5
Related electrical circuit diagram L.H. turn signal
I alllo - (25W)
WA1 200-3
20-269 0
TROUBLESHOOTING
METHOD OF USING MAiRlX TROUBLESHOOTINGTABLES
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 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.
1.
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 leakage 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.
Checks before
Step 3. Using cross-referencetable 1) 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. 2)
20-270 0
Find the appropriate cause from the cause column. If the symptom appears, the 0 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.) lf there is only one 0: Carry out the other troubleshooting items (where the same cause is marked with 0), check if the symptom appears, then repair. If there are two 0: Go on to Step 3) to narrow down the possible causes.
Steering does not work t
Symptom [Example]
Ask the operator about the following points. Did the steering suddenly stop working + Had the steering gradually been becoming heavy? + Internal wear of steering equipment,
starting
[Example]
Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is there any leakage of oil from the steering valve or Orbit-roll? Has the safety bar been removed from the frame?
l
l
l
[Example
1I
No- Problems 1
Remedy
Steering does not work to the left or right. I
3
Same as item 1, but abnormality in actuation of work equipment
3
Steering can only be operated to one side.
4
Steering wheel is heavy and cannot be turned.
[Example 21
-i--H WA1 200-3
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING
3)
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 I), and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 5).
4)
Find the appropriate cause from the cause column. In the same way as in Step 21, if the symptom appears, the 0 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-1
5)
6)
Narrow down the possible causes. There is one common cause among’the causes located in Steps 2) and 41. (One cause marked 0 appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps 1) and 3). Jr The causes which are not common to both troubleshooting items (items which are not marked 0 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 cause for Troubleshooting Item 5 are b or e, so cause e is common to both.)
L
LApplicable
TABLES
troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
I
///‘I1 Janore
these causes
causes
Repeat the operations in Steps 31, 4) and 5) until one cause (one common cause) remains. J, If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible.
n to take
71 Remedy If the causes are narrowed down to one common cause, take the aciton given in the remedy column. The symbols given in the remedy column indicate the following: X: Replace, a: Repair, A; Adjust, C: Clean
WA1 200-3
4 101 5_--__I_+3c_I_
1 JOI i I
20-271 0
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)
Display method of CUMMINS
engine controller failure codes and contents of display .............. 20-302
Failure codes and actions table .... ........ .................. ..... ..... ...... ...... ..... ........-..........................................
WA1 200-3
20-303
20-301 0
TROUBLESHOOTING
DISPLAY METHOD OF CUMMINS ENGINE CONTROLLER FAILURE CODES AND CONTENTS OF DISPLAY
DISPLAY METHOD OF CUMMINS ENGINE CONTROLLER FAILURE CODES AND CONTENTS OF DISPLAY 1. The failure codes from the CUMMINS
engine controller are transmitted (CAN) line to the VHMS controller, where they are processed.
through communication
2.
The failure codes and contents of the failures (displayed messages) are saved as failure history.
3.
The failure codes are displayed on the alarm screens corresponding to the operator codes (for the customer).
4.
Operator codes [Oil - I041 and other five screens are set for the alarm screens (for the customer).
5.
If a failure which is not shown in this list occurs, the alarm screen of occurrence of an unregistered error appears.
20-302 0
WA1 200-3
FAILURE CODES AND ACTIONS TABLE
TROUBLESHOOTING
FAILURE CODES AND ACTIONS TABLE
I
I
124
Abnormal
Cl36 Cl37
135 136 137
Abnormal Abnormal Abnormal
Cl41 Cl43
141 143
Cl24
I
LB suction Dressure Hi
1
I SeeCummins Manual I
1
See CumminsManual See CumminsManual
Short circuit in PTO circuit Lo Cl35
I
I
Cl51 Cl53
I
151 153
Cl54
I
154
Cl55 Cl56 Cl57
155 156 157
Cl56 Cl59 Cl61
156 159 161
Cl62 Cl63 Cl64
162 163 164
Cl65 c212 C213 C214
165 212 213 214
c219 c221 c222 C223 C225
WA1 200-3
1
oil pressure sensor Hi filter inlet pressure sensor Hi. filter inlet pressure sensor Lo
6 6
1Abnormal oil pressure sensor Lo I Oil rxessure Lo
Coolant Hi 1 Abnormal
1
1
See CumminsManual 1See CumminsManual
4
1See Cummins Manual
3 1 1
1See CumminsManual 1See CumminsManual I SeeCumminsManual
4
See CumminsManual See CumminsManual See CumminsManual
LBF air boost temDerature 1Abnormal LBF air boost temoerature LBF air boost temperature Hi
sensor Hi sensor Lo
Abnormal LBR air boost temperature Abnormal LBR air boost temperature LBR air boost temperature Hi
sensor Hi sensor Lo
6 6 4
Abnormal RBF air boost temperature Abnormal RBF air boost temDerature RBF air boost temperature Hi
sensor Hi sensor Lo
6 6 4
Abnormal RBR air boost temperature Abnormal RBR air boost temperature RBR air boost temperature Hi Abnormal oil temperatuer sensor Hi
sensor Hi sensor Lo
6 6 4
1
See CumminsManual See CumminsManual See CumminsManual
3
See CumminsManual See CumminsManual See CumminsManual I SeeCumminsManual I
1
See CumminsManual
6 6
219
oil temDerature sensor Lo Hi Remote oil level Lo
221
Abnormal
sensor Hi
6
See CumminsManual
222 223
Abnormal atmospheric temperature sensor Lo Short circuit in CORS BV solenoid Lo Short circuit in CORS M valve Lo
6 1 1
See CumminsManual See CumminsManual See CumminsManual
225
Abnormal
See CumminsManual See CumminsManual See CumminsManual
I Oil temoerature
atmospheric
temperature
I
20-303 0
FAILURE CODES AND ACTIONS TABLE
TROUBLESHOOTING
Contents
1
C452
452
Fuel rail pressure
A-double
output
527 528
1Abnormal
c529
528
B-double
c55S c554 c555
553 554
Fuel rail pressure
C527 C528
C611
20-304 0
I
555 611
of failure
Lo
Hi
aenerator output Hi Hi
Abnormal fuel rail pressure Blow-by pressure Hi Sudden stop of overheating
I
1
1See Cummins Manual
1
1See Cummins Manual 1See Cummins Manual
1 1 4
See Cummins Manual
2 4
See Cummins Manual See Cummins Manual
8
See Cummins Manual
See Cummins Manual
WA1 200-3
FAILURE CODES AND ACTIONS TABLE
TROUBLESHOOTING
c
Komatsu failure code
Cummins failure code
C612 C616 C621 C622
612 616 621 622 623
Oil filter pressure Hi LBR turbocompressor #1 LB low pressure #2 LB low pressure #3 LB low oressure
624 625 626 627 628
#4 #5 #6 #7 #8
631
#1 RB over-outout
C623 C624 C625 C626 C677
t-
t
C631
C642 C643 C644 C645 C646 C647
I
low low low low low
646 647
1#6 LB over-exhaust 1#7 LB over-exhaust
$7 638 641 642 643 644
RB over-output RB over-output RB over-output RB over-output RB over-output RB over-output RB over-outout LB over-exhaust LB over-exhaust LB over-exhaust LB over-exhaust LB over-exhaust
LB over-exhaust #l RB over-exhaust #2 RB over-exhaust / #3 RB over-exhaust
t
C656 C657 C658 C661 i-x67 ___-
1 c
C663 C664 C665 C666
I
I
1
1
663 664 665 666 667
C667 C6fi8 ---_
656 657 658 661 6f -_ i2
I
suction temperature
temperature temperature temperature temperature temperature temperature
temperature temperature temoerature temperature
#8 RB over-exhaust #I LB over-output I #2 LB over-output
temperature
#5 LB over-output #6 LB over-output #7 LB over-output
Action (Diagnosis code)
2 6 1 1
See CumminsManual See CumminsManual See CumminsManual Sea CummincManll:
1
scva ___ fhnrnil _I........is
I
. .._.._.ij
Manual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See --- Cflmminc __........._ Mant~al
1 1 1 1 1
See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual
1 1
See CumminsManual See ..._..__. -__ Cummins _- .. ....._ Mniwal
4 4 4 4
See CumminsManual See CumminsManual See CumminsManual
,.,“..““.
4
1See CumminsManual 1 / See CumminsManual 1 1See CumminsManual
4
I See Cummins Manual
4 4 4 4
See CumminsManual See CumminsManual See CumminsManual 1See CumminsManual 1
4 4
1See CumminsManual 1 1See CumminsManual
4
I See Cummins Manual
.4 4
I
.”
1 1
4
temoerature temperature temperature temperature temperature
RB over-exhaust
I #3 LB over-output I #4 LB over-outout
Cummins operator code
1 1 1 1
RB over-exhaust RB over-exhaust RB over-exhaust
-#4 #5 1#6 #7
Hi
pressure pressure pressure pressure pressure
645
i
C641
LB LB LB LB LB
#2 #3 #4 #5 #6 #7 #8 #l #2 #3 1#4 1#5
636
I
Contents of failure (System)
2
See CumminsManual See CumminsManual See CumminsManual
2 2 2
1See CumminsManual1 ) See CumminsManual 1 1SeeCumminsManual 1
2 2 2
See CumminsManual Saa CumminsManual See CumminsManual
f% __
C6:
WA1 200-3
20-305 0
TROUBLESHOOTING
FAILURE CODES AND ACTIONS TABLE
Contents of Cummins operator codes and display of CGC [message) * Operator codes [ll - [41 are displayed. Operator codes [51- I81 are not displayed, however, and they are only saved as history. (Ill - 141 are saved as history, too.) l
l
l
l
l
l
Operator Operator Operator Operator
Check and maintain when the work is finished or the operator is changed. Stop the machine on a safe place, then check and maintain immediately. Operate the machine with the engine speed and travel speed low. Stop the machine immediately on a safe place and stop the engine, then check and maintain immediately. Operator codes 5 - 8: They are only saved as history (not displayed). Failures other than above: Contact your distributor.
20-306 0
code code code code
1: 2: 3: 4:
WA1 200-3
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)
Judgement table for transmission
control system related parts ......................................................
20-404
Operations of controller against abnormality and conditions of machine caused by abnormality ..........................................................................................................
20-406
Electrical circuit diagram for transmission controller system ...........................................................
20-416
T- 1
Failure code [IO] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed .................................................................
T- 2
Error code [l II (Disconnection in modulated clutch outlet rotation signal sensor system) is displayed .....................................................................................................
T- 3
20-423
Error code [161 (Short circuit, disconnection, or short circuit with power source in 3rd solenoid system) is displayed.. ...........................................................
T- 8
20-422
Error code II51 (Short circuit, disconnection, or short circuit with power source in 2nd solenoid system) is displayed .............................................................
T- 7
.20-421
Error code 1141 (Short circuit, disconnection, or short circuit with power source in 1st solenoid system) is displayed ..............................................................
T- 6
20-420
Error code 1131 (Short circuit, disconnection, or short circuit with power source in R solenoid system) is displayed ................................................................
T- 5
20-419
Error code 1121 (Short circuit, disconnection, or short circuit with power source in F solenoid system) is displayed .................................................................
T- 4
20-418
.20-424
Error code 1181 (Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid system) is displayed ................................ -20-425
T- 9
Error code 1201 (Short circuit or disconnection in joystick FNR switch system) is displayed.. .............................................................................
T-IO
Error code 1211 (Short circuit or disconnection in joystick shift-up/shift-down
T-II T-12
20-426
switch system) is displayed ......................................................
20-427
Error code [221 (Disconnection in travel speed sensor system) is displayed.. .................. 20-428 Error code 1231 (Short circuit or disconnection in engine speed sensor system) is displayed.. ...........................................................................
20-429
T-13
Failure code 1241 (Short circuit, disconnection in EEP ROM) is displayed ........................ 20-430
T-14
Error code 1251 (Short circuit in transmission
T-15
Error code 1261 (Short circuit in F ECMV fill switch system) is displayed ......................... 20-432
T-16
Error code 1271 (Short circuit in R ECMV fill switch system) is displayed.. ....................... 20-432
T-17
Error code I281 (Short circuit in 1st ECMV fill switch system) is displayed ...................... 20-433
T-18
Error code 1291 (Short circuit in 2nd ECMV fill switch system) is displayed.. ................... 20-433
T-19
Error code [301 (Short circuit in 3rd ECMV fill switch system) is displayed.. .................... 20-434
T-20
Error code [321 (Disconnection in F or R ECMV fill switch system) is displayed ............. 20-435
oil temperature sensor system)
is displayed ................................................................................................................................
WA1 200-3
20-431
20-401 0
T-21
Error code [331 (Disconnection in lst, 2nd, or 3rd ECMV fill switch system) is displayed ................................................
T-22
20-436
................................................................................
Error code 1341 (Disconnection or 3rd short circuit with power source in 20-437
F bypass solenoid system) is displayed ................................................................................. T-23
Error code [351 (Short circuit in F bypass solenoid system) is displayed ......................... 20-438
T-24
Error code [361 (Disconnection or short circuit with power source in R bypass solenoid system) is displayed .................................................................................
20-439
T-25
Error code [371 (Short circuit in R bypass solenoid system) is displayed .........................
20-440
T-26
Error code 1381 (Disconnection or short circuit with power source in 20-441
1st bypass solenoid system) is displayed .............................................................................. T-27
Error code 1391 (Short circuit in 1st bypass solenoid system) is displayed ...................... 20-442
T-28
Auto/Manual
T-29
Kickdown switch system ..........................................................................................................
T-30
Transmission
T-31
Steering lock switch signal system .........................................................................................
20-445
T-32
Neutralizer relay signal system ...............................................................................................
20-446
T-33
Buzzer signal system ................................................................................................................
20-447
T-34
Network system .........................................................................................................................
20-448
T-35
Transmission
20-443
selector switch system ......................................................................................
20-443 20-444
cut-off switch signal system ............................................................................
controller power supply system ......................................................................
20-449 20-450
T-36
Short circuit in travel speed sensor system ...........................................................................
T-37
Short circuit in modulated clutch outlet rotation sensor system ........................................ 20-451
T-38
Disconnection
T-39
Fl (Forward 1st gear) signal system .......................................................................................
20-453
T-40
Abnormality
in auto shift indicator lamp ...............................................................................
20-454
20-402 0
in transmission oil temperature sensor system ...........................................
20-452
WA1 ZOO-3
JUDGEMENT TROUBLESHOOTING
TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR TRANSMISSION SYSTEM RELATED PARTS i
CONTROL Self-diaanosis disolav (Dis av of abnormality)
Location of failure
Failure mode controlle 1 1Machine cannot travel 2 1Machine can travel even if steering lock lever is in ‘LOCK’ position 3 1Gear is not shiited automaticailv 4 FNR (Forward/Reverse) 5 Machine travels forward
switch is not matched to travel direction even if FNR (Forward/Reverse)
switch is not in ‘F’ position
6 Machine travels in reverse even if FNR (ForwardlReverse) switch is not in ‘R’ oosition 7 Gear is shifted down, regardless of travel speed 8 Gear is shifted up, regardless
of travel speed
9 Large shocks are made when gear is shifted 10
Gear shift hunting occurs during travel
11
Gear shift huntina occurs when aear is shifted
12
Gear shift indicator does not follow up gear shift-up/down
13
Gear speed cannot be controlled with gear shift-up/down
14
Gear shifting operation
15
Travel mode (Manual/Auto)
16 17
and travel speed are abnormal
switch in auto mode switch in manual mode
in auto mode
cannot be changed.
Kickdown svstem does not work (Travel sot?4 must be below 13 km/h in auto mode)
1Scooping
power is lost when kickdown system operates.
18 I Transmission
is not cut off when left brake is aonlied
19 1Machine can travel while oarkina brake is aoolied 20 21
1Backup lamp and 1F-R chanae alarm
alarm buzzer do not operate buzzer does not sound durina hiah-soeed
travel
22
Alarm buzzer does not stop sounding
23
Main motor does not display transmission controller information (Alarm buzzer, failure code, etc.)
24
Modulated
25
Travel mode (and gear shift range)when key is turnedto OFF is not saveduntil engine is startedagain
clutch controller
does not function
26
Auto aear shift indicator lamo does not liaht uo in auto mode Diagnosis code when failure code is displayed
20-404 0
T-1 T-2 T-3 T-4 T-5 T6 T-7 T-8 T-9 T-10T-11T-12T-13T-14
WA1 200-3
JUDGEMENT TROUBLESHOOTING
Self-diagnosis
display (Dis
Transmission
WA1 200-3
TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
controller error
20-405 0
OPERATIONS
OF CONTROLLER
CONDITIONS
TROUBLESHOOTING
AGAINST
ABNORMALITY
AND
OF MACHINE CAUSED BY ABNORMALlTY
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY (1) TRANSMISSION I Failure code
10
11
12
13
14
15
20-406 0
CONTROLLER SYSTEM Abnormal
system
Contents
of abnormality
Short circuit, disconnection, or short circuit with power source in backup lamp relay system
1) Defective backup lamp relay 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller Cl (female) (11) - L54 (1) 3) Disconnection or defective contact in wiring harness between backup lamp relay L54 (female) (2) - chassis ground 4) Defective transmission controller
Disconnection in modulated clutch outlet rotation signal sensor system
1) Defective modulated clutch outlet rotation sensor 2) Disconnection or defective contact in wiring harness between transmission controller C4 (female) (9) - T16 (female) (2) 3) Disconnection or defective contact in wiring harness between transmission controller C4 (female) (2) - T16 (female) (1) 4) Defective transmission controller
Short circuit, disconnection, or short circuit with power source in F ECMV solenoid system
1) Defective F ECMV solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (2) - T13 (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (13) - T13 (female) (2) 4) Defective transmission controller
Short circuit, disconnection, or short circuit with power source in R ECMV solenoid system
1) Defective R ECMV solenoid 2) Disconnection,defectivecontact,short circuitwith chassis ground, or shortcircuitwith power sourcein wiring harness between transmissioncontrollerC2 (female) (3) - Tll (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (14) - Tll (female) (2) 4) Defective transmission controller
Short circuit, disconnection, or short circuit with power source in 1st ECMV solenoid system
1) Defective 1st ECMV solenoid 2) Disconnection,defectivecontact,short circuitwith chassis ground, or short circuitwith power sourcein wiring harness between transmission controller C2 (female) (7) - T3 (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (17) - T3 (female) (2) 4) Defective transmission controller
Short circuit, disconnection, or short circuit with power source in 2nd ECMV solenoid system
1) Defective 2nd ECMV solenoid 2) Disconnection,defectivecontact,short circuitwith chassis ground, or shortcircuitwith power sourcein wiring harness between transmission controller C2 (female) (8) - T5 (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (18) - T5 (female) (2) 4) Defective transmission controller
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALlTY AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
Normal condition (voltage, current, resistance) 1) Relay coil resistance: 200 - 400 R 2) Voltage between transmission controller Cl (11) - chassis ground in neutral: Below 1 V 3) Resistance of harness between transmission controller Cl (female) (11) - L54 (female) (1): Max. 1 Q 4) Resistance of harness between backup lamp relay L54 (female) (2) - chassis ground: Max. 1 R
Operation of controller against abnormality
Condition of machine caused by abnormality
Neutral (All ECMV output: OFF)
Backup lamp does not light up when machine moves in reverse.
1) Modulated clutch outlet rotation sensor Resistance between T16 (male) (1) - (2): 500 Assumes MOD/C 1000 R outlet rotation to be Resistance between T16 (male) (11, (2) - chassis 2100 rpm. ground: Min. 1 MS2
1) Resistance between transmission controller C2 (female) (2) - (13): 10 - 20 R 2) Voltage between transmission controller C2 (2) - chassis ground in neutral: Below 1 V 3) Resistance between transmission controller C2 (female) (21, (13) - chassis ground: Min. 1 MQ 4) Resistance of harness between transmission controller C2 (female) (21, (13) - 113 (female) (11, (2): Max. 1 R
1) Resistance between transmission controller C2 (female) (3) - (14): 10 - 20 Q !I Voltage between transmission controller C2 (3) - chassis ground in neutral: Below 1 V 3) Resistance between transmission controller C2 (female) (31, (14) - chassis ground: Min. 1 MR 4) Resistance of harness between transmission controller C2 (female) (3). (14) - Tll (female) (l), (2): Max. 1 Q I) Resistance between transmission controller C2 (female) (7) - (17): 10 - 20 R !I Voltage between transmission controller C2 (7) - chassis ground in neutral: Below 1 V 8) Resistance between transmission controller C2 (female) (71, (17) - chassis ground: Min. 1 MR 1) Resistance of harness between transmission controller C2 (female) (71, (17) - T13 (female) (1). (2): Max. 1 R I) Resistance between transmission controller C2 (female) (8) - (18): 10 - 20 R !I Voltage between transmission controller C2 (8) - chassis ground in neutral: Below 1 V r) Resistance between transmission controller C2 (female) (81, (18) - chassis ground: Min. 1 MR L) Resistance of harness between transmission controller C2 (female) (81, (18) - T5 (female) (1). (2): Max. 1 Q
WA1 200-3
Diagnos code
T-l
Gear is not shifted automatically.
T-2
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-3
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-4
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-5
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-6
20-407 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDlllONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
-ailwe code
I6
18
20
21
22
20-408 0
Abnormal system
Contents of abnormality
Short circuit, disconnection, or short circuit with power source in 3rd ECMV solenoid system
1) Defective 3rd ECMV solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (9) - 17 (female) (I) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (19) - 17 (female) (2) 4) Defective transmission controller
Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid system
I) Defective R clutch drain valve solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller Cl (female) (8) - T23 (female) (I) 3) Disconnection or defective contact in wiring harness between T23 (female) (2) - chassis ground 4) Defective transmission controller
Short circuit or disconnection in joystick FNR switch system
I) Defective joystick FNR switch system 2) Disconnection or defective contact in wiring harness between Cl (male) (71, (13) or C2 (male) (11, (12) - JSI (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness between JSl (female) (21, (31, (4) - C3B (female) (71, (141. (15) 4) Defective transmission controller
Short circuit or disconnection in joystick shift-up/shiftdown switch system
I) Defective joystick shift-up/shift-down switch system 2) Disconnection or defective contact in wiring harness between Cl (male) (71, (13) or C2 (male) (I), (12) - JSl (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness between JSl (female) (51, (61, (7). (8) - C3B (female) (81, (91, (161, (17) 4) Defective transmission controller
Disconnection in travel speed sensor system
I) Defective travel speed sensor 2) Improper installation and adjustment of travel speed sensor 3) Disconnection or defective contact in wiring harness between C5 (female) (2)- TO5 (female) (1) 4) Disconnection or defective contact in wiring harness between C5 (female) (I), (IO) - T15 (female) (2) 5) Defective transmission controller
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Normal condition current, resistance)
(voltage,
1) Resistance between transmission controller C2 (female) (9) - (19): 10 - 20 R 2) Voltage between transmission controller C2 (9) - chassis ground in neutral: Below 1 V 3) Resistance between transmission controller C2 (female) (91, (19) - chassis ground: Min. 1 MD 4) Resistance of harness between transmission controller C2 (female) (91, (19) - 17 (female) (I), (2): Max. 1 R
Operation of controller against abnormality
Condition of machine caused by abnormality
Diagnosi
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-7
Draining speed of oil in R clutch lowers. When R is selected next time, abnormally large gear shift shock may be made. If R clutch drain valve solenoid output is kept turned ON, hydraulic pressure is not applied to R clutch and machine cannot travel in reverse.
T-8
I) R clutch drain valve solenoid Resistance between T23 (male) (1) - (2): 5-15R Resistance between T23 (male) (1). (2) - chassis ground: Min. 1 MD
R clutch drain valve solenoid output: OFF
I) Voltage between C3B (14) - chassis ground When joystick FNR switch is in ‘F’: 17 - 30 V When joystick FNR switch is not in ‘F’: Max. 1 V !) Voltage between C9B (7) - chassis ground When joystick FNR switch is in ‘N’: 17 - 30 V When joystick FNR switch is not in ‘N’: Max. 1 V 1)Voltage between C3B (15) - chassis ground When joystick FNR switch is in ‘N’: 17 - 30 V When joystick FNR switch is not in ‘N’: Max. 1 V
I) In ‘F’: Machine stops. 2) In ‘N’ or ‘R’: Ma1) When “N’ signal is chine travels forinput: Sets in ‘N’ ward suddenly. is 3) Ins;N~r;l~~ ~~tpllt is 2) $h:$i$$y;ignal input: Sets in ‘N” 4) In ‘F’ or ‘R’: Gear is immediately. set in neutral 3) When no signals suddenly. are input: Holds for 5) In ‘R’: Machine 2 set, then sets in stops. ‘N’. 6) In ‘N’ or ‘F’: Machine travels in reverse suddenly.
C5 (8) - chassis ground When joystick shift-up switch (N.0) is in ON: Max. 1 V When joystick shift-up switch (N.0) is in OFF: 17 - 30 V 1 Voltage between C5 (9) - chassis ground When joystick shift-down switch (N.0) is in ON: Max. 1 V When joystick shiidown switch (N.0) is in OA: 17- 30 V 1) Holds forward gear. 1 Voltage between C5 (16) - chassis ground When joystick shift-up switch (N.C) is in ON: 17 - 30 V When joystick shift-up switch (N.C) is in OFF: Max. 1 V 1 Voltage between C5 (17) - chassis ground When joystick shiftdown switch (N.C)is in ON: 17 - 30 V When joystick shiftdown switch 1N.C)is in OFF:Max. 1 V
code
T-9
1 Voltage between
1) Gear cannot be shifted up. 2) Gear cannOt be
T-IO
shifted down.
1Travel speed sensor Resistance between T15 (male) (1) - (2): 500 - 1,000 n Resistance between T15 (male) (1). (2) - chassis ground: Min. 1 MR
WA1 200-3
I) Sets in manual mode.
1) Gear shift pattern is different. 2) Machine overruns.
T-11
20-409 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
I‘ailure
code
Abnormal
system
Contents
of abnormality
1) Defective engine rotation sensor 2) Improper installation and adjustment of engine rotation sensor 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between transmission controller C4 (female) (1) - T17 (female) (1) 4) Disconnection or defective contact in wiring harness between transmission controller C4 (female) (9) - T17 (female) (2) 5) Short circuit in wiring harness between transmission controller C4 (female) (1) - T17 (female) (1) and between C4 (female) (3) - T17 (female) (2) 6) Defective transmission controller
23
Short circuit or disconnection in engine rotation sensor system
24
Short circuit or disconnection in memory (FEPROM)
I) Defective transmission controller
25
Short circuit in transmission oil temperature sensor system
1) Defective transmission oil temperature sensor 2) Short circuit with chassis ground in wiring harness between transmission controller C3A (female) (11) - T19 (female) (1) 3) Short circuit in wiring harness between FR2 (male) (12) - Tl9 (female) (1) and between FR2 (male) (20) - Tl9 (female) (2) 4) Defective transmission controller
26
Short circuit in F ECMV fill switch system
1) Defective F ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (2) - T14 (female) (1) 3) Defective transmission controller
Short circuit in R ECMV fill switch system
1) Defective R ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (10) - T12 (female) (I) 3) Defective transmission controller
-
27
28
29
20-410 0
Short circuit in 1st ECMV fill switch system
Short circuit in 2nd ECMV fill switch system
1) Defective 1st ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (3) - 14 (female) (1) 3) Defective transmission controller
1) Defective 2nd ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (11) - T6 (female) (1) 3) Defective transmission controller
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABN0RMALl-W AND CONDITIONS OF MACHINE CAUSED BY ABNORMALm
Normal condition (voltage, current, resistance)
I) Resistance between engine rotation sensor T17 (male) (I) - (2): 100 - 500 R 2) Voltage between transmission controller C4 (female) (I) - (9): Min. 0.5 V
Operation of controller against abnormality
Condition of machine caused by abnormality
Diagnosi! code
,) Can trave, with engine speed at 2,100 rpm.
1) Learning function is turned off and default data are
Gear shift shock is made.
T-12
Gear shift shock is made.
T-13
Gear shift shock is made.
T-14
Machine cannot travel.
T-15
Neutral (~11 ECMV output: OFF)
Machine cannot travel.
T-16
I) Resistance between transmission controller C3B Neutral (~11 ECMV (female) (3) - chassis ground in neutral output: OFF) (1st ECMV: OFF): Min. 1 MR
Machine cannot travel.
T-17
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-18
Gear shift shock is reduced by learning function.
used.
1) Resistance between transmission oil temperature sensor T19 (female) (1) - (2): 38 - 48 kS2 (Approx. 25°C) 2) Voltage between transmission controller C3A (female) (II) - (17): 1 - 5 V
When gear is shifted, data of low transmission oil temperature are used.
1) Resistance between transmission controller C3B Neutral (All ECMV (female) (2) - chassis ground in neutral output: OFF) (F ECMV: OFF): Min. 1 MC?
I) Resistance between transmission controller C3B (female) (IO) - chassis ground in neutral (R ECMV: OFF): Min. 1 MR
I) Resistance between transmission controller C3B (female) (1 I) - chassis ground in neutral (2nd ECMV: OFF): Min. 1 Mh
WA1 200-3
20-411 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Failure code
Abnormal
system
Contents
of abnormality
Short circuit in 3rd ECMV fill switch system
I) Defective 3rd ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C5 (female) (I 1) - T8 (female) (I 1 3) Defective transmission controller
Disconnection in F or R ECMV fill switch system
I) Defective F or R ECMV fill switch 2) F ECMV fill switch: Disconnection or defective contact in wiring harness between transmission controller C3B (female) (2) - T14 (female) (I) 3) R ECMV fill switch: Disconnection or defective contact in wiring harness between transmission controller C3B (female) (IO) - T12 (female) (1) 41 Defective transmission controller
Disconnection in Ist, 2nd. or 3rd ECMV fill switch system
1) Defective 1st. 2nd, or 3rd ECMV fill switch Disconnection or defective contact in any of following wiring harnesses 2) 1st ECMV fill switch: Transmission controller C3B (female) (3) - T4 (female) (I) 3) 2nd ECMV fill switch: Transmission controller C3B (female) (I I) - T6 (female) (I) 4) 3rd ECMV fill switch: Transmission controller C5 (female) (11) - T8 (female) (1) 5) Defective transmission controller
34
Disconnection or short circuit with power source in F bypass solenoid system
I) Defective F bypass solenoid 2) Disconnection, defective contact, or short circuit with power source in wiring harness between transmission controller Cl (female) (3) - T22 (female) (1) 31 Disconnection or defective contact in wiring harness between T22 (female) (2) - chassis ground 4) Defective transmission controller
35
Short circuit in F bypass solenoid system
1) Defective F bypass solenoid 2) Short circuit with chassis ground in wiring harness between transmission controller Cl (female) (3) - T22 (female) (I) 3) Defective transmission controller
30
32
33
20-412 0
WA1 ZOO-3
TROUBLESHOOTING
OPERATIONS OF CON-IXOLLER AGAINST ABNORMALlTY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
Operation of controller against abnormality
Condition of machine caused by abnormality
Diagnosi: code
Neutral (All ECMV output: OFF)
Machine cannot travel.
T-19
I) Resistance between transmission controller C3B (female) (2) - chassis ground in forward When gear is shifted, (F ECMV: ON): Below I Q 2) Resistance between transmission controller C3B data without fill sw’tch signals are used. (female) (IO) - chassis ground in reverse (R ECMV: ON): Below 1 R
Gear shift shock is made.
T-20
I) Resistance between transmission controller C3B (female) (3) - chassis ground during travel in 1st gear (1st ECMV: ON): Below 1 R 2) Resistance between transmission controller C3B When gear is shifted, data without fill switch (female) (11) - chassis ground during travel in signals are used. 2nd gear (2nd ECMV: ON): Below 1 R 3) Resistance between transmission controller C5 (female) (II) - chassis ground during travel in 3rd gear (3rd ECMV: ON): Below 1 Q
Gear shift shock is made_
T-21
I) When harness is disconnected: Cannot operate at all. (Since this failure cannot be distinguished from short circuit with power source, controller sets in neutral and cannot travel.) 2) When harness has short circuit with power source: Controller sets in neutral and can travel.
1) F clutch makes gear shift shocks and it takes long time to engage (It engages at last). 2) F clutch cannot be disengaged.
T-22
I) Stops outputting.
I) F clutch makes gear shift shocks and it takes long time to engage (It engages at last).
T-23
Normal condition (voltage, current, resistance)
I) Resistance between transmission controller C5 (female) (1 I) - chassis ground in neutral lF ECMV: OFF): Min. 1 MQ
1) F bypass solenoid Resistance between T22 (male) (I) - 12): 5-15R Resistance between T22 (male) (I), (2) - chassis ground: Min. 1 MR
1) F bypass solenoid Resistance between T22 (male) (I) - (2): 5-75n Resistance between 122 (male) (I), (2) - chassis ground: Min. 1 MS2
WA1 ZOO-3
20-413 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
:ailure code
Abnormal system
Contents of abnormality
Disconnection or short circuit with power source in R bypass solenoid system
I) Defective R bypass solenoid 2) Disconnection, defective contact, or short circuit with power source in wiring harness between transmission controller Cl (female) (10) - T21 (female) (1) 3) Disconnection or defective contact in wiring harness between T21 (female) (2) - chassis ground 4) Defective transmission controller
Short circuit in R bypass solenoid system
I) Defective R bypass solenoid 2) Short circuit with chassis ground in wiring harness between transmission controller Cl (female) (IO) - T21 (female) (I) 3) Defective transmission controller
38
Disconnection or short circuit with power source in 1st bypass solenoid system
1) Defective 1st bypass solenoid 2) Disconnection, defective contact, or short circuit with power source in wiring harness between transmission controller Cl (female) (5) T20 (female) (1) 3) Disconnection or defective contact in wiring harness between T20 (female) (2) - chassis ground 4) Defective transmission controller
39
Short circuit in 1st bypass solenoid system
1) Defective 1st bypass solenoid 2) Short circuit with chassis ground in wiring harness between transmission controller Cl (female) (5) - T20 (female) (I) 3) Defective transmission controller
36
37
20-414 0
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Normal condition (voltage, current, resistance)
Operation of controller against abnormality
Condition of machine caused by abnormality
1) When harness is .disconnected: Cannot operate at all. (Since this failure cannot be distinguished from short circuit with power source, controller sets in neutral and cannot travel.) 2) When harness has short circuit with power source: Controller sets in neutral and can travel.
1) R clutch makes gear shift shocks and it takes long time to engage (It engages at last). 2) R clutch cannot be disengaged.
T-24
1) R bypass solenoid Resistance between T21 (male) (1) - (2): 5-15R Resistance between T21 (male) (11, (2) - chassis ground: Min. 1 MR
1) Stops outputting.
1) R clutch makes gear shift shocks and it takes long time to engage (It engages at last).
T-25
1) 1st bypass solenoid Resistance between T20 (male) (I) - (21: 5-15R Resistance between T20 (male) (I), (2) - chassis ground: Min. 1 ML2
1) When harness is disconnected: Cannot operate at all. (Since this failure cannot be distinguished from short circuit with power source, controller sets in neutral and cannot travel.) 2) When harness has short circuit with power source: Controller sets in neutral and can travel.
1) 1st clutch makes gear shift shocks and it takes long time to engage (It engages at last). 2) 1st clutch cannot be disengaged.
T-26
1) Stops outputting.
1) 1st clutch makes gear shift shocks and it takes long time to engage (It engages at last).
T-27
1) R bypass solenoid Resistance between T21 (male) (1) - (2): 5-15P Resistance between T21 (male) (I), (2) - chassis ground: Min. 1 ML?
1) 1st bypass solenoid Resistance between T20 (male) (I) - (2): 5-15R Resistance between T20 (male) (I), (2) - chassis ground: Min. 1 MR
WA1 200-3
Diagnosis code
20-415 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
20-416 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
Auto shift indicator i'
TXWO2561
WA1 ZOO-3
20-417 0
T-l
TROUBLESHOOTING
T-l
Failure code [lo] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing connector and inserting the T-adapter, or when monitor display, the the on displayed longer no is code error to its original position, if the problem has been removed.
*
are properly inserted. Before carrying out troubleshooting, check that all the related connectors step. next the to Always connect any disconnected connectors before going on
*
f
Cause
Remedy
f 4YES Is resistance between L54 - (female) (2) and 3 chassis ground ~normal? . Max. 1 R - * Turn starting switch OFF. * Disconnect Cl and L54.
cGotoA
yes Is resistance YES between Cl - (female) (11) and chassis ground 2 - normal? Is resistance * Min. 1 MR YES between Cl (female) (17) and w (female) - *Turn starting switch OFF. (1) normal? 1 * Disconnect Cl ' locode Is failure Max. 1 R and L54. displayed when _ * Turn starting backup relay is NO switch OFF. replaced with other Disconnect Cl relay of same type? and L54. *Turn starting switch OFF. I NO * Replace backup relay with other relay of same type. -Turn startino switch ON. * Set directional lever to Ft. 5 YES
Defective contact or disconnection in wiring harness between L54 (female) (2) and chassis ground Short circuit with chassis ground in harness between Cl (female) (11) and L54 (female1 (1)
-
NO
NO
Defective contact or disconnection in wiring harness between Cl (female) (11) and L54 (female) (1)
l
l
Is vottage between _ Cl (female) (11) and chassis ground normal?
From A _
I
Turn starting switch ON. Disconnect Cl and L54. * Max. 1 V
Repair or replace
Repair or replace
Defective backup lamp relay
Repair
Defective transmission controller
Repair
Short circuit with power source in wiring harness
l
Repair or replace
?epair or .eplace
l
T-l
Related
electrical
circuit diagram
Transmission controller
Cl (MICl3) Backurr lamp relay
1 23 11 11 ‘. 5fG Backup relay
lam
TXW02444
20-418 0
WA1 200-3
TROUBLESHOOTING
T-7
T-2 Error code [Ill (Disconnection in modulated signal sensor system) is displayed
clutch outlet rotation
*
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 resistance YES between C4 (female) (9) and T16 2 (female) (2) normal?
n 1 T16 hale)
11) and (2)
andbetween(1).(21and chassis groundnormal? Between (1) - (2): 500-lOOOR Between (l), (2) chassis ground: Min. 1 MR Disconnect T16. * Turn starting switch OFF. l
T-2 Related
Is resistance between C4 (female) (21and T16 (female) (1) normal? - Max. 1 R * Disconnect C4, T16, and M02B. -Turn starting switch OFF.
- Max. l R NO * Disconnect C4, T16, and M02B. -Turn starting switch OFF. NO
0
electrical
Defective transmission controller
Remedy
Replace
Disconnection or defective contact in wiring harness between C4 (female) (9) T16 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between C4 (female) (2) 116 (female) (1)
qepair or splace
Defective modulated clutch outlet rotation sensor
3epair or Pplace
circuit diagram
RT2 (HD-85086)
TXWO2445
WA1 200-3
20-419 0
T-3
TROUBLESHOOTING
T-3 Error code [I21 (Short circuit, disconnection, or shot-t circuit with power source in F solenoid system) is displayed *
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting the connector connector and inserting the T-adapter, or when removing the T-adapter and returning display, the monitor the on to its original position, if the error code is no longer displayed problem has been removed.
*
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
*
CaUSe
4YES
resistance bet-
l-l Is
* Min. 1 MD * Turn startina switch OFF.* Disconnect C2 and T13.
YES ween C2 (female) (13) and T13
- Max.
1R * Turn starting switch OFF. * Disconnect CZ and T13.
T13 (male) (1) and (2) and between (1). (2) and chassis ground
Between (1) (2): 5 - 15 n Between (1). (2) chassis ground: Min. 1 MD -Turn starting switch OFF. * Disconnect T13. -
I
NO
--
GotoA Disconnection or defective contact in wiring harness between C2 (female) (2) T13 (female) (1)
Repair or reolace
Short circuit with chassis ground in wiring harness between C2 (female) 113) T13 (female1 (2)
Repair or replace
Disconnection or defective contact in wiring harness between C2 (female) (13) T13 (female) (2)
Repair or replace
Defective F solenoid
Replace
Defective transmission controller
Repair or replace
Shon circuitwith power source in wiring harness between C2 (female) (13) T13 (female) (21
Repair or replace
Short circuit with power source in wiring harness between C2 (female) (2) -Tl: (female) (1)
Repair or replace
Short circuit in wiring harnessbetween C2 (female) (2) -T13 (female) (1) and between C2 (female) (13lT13 (female1(2)
Repair or replace
Short circuit with chassis ground in wiring harness between C2 (female) (2) - T13 (female) (1)
Repair or replace
NO
8YES
,Is resistance YES between C2 (female) (2) and 5
6
-
C2 (female) (2) and _ -Turn starting awitch NC ON. chassis ground * DisconnectC2 and 113. normal? -Max. 1V - Turn starting sGtch ON. * Disconnect C2 and Tl3.
-From 1
T-3 Related
- Disconnect C2 and T13.
I
Ez
* Turn starring switch OFF. * Disconnect C2 and T13.
’
Remedy
I NO
electrical
NO
circuit diagram
Transmission controller
F solenoid
TXW02446
20-420 0
WA1 200-3
T-4
TBOUBLESHOOTING
T-4 Error code [I31 (Short circuit, disconnection, or short circuit with power source in R solenoid 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
QYES
pIs resistance YES between C2 - (female) (14) and chassis ground 2 normal?
-
1 TM1(male1(11and(2) andbetween(11,(21and chassis groundnormal?
l
Disconnectionor defective contact in wiring harness between C2 (female1(3lTM1 (female) (7)
Repair or replace
with chassis ground in wiring harness between C2 (female) (14) Tl 1 (female) (2)
Repair or replace
Disconnectionor defective contact in wiring harness batween C2 (female) (14lill (female) 12)
Repair or replace
Short circuit
Defective R solenoid
Defective transmission controller
From Is resistance betA _ ween C2 (female) (3) and chassis ground normal7 * Min. 1 MR -Turn starting switch OFF. * DisconnectC2 and Tll.
_
‘5-15Ct * Turn starting switch OFF. - Disconnect C2.
-* Turn startingswitch ’
ON. * DisconnectC2 and CN14. * Max. 1 V
IO
NO
electrical
Transmission controller
.Max.lR NO * Turn starting switch OFF. * DisconnectCt and Tll.
Gotok
NO
Is resistance YES between C2 - (female) t3) and (14) normal7 5
T-4 Related
-
Is resistance bet* Min. 1 M R ween C2 (female) - -Turn staning switch NO (14) and 111 OFF. (female) (2) normal? . DisconnectC2 and p * Max. 1 R Tll. . Turn starting NO switch OFF. * Disconnect C2 and Tll.
YI
* Between (1) - (2): 5-154-t Between (1). (2) chassis ground: Min. 1 MS-I - Turn starting switch OFF. * DisconnectTMl.
Is resistance betYES ween ~2 (female) 3 - (3) and TM1 (female) (1) normal?
Remedy
circuit
l
Max.
NO
1V
Short circuit with power source in wiring harness between C2 #amale) (141Tll (female) (2)
Repair or replace
Short circuit with power source in wiring harness between C2 (female) (3l- Tl’ (female) (1)
Repair or reDlace
Short circuit in wiring harness between C2 (female) (3) - Tl 1 (female) (1) and between C2 (female) (14) Tll (female) (2)
Repair or replace
Shon circuit with chassis ground in wiring harness between C2 (female) (31-Tll (female) Ill
Repair or replace
diagram
R solenoid
TXW02447
WA1 200-3
20-42 1 0
T-5
TROUBLESHOOTING
T-5 Error code 1141 (Short circuit, disconnection, or short circuit with power source in 1st solenoid system) is displayed *
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting connector the returning and T-adapter the removing when or T-adapter, the connector and inserting 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
Remedy
Go to A.
Is resistance betYES ween C2 (female) - (17) and ~3 (female) - ‘Turn starting switch NO OFF. (2) normal? 1 . DisconnectC2 and 1 between Is resistance T3. . Max. 1 R T3 (male)11)and(21and - “0”~;: starting switch NO between(1).(21and groundnormal? chassis * Disconnect C2 and T3. . Between (1) - (2):
--c
between C2 ffemale)f7)and chassisground normal?
IRepair or ’replace
Disconnectionor defective contact in wiring harness between C2 (female) (17) - T:3 (female) (2)
IRepair or Imeplace
Short circuit with chassis ground in wiring harness between C2 (female) (7) - T3 (female) (1)
NO
electrical
Transmission controller
Short circuit with chassis ground in wiring harness between C2 (female) I171- T 3 (female) (2)
aYE S Defective transmission controller Is voltage between YES ~2 (female) (17) and chassis ground 7Short circuit with power normal? source in wiring harness L _I Isvoltage between between C2 (female) (17) -T 3 N( D YES ~2 {female) (7) and _ -Turn starting (female) (2) chassis ground wftch ON. 6 normal? * DisconnectC2 and T3. Short circuit with power *Max.lV Is resistance betsource in wiring harness * Turn starting switch ES_ wean C2 (female) _ Ibetween C2 (female) (7) - T3 ON. NO (71 and (17) Iifemale) (1) - Disconnect C2 and 5 normal? T3. Short circuit in wiring . Max. 1 V Iharnessbetween C2 (female) .5-15R I17)- T3 (female) 11)and - * 2;; stamng swtch NO Ibetween C2 (female) (17) - TZ3 IIfemale) (2) * Diionnect C2.
* Min. 1 MR * Turn starting switch OFF. - DisconnectC2 and T3.
T-5 Related
IRepair or Ireplace
Defective 1st solenoid
5-155-Z NO * Between (1). (2) chassis ground: Min. 1 MC? . Turn starting switch OFF. * DisconnectT3.
A
Disconnectionor defective contact in wiring harness between C2 (female) (7) - T3 (female) (1)
IReplace
f3epair or 1,eplace
FIepair or replaca
FXepair or r,eplace
Repair or reDlace
circuit diagram
id
TXWQ2448
20-422 0
WA1 200-3
T-6
TROUBLESHOOTING
T-6 Error code [I!51 (Short circuit, disconnection, or short circuit with power source in 2nd solenoid 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
4YES Is resistance between c2 (fernate) (8) and T5 (female) (1) normal?
YES 3 P YES _2 Is resistance between C2 (female1 (18) and T5 (female) (2)
yes
IS resistsnce belwee”
1
1 normal7
T5 (male)Ill and12) andbetweenIll, (2) andchassisground n0tmai? ~
-
Is resistancebetween ~2 (female) (18) and chassis ground normal?
NO
-Max. IR - Turn starting switch OFF. * Disconnect CZ and T5.
* Min. 1 MR * Turn startingswitch NO OFF. DisconnectC2 and Ts.
I * Max. 1 R . :I; starting switch NO l
Remedy
Go to A.
Disconnection or defective contact in wiring harness between C2 (female) (8) - T5 (female) (1)
?epair or Feplace
Short circuit with chassis ground in wiring harness between C2 (female) (18) -T? (female) (21
Repair or replace
Disconnection or defective contact in wiring harness between CZ (female) (18) -I? (female) (2)
Repair or replace
Defective 2nd solenoid
Replace
Defective transmission controller
?eplace
* DisconnectC2 and
T5. Between (l)-(2): 5-15R NO * Between 11). 12)chassis ground: Min. 1 MR * Turn starting switch OFF. * DisconnectT5. l
BYE! YES 7 Is voltage between YES ~2 (female) (8) and chassisground 6 normal?
Is resistance betYES_ ween cz (female) (8) and (18) _5 normal? From Is resistance betA ween C2 (female) (8) and chassis ground normal? * Min. 1 MR * 2;; aartlng swtch
_
Is voltage between ~2 (female) (18) and chassis ground normal?
*5-15R *~F;stanmgswnch
_
* Turn startingswitch ON. - DisconnectC2 and T5. Max. 1 V
l
NO
* DisconnectCZ.
_
* Turn starting switch NC ON. DisconnectC2 and T13. * Max. 1 V
l
NO
Short circuit with power source in wiring harness
between C2 (female) (18) - E (female) (2) Shoti circuit with power source in wiring harness between C2 (female) (8) -T5 (female) (1)
?epair or .eplace
Shon circuitin wiringharness behveenC2 (female)(81-T5 (female)(1) and betweenC2 (female)(13) -T5 (female)(2)
3epair or ,eplace
Short circuit with chassis ground in wiring harness
NO
3epair or Feplace
between
C2 (female)
(female)
(1)
(8) -TS
Repair or replace
. Disconnect C2 and T5.
T-6 Related
electrical
circuit diagram
Transmission controller id
TXW02449
WA 1200-3
20-423 0
T-7
TROUBLESHOOTING
T-7 Error code [IS] (Short circuit, disconnection, or short circuit with power source in 3rd solenoid 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. check that Before carrying out troubleshooting, related connectors are properly inserted. connectors any disconnected Always connect going on to the next step.
* *
all the
Cause
Remedy
before 4YEL
I Is resistancebet-
Gotok
lfrxnalel 1 normau IL NO -.. . -1 ‘- -‘=2ing switch
YE 1 l7 Imale) (1)and12) and betwean(1). (2) and chassisground Between (1) - (2): 5-15R * Between (11, (2) chassis ground: Min. 1 MR . Turn STartin swirch OFF. * Disconnect17.
Is I bek,e.x,w staning switch NO (female) (19) antd ~7 H *Turn __ I I W-F. (fema,e)(“‘__--_‘, I * DisconnectC2 and 17. . Max. 1 R
z.LrzJ
st C2 and 17.
I
Disconnectionor defective contact in wiring harness between C2 (female) (9) -l7 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between C2 (female) (19) -T; (female) (2)
Repair or replace
Disconnectionor defective contact in wiring harness between C2 (female) (19) -T; (female) (2)
Repair or replace
Defective 3rd solenoid
bolace
- Disconnect C2 and 17.
l
normal?* Min. 1 MQ -Turn starting switch OFF. * DisconnectC2 and 17.
0
SYES -IIs voltage between YES cz (female) (19) and u chassis around 7
r-l
. DisconnectC2.
NO
Defective transmission controller
Short circuit with power source in wiring harness between C2 (female) (19) -Ti Ifemale) (2)
Repair or replace
Short circuit with power source in wiring harness between C2 (female) (9) - l7 (female) (1)
?epair or replace
Shon circuit in wiring harness between C2 (female) (9) - 17 (female) (1) and between C2 (female) (19) - T: (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between C2 (female) (9) -T7 (female) (1)
Repair or replace
T-7 Related electrical circuit diagram
Transiaission controller
id
TXW02450
20-424 0
WA1 ZOO-3
TROUBLESHOOTING
T-8
T-8 Error code [I81 (Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid 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
Remedy
Go to A. YE
-Max.
1R
(8) and chassis
NC
*Turn starting switch OFF. * Disconnect T23.
NO IS reslstawe
between
l23 bnale)(11and2 and _ between(11,(2)and chassisground normal? * Between (1) - (2): 5-15R * Between (1). (2) chassis ground: Min. 7 MR * Disconnect T23. + Turn starting switch OFF.
- Max. 1 R * Turn starting switch OFF. . Disconnect Cl and T23.
and T23. NO
YES
5 between Cl (female1(61 and chassis ground normal?
Short circuit with chassis ground in wiring harness between Cl (female) (8) T23 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between Cl (female) (8) T23 (female) (1)
Repair or replace
Defective transmission controller
Is voltage
Turn srening switch ON. * DisconnectCl and T23. Max. 1 V
l
Repair or replace
Defective R clutch drain valve solenoid
No
From A -D
Disconnection or defective contact in wiring harness between T23 (female) (2) chassis ground
_ Short circuit with power source in wiring harness between Cl (female) (8) T23 (female) (I)
NO
Repair or replace
l
T-8 Related electrical circuit diagram
Transmission controller FRI (HO-660661
R clutch drain valve solenoid
RTI (HD-860661
11
WA1 200-3
TXW02451
20-425 0
T-9
TROUBLESHOOTING
T-9
1:
* * *
Error code [201 (Short circuit or disconnection switch system) is displayed
in joystick FNR
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. Check that fuse ii (6) 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. Remedy
Defective transmission controller
I:;showninTable
- Turn
starting switch ON.
Is voltage between JSl (2). (3). (4) and chassis ground as shown in Table 17 l
Turn starting switch ON.
Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness between JSl (female) (2). (3). [;;;C3B (female) (71, (14).
11 NO
uo
NO
Replace
Repair or replace
Disconnection or defective contact in wiring harness between Cl (male) l7). (13) or C2 (male) (1). (12)- JSl (female) (1)
Repair or replace
Defective joystick FNR switch
Replace
Table 1 Voltage measured with joystick FNR switch at each position Position of FNR switch
F
N
R
Terminals JSI (male) (1) - (2)
C3B (14) - Chassis ground
20 - 30 V Max. 1 V Max. 1 V
JSl (male) (I) - (3)
C3B (7) - Chassis ground
Max. 1 V 20 - 30 V Max. 1 V
JSI (male) (1) - (4)
C3B (15) - Chassis ground
Max. 1 V Max. 1 V 20 - 30 V
T-9 Related electrical circuit diagram Transmission control
Joust ick lever switch
TXW02452
20-426 0
WA1 200-3
T-IO
TROUBLESHOOTING
T-10
Error code [211 (Short circuit or disconnection switch system) is displayed up/shift-down
in joystick shift_
’
*
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting connector the returning and T-adapter the removing when or T-adapter, connector and inserting the display, the to its original position, if the error code is no longer displayed on the monitor problem has been removed.
* * *
Check that fuse II (6) 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. Remedy
Is
L5 (ternale) v3). (9).
-
(16). (17) and chassisground as shown in Table 17
2 _ Is voltage YES_ between JSl (I) and chassis 1 ground normal?
p ISvoitage between JSl (5). (6). (7). (8) and chassisground as shown in Table 17
-2O-30V -Turn starting switch ON.
Replace
v&agebetween .-.
__ ._
yes
_ - Turn starting switch ON.
Disconnection,defective
contdct, short circuit with
chassisground. or short circuit in wiring harness between JSl (female) (5). (6). (7). (8) - C5 (female) (8), (9). 116).(17)
NO
Disconnectionor defective cOntactin wiring harness between Cl (male) VI, (131 or C2 (male) (lb, 112)- JSl (female) (1)
NO
-Turn starting switch ON.
Terminals
switch at each position
Shift-up switch ON
Shift-down switch ON
JSI (5) - Chassis ground
C5 (17) - Chassis ground
20 - 30 v
Max. 1 V
JSl (6) - Chassis ground
C5 (91- Chassis ground
Max. 1 V
20 - 30 v
JSl (7) - Chassis ground
C5 (16) - Chassis ground
Max. 1 V
20 - 30 v
JSI (8) - Chassis ground
C5 (8) - Chassis ground
20 - 30 v
Max. 1 V
Transmission controller
Repair or replace
Replace
Table 1 Voltage measured with joystick shift-up/shift-down
T-IO Related
Repair or replace
electrical
circuit diagram Joust ick lever switch
TXW02452
WA1 200-3
20-427 0
TROUBLESHOOTlNG
T-11
T-11
Error code [22] (Disconnection displayed
in travel speed sensor system) is
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.
Remedy
Cause
3
Es 1 Is resistancebetween T15 lmalet (1) and (2) and-n (V. (2) and chassisground normal?
Ii
. Between (1) - (2): wo- lOM)R * Between (l), (2) chassis ground: Min. 1 MR * Disconnect T15. * Turn starting switch OFF.
T-l 1 Related
YES
1normal? II Isresistance between C5 NO _ *Max. 1 Q (female) (2) and T15 Disconnect T75, C5, (female) (1) normal? M02A, U8, and L07. P . Max. 1 R NO * Disconnect T1.5, C5, M02A. L28, and L07. * Turn starting switch OFF. l
I
NO
electrical
circuit
diagram
Defective transmission controller
Replace
contact in wiring harness batwaen C5 (female) Ht. (10) -T15 (female) (2)
Repair or replace
Disconnaction or defective contact in wiring harness beween C5 (female) 12) T15 (female) (1)
Repair or replace
Defective travel speed sensor
Replace
RT2 m-85086)
1I 5 IDTZ)
Work
equipment controller
TXW02453
20-428 0
WA1 200-3
T-12
TROUBLESHOOTING
T-12
Error code [23] (Short circuit or disconnection sensor system) is displayed
in engine speed I
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting 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
QYE! YES 3 - Is resistance YES between C4 - (female) 11)and chassis ground 2
-
Is resistance between c4 (female) (9) and T17 (female) (2) normal? .Max.lR NC - DisconnectC4,T1J. LOJ, and MO2B *Turn starting switch OFF.
NO nect C4, )7, and M02B , switch
* Turn starting switch OFF.
~100-500R - Disconnect T17. * Turn starting switch OFF.
NO
YES
5
From A
-I
Is resistance between C4 (female) (1) and (9) normal?
* Min.
Y
I
1 MR * Disconnect C4, T17, L07, and M02B * Turn starting switch OFF.
T-12 Related
electrical
Transmission controller
I I
NO
Go to A.
Disconnection or defeotive contact in wiring harness between C4 (female) (9) - T17 (female) (2)
Repair or replace
circuitwith chassis ground in wiring harness between C4 (female) (1) -T17 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between C4 (female) (1) - T17 (female) (1)
Repair or replace
Defective engine speed sensor
qeplace
Short
Defective transmission controller Short circuit in wiring harness between C4 (female) (1) -T17 (female) (1) and between C4 (female) (3) - T17 (female) (2)
Repair or replace
circuit diagram
c4 (MICl.2)
LO7 I040 121 3 I24ElTachometer I I3FI
Main monitor
TXW02454
WA1 200-3
20-429 0
T-13
TROUBLESHOOTING
T-13
Failure code [24] (Short circuit, disconnection displayed
in EEP ROM) is
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. Remedy
Defective transmission controller
20-430 0
Replace
WA1 200-3
TROUBLESHOOTING
T-14
T-14
Error code 1251 (Short circuit in transmission sensor system) is displayed
oil temperature
J,
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.
f
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 resistance
-
Is resistance yES betweenc3A r- (female) (111 and chassis ground 1 Is resinancebetwe& norrna’7 * Min. 1 MC! T19 (male)(1) and (2) andbetween( andchassisground IlOnlUl?
- Between (1) - (2): 39 - 49 Id2 fat 25°C) * Between (l), (2) chassis ground: Min. 1 MR *Turn starting switch OFF. - Disconnect T19.
T-14 Related
*Turn startin9 switch OFF. * Disconnect C3A and T19.
YES betweenFlU _ (male) (12) and 2 (20) normal? * Min. 1 MR . Turn -Ring switch OFF. * Disconnect FR2 and T19.
-
NO
NO
electrical
Transmission controller
NO
Defective transmission controller
Replace
Short circuit in wiring harness between FR2 (male) (12) -119 (female) (1) and between FR2 (male) (20) -T19 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between C3A (female) (ll)-T19 (female) (1)
Repair or replace
Defective transmission oil temperature sensor
Replace
circuit diagram
C3A(040201 T/M oil temerature
WA1 200-3
-
Remedy
328
11
‘. 5’u
J T3 (DTZB)
20-43 1 0
T-15, T-16
TROUBLESHOOTING
T-15 +
Error code [26] (Short circuit in F ECMV fill 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 problem has been removed. * Before carrying out troubleshooting, check that all the Cause related connectors are properly inserted. Jr Always connect any disconnected connectors before going on to the next step. 2
YES
Is resistance bat-
Is resistance between T14 hale) (1) and chassis ground normal? * Min. 1 MR * Disconnect T14. * Turn starting switch OFF.
T-16 *
* *
_
NO Min. 1 MR s Disconnect C3B. T14, and M02A. . Turn starting switch OFF. *
NO
Defective transmission controller
display, the Remedy
Replace
Short circuit with chassis ground in wiring harness between C3B (female) (2) -T14 (female) (1)
Repair or replace
Defective F ECMV fill switch
Replace
Error code [271 (Short circuit in R ECMV fill switch system) is displayed
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 Remedy Cause related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. This troubleshooting
2 __/lsresistancebet-
- Disconnect T12. * Turn starting switch OFF.
YES
1 Ii
NO
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between C3B (female) (10) -T12 (female) (1)
Repair or replace
Defective R ECMV fill switch
Replace
T-15, 16 Related electrical circuit diagram
TXW02456
20-432 0
WA1 200-3
TROUBLESHOOTING
T-17
T-17, T-18
Error code E281 (Short circuit in 1st ECMV fill switch svstem) is I 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 orooerly inserted. Always connect any disconnected connectors before going on to the next step. ’ ChUSe
2
YES
Is resistance bet-
(1) and chassis
* Disconnect C3B. T4, and
Remedy
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between C36 (female) (3) -T4 (female) (1)
Repair or replace
MOZA
Min. 1 MR * Disconnect T4. * Turn starting switch OFF.
l
-
T-18
Turn
starting switch OFF.
NO
Defective 1st ECMV fill switch
Error code 1291 (Short circuit in 2nd ECMV fill 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
2
. Disconnect T6. -Turn starting switch OFF.
WA1 200-3
NO
YES
Remedy
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between C3B (female) (ll)-T6 (female) (1)
Repair or replace
Defective 2nd ECMV fill switch
Replace
20-433 0
T-1Q
TROUBLESHOOTING
T-19
Error code [30] (Short circuit in 3rd ECMV fill switch svstem) 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.
2 YES yes
Is resistance __
0etweenC5
- (female) (11) and between T8 (female) (1) and chassis ground
-
NO * Min* ’ MR * Disconnect C5. T8, and
NO
electrical
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between CS (female) (11) -T8 (female) (1)
Repair or replace
Defective 3rd ECMV fill switch
Replace
-
* Turn starting switch OFF.
* Min. 1 MR . Disconnect T8. * Turn starting switch OFF.
T-19 Related
II
circuit diagram
Transmission
TXW02457
20-434 0
WA1 200-3
T-20
TROUBLESHOOTING
T-20 *
in F or R ECMV fill switch
Error code 1321 (Disconnection system) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and connector and inserting the T-adapter, or when removing the T-adapter monitor display, the the on displayed longer to its original position, if the error code is no 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
s
Defective transmission
Remedy
Replace
M 3
-
‘0”;;. starting switch N( I
YES 2 Is resistance between C3B . (female) (10) and T12 (female) (1)
n
n0ITlall
Max. 1 R Turn starting switch OFF. . Disconnect C3B, T12, and M02k l
l
(female) (2) and T14 (female) (11 normal? * Max. 1 R * Turn starting switch OFF. Disconnect C3B. T14, and M02A. l
T-20 Related
-
tf T14 (female) (1) is grounded to chassis, is ‘32” displayed?
IDisconnection or defective ,:ontact in wiring harness Ibetween C3B (female) (10) -T12 (female) (1) IDisconnection or defective ,Contact in wiring harness Ibetween C3B (female) (2) T14 (female) (1)
NO
electrical
* DisconnectT12. - Start engine. * Turn transmissioncut-oiR switch OFF (Put out lame). . Turi parking brake switch OFF. * Press brake. . Set directionalswitchin FI. I3efective F ECMV fill switch IUO
*Turn startingswitch OFF. - Disconnect Tl4. engine. -Start *Turn transmissioncut-offswitchOFF(Putout lamp). *Turn parkingbrakeswitchOFF. * Pressbrake. * Set directionalswitchto F. NO
Defective R ECMV fill switch
Replace
qepair or ‘eplace
3epair or pplace
circuit diagram
Transmission
Mod CC”
TXW02456
WA1 200-3
20-435 0
TROUBLESHOOTING
T-21 *
* *
T-21
in lst, 2nd, or 3rd ECMV fill
Error code 1333 (Disconnection switch system) is displayed
This troubleshooting is carried out when there is still an abnormalii, 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
, Is resistance betweenC5 Ifemale) (11) and T6
_rl
YES
(female)
(lil
and T6
(female) 11)normal?
- Max.
1R * Turn starting switch OFF. . Disconnect C3B. 14. and M02A.
I I
* Turn starting switch OFF. . Disconnect C3B. T6, and M02A.
H I
Replace
_m_^^^ _- T,. Disconnection or defective contact in wiring harness between C5 (female) I1 1)T8 (female) (1)
*Turn starting switch OFF. * Disconnect CS, T8. and M02A
Disconnection or defective contact in wiring harness between C3B (female) (11) - T6 (female) (1)
NO
Disconnection or defective contact in wiring harness between C3B (female) (3) 14 (female) (1)
NO
6
From A -
Defective 1st ECMV fill switch
Remedy
YES
If TS (female) (1) is YES grounded to chassis, is ‘33” 5 displayed? ifT6 (female) (1) is NO . Td;‘F:startingswitch grounded to chassis, is ‘33” * DisconnectT6. . Start engine. displayed? - Set directionalswitchin N. - Set gear shift cnsition in %-I - Turn starting switch OFF. NO - Disconnect T6. * Start engine. * Set directional switch in N. * Set gear shift position in 2nd.
Repair or replace
Repair or replace
Repair or replace
Defective transmission controller
Defective 3rd ECMV fill switch
Replace
Defective 2nd ECMV fill switch
3eplace
T-21 Related electrical circuit diagram Transmission
TXWO2457
20-436 0
WA1 200-3
TROUBLESHOOTING
T-22
T-22
Error code [341 (Disconnection or short circuit with power source in F bypass solenoid 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.
f
Cause
I
-
Is resistance
bet-
YES weenT22 (female) 2
(21and chassis ground normal?
Is resistance * Max. 1 Q YES between CI (female) (3) and T22 - -Turn starting switch OFF. 1 (female) (1) normal? p * Disconnect T22. * Max. 1 R between T22 (male) (1) and (2) and between (11, (2) and - * Turn starting NO switch OFF. chassis ground normal? - Disconnect Cl and T22. * Between (1) - (2): 5-15R - Between (l), (2)chassis ground: Min. 1 MR * Turn starting switch OFF. . Disconnect T22.
T-22 Related
NO
electrical
4YEs ,A
YES
Is voltage between Cl (female) (3) and
3
chassis ground normal? - Max. 1 V
- Turn starting
N( switch
OFF.
. DisconnectCl and T22. NO
Remedy
Defective transmission controller
Replace
Short circuit with power source in wiring harness between Cl (female) (3) TZ2 (female) (11
Repair or replace
Short circuit with chassis ground in wiring harness between T22 (female) (2) chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between Cl (female) (3) T22 (female) (1)
Repair or replace
Defective F bypass solenoid
Replace
circuit diagram
Transmission
controller
F brrass
k WA1 200-3
TXW02458
20-437 0
TROUBLESHOOTING
T-23
T-23
Error code [35] (Short circuit in F bypass solenoid system) is displayed
This troubleshooting is carried out when there is still an abnormalii, 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.
GWX!
2 Is resistance between Cl (female) (3) and chassis ground normal?
. Between (1) - (2): 5-15R * Between (1 L (2) chassis ground: Min. 1 MR . Turn starting switch OFF. * Disconnect T22.
* Min. 1 MR * Turn starting switch OFF. * Disconnect Cl and T22.
Remedy
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between Cl (female) (3) T22 (female) (1)
Repair or replace
Defective F bypass solenoid
Replace
T-23 Related electrical circuit diagram
Transmission controller
F bylass
TXW02458
20-438 0
WA1 200-3
TROUBLESHOOTING
T-24
*
T-24
Error code [361 ( Disconnection or short circuit with power source in R bypi ISS solenoid system) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting connector and inserting the T-adapter, or when removing the T-adapter and returning the connector if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. -k Always connect any disconnected connectors before going on to the next step.
*
Cause
n 2
I Is resistance between
1
(female) (3) and T21 (female) (1) normal?
* Between (1) - (2): 5-15R - Between (1). (2) chassis ground: Min. 1 MD * Turn starting switch OFF. - Disconnect T27.
1
I
. Turn starting switch OFF. * Disconnect Cl and T21.
NO
I NO
electrical
A
Max. 1 R * Turn starting switch OFF. * Disconnect T21.
- Disconnect
-
- Max. 1 R
between T21 (male) 11)and (2) and between (1). (2) and &s;,ground
T-24 Related
cl
YES
NO
Cl and T21.
Remedy
Defective transmission controller
Replace
Short circuit with power source in wiring harness between Cl (female) (10) T21 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between T21 (female) (2) chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between Cl (female) (10) T21 (female) (1)
Repair or replace
Defective R bypass solenoid
Replace
circuit diagram
Transmission controller
Tl
WA1 200-3
TXW0.2459
20-439 0
TROUBLESHOOTING
T-25 *
* +
T-25
Error code [37] (Short circuit in R bypass solenoid 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
YES 1 Is resistance between l-21 tmale) (11and (21and _ between (1). (2) and chassis ground
n0nllall . Between (1) - (2): 5-15n * Between (1). (2) chassis ground: Min. 1 MD . Turn starting switch OFF. * Disconnect T21.
Is resistance between Cl (female) (10) and chassis ground normal?
lMin.lMQ l
l
NO Turn starting switch OFF. Disconnect Cl and T21.
NO
Remedy
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between Cl (female) (10) - T21 (female) (1)
Repair or replace
Defective R bypass solenoid
Replace
T-25 Related electrical circuit diagram
I74 11
20-440 0
TXW02459
WA1 200-3
TROUBLESHOOTING
T-26
T-26
Error code 1381 (Disconnection or short circuit with power source in 1st bypass solenoid 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.
Sr
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.
*
I 4YES 7” Is resistance YES between T20 - (female) (21and chassisground 2 normal?
-
resistance * Max. 1 R YES between Cl (female) (5) and TZO - -Turn starting switch OFF. (female) (1) normal? 1 . Disconnect T20. * Max. 1 R between T20 (male) (1) and (2) and * Turn starting between (1). (21 and NO switch OFF. ;;z;7ground . Disconnect Cl and T20. - Between (1) - (2): Is
5-15R * Between (1). (2) chassis ground: Min. 1 MD * Turn starting switch OFF. . Disconnect T20.
T-26 Related
-
. MaxV’ ” * Turn starting switch
NO
OFF.
* DisconnectCl and T20. NO
Defective transmission controller
Short circuit with chassis ground in wiring harness between T20 (female) (2) -chassis ground Disconnection or defective contact in wiring harness between Cl (female) (5) - T20 (female) (1)
Replace
Repair or replace
Repair or replace
Replace
circuit diagram
11
WA1 200-3
1 Remedy
Short circuit with power source in wiring harness 1 Repair or replace between Cl (female) (5) T20 (female) (1)
Defective 1st bypass solenoid
NO
electrical
1
Is voltage between Cl (female) 6) and _ chassis ground normal?
Cause
TXW0.2460
20-441 0
1
TROUBLESHOOTING
T-27
T-27
Error code [391 (Short circuit in 1st bypass solenoid 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
2
YES
~~
* Between (1) - (2): 5-15n * Between (l), (2) chassis ground: Min. 1 MR * Turn starting switch OFF. - Disconnect T20.
T-27 Related
electrical
circuit
Remedy
Defective transmission controller
Replace
Short circuit with chassis ground in wiring harness between Cl (female) (5) T20 (female) (1)
Repair or replace
Defective 1st bypass solenoid
Replace
diagram
Transmission controller
TI
20-442 0
TXWO2460
WA1 200-3
TROUBLESHOOTING
T-28 * f +
Auto/Manual
T-28, T-29
selector switch system
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. the connector or connecting the TAlways turn the starting switch OFF before disconnecting adapter (or socket). Cause Remedy
3 YES
Defective transmission controller
Replace
Disconnection in wiring harness between L15 (female) (4) -chassis ground
Repair or replace
Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C38 (female) (1) - L15 (female) (3)
Repair or replace
Defective Auto/Manual selector switch
Replace
$S/-
(1) and L15 lfemalel I
* Disconnect C3B. * Auto/Manual selector switch ON: Max. 1 R OFF: Min. 1 MR
(male) (3) and (4)
I
NO
NO
I
- Auto/Manual selector switch ON: Max. 1 R OFF: Min. 1 MD
T-29
II - Max. 1 R * Disconnect Ll5.
No
Kickdown switch system Cause
3 YES Is resistance betYES Wee” L15 (female) (2) and chassis ground normal? _ 2 Is resistance YES between c3A (female) 20 and ~15 (female) 11) normal? 1
* Max. 142 - Disconnect L15.
* Disconnect C3A (male) (1) and (2) * Disconnect L15. * Kickdown switch ON: Max. 1 R OFF: Min. 1 MR
* Kickdown switch ON: Max. 1 R OFF: Min. 1 MD NO
NO
Remedy
Defective transmission controller
Replace
Disconnection in wiring harness between L15 (female) (2) -chassis ground
Repair or replace
Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C3A (female) (20) - L15 (female) (1)
Repair or replace
Defective kickdown switch
qeplace
T-28, T-29 Related electrical circuit diagram Transmission
Kick-doun k manual swrtch
TXW0246 1
WA1 200-3
20-443 0
T-30
TROUBLESHOOTING
T-30 f f f
Transmission
cut-off switch 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 Tadapter (or socket).
Remedy
2
I YES
Is resistance between L12 (male) (1) and (2) normal? Disconnect L12. . Transmission cut-off switch ON: Max. 1 R OFF: Min. 1 MR
1 -
YES
Is resistance betveen CSA (female)
chassis ground normal?
(10) and
*Transmission cut-off ND switch ON: Max. 1 Q OFF: Min. 1 h4Q * Disconnect C3A L06. and M02A.
l
T-30 Related
NO
electrical
Defective transmission controller Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C3A (female) (10) - L12 (female) (1)
Repair or replace
Defective transmission cut-off switch
circuit diagram
Transmission
ed when stwoino Pedal. left brake
on 1
TXW02462
20-444 0
WA1 200-3
T-31
TROUBLESHOOTING
T-31 * * *
Steering
lock switch 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 Tadapter (or socket).
Cause
YES 1 Is voltage between C3B (female) (9) and chassis ground normal?
- Stat-t engine. Steering lock lever LOCK: 17 - 30 v FREE: Max. 1 V l
T-31 Related
2 YES Is voltage between _ STL (male) (1) and _ NO chassis ground normal? - Start engine. * Steering lock lever LOCK: 17 - 30 v FREE: Max. 1 V
electrical
Transmission
NO
Remedy
Defective transmission controller
Replace
Defective steering lock switch
Replace
Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C3B (female) (9) - STL (female) (1)
Repair or replace
circuit diagram
Sleeri
ng lock
co
controller
WA 1200-3
20-445 0
T-32
TROUBLESHOOTING
T-32 * * * *
Neutralizer relay 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 Tadapter (or socket).
Cause
YES
4YE!
1 Is voltage between C3A (19) _ and chassis ground normal? 2 Is resistance between L58 - (female) (2) and NO chassisground normal?
L
l
electrical
circuit
Disconnect C3A, Nc C3B. and L5B. . Short L58 (3) to (5). - Max. 1 R l
* Disconnect LB5 . Turn starting uo switch ON. . Parking brake switch ON --f OFF *20-30V
-
* Disconnect L5B. Max. 1 R
T-32 Related
Defective :ontroller
transmission
Iefective alay
neutralizer
Replace
Replace
(female) (6) and Is voltage between L56 (female) (1)
j
- Turn starting switch ON. . Parking brake switch ON --f OFF l20-30V
Remedy
N0
:ontact in wiring harness between C3A (female) (6) (19)
Replace
Short circuit with chassis ground, disconnection, or defective contact in wiring harness between L58 (female) 11) - LO1 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between L58 (female) (2) chassis ground
Repair or replace
diagram Parkino switch ^
Transmission controller
brake
__.
Neutralizer relay Fuse FS2 (S12)(t?luel
(I 1
L59 Parkino safety
brake relay
88E
lpn
;
I-
li3A;i --
0.5fY 0.75fU 0 5fB 0:5tIf
t,
LR~ (HD-760861 ” 4
20-446 0
WA1 ZOO-3
TROUBLESHOOTING
T-33 * * * +
T-33
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 Tadapter (or socket).
2 YES 1 Is resstance between Cl (female) (2) and chassis ground normal? - Disconnect Cl, L08, and L28. * Min. 1 MR
T-33 Related
_
YES
Is resistance between Cl ffemale) (2) and chassis ground normal? *DisconnectCl, L08, and U8. * Max. 1 R
NO
NO
electrical
Defective transmission controller
Replace
Disconnection or defective contact in wiring harness between Cl (female) (2) Lo8 (female) (6) or L26 (female) (16)
Repair or replace
Short circuit with chassis ground in wiring harness between Cl (female) (2) LO8(female) (6) or L28 (female) (16)
Repair or replace
circuit diagram JLIE
(DT2)
Transmission controller
or
TXW02465
WA1 200-3
20-447 0
TROUBLESHOOTING
T-34 f * *
Network
T-34
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 Tadapter (or socket).
Remedy
Call93
2
YES
Defective transmission controller Disconnectionor defective contact in wiring harness between c3B (female) (4). (121-LOS (female) (1 t, (31. MO1 (female) (1). (12) or L26 (female) (11, (12). or V3A (female) (8). (18)
~
I
I
- Min. 1 MR -Turn starting switch OFF. - Disconnect C3B. L08, MOl, L26, and V3A
I
l
l
Disconnect c3B. LO8, MOl, L26, and V3A Short LO8 (female) (1). (3) to chassis.
Shon circuit with chassis ground in wiring harness between C3S (female) (41, (12) -LOS (female) (1). (3). MO1 (female) (1). (121or L26 (female) (1). (12). or V3A (female) (8). (18)
Replace
Repair or replace
Repair or replace
T-34 Related electrical circuit diagram
I
VHMS controller
Transmission
controller
I
TXW02466
20-448 0
WA1 ZOO-3
TROUBLESHOOTING
T-35 * * * *
T-35
Transmission
controller power supply system
Check that fuse II (6) 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 Tadapter (or socket).
2 YES Is r&Stance betYES ween Cl (female) (6). - W2). CZ (female) Ill), 1 (21) and chassis _, Is voltage between ground normal? Cl (71, (13). c2 (1). NO (12) and Cl (6). (12). - * Max* ’ n * Turn starting switch OFF. c2 (11). (21) * Disconnect Cl and C2. normal? *20-30V *Turn starting switch ON.
T-35 Related
I
NO
electrical
circuit
Defective transmission controller
Replace
Short circuit with chassis ground, disconnection,or defective contact in wiring harness between Cl (female) 171,(13). C2 (female) (1). (12) - FS5 (female) (6)
Repair or replace
Disconnectionor defective contact in wiring harness between Cl (female) (6). (12). C2 (female) (1). (121-chassis ground
Repair or replace
diagram
Fuse (II) Transmission controller
FS5 (M6) Cl
f I
”
6
90A
RAI 0 (DTHD4)
Battery
=Yz= TXW02467
WA1 200-3
20-449 0
T-36
TROUBLESHOOTING
T-36 Ir *
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
Defective transmission controller
YES
2 Is resistance YES between CS I r (female) (2) and
Remedy
Replace
Short circuit in wiring
-
harness between CS (female) (2) -TlS (female) (11and between Cl5 (female) (10) T15 (female) (21
ween C5 (female) (2) and chassis ground normal?
Short circuit with chassis ground in wiring harness
.I
. Min. 1 MR -Turn starting switch OFF. . Disconnect C5, L07, M028, L28, and T15.
1’ between (female)
C5 (female) (1)
(2) - TlE
Repair or replace
Repair or replace
T-36 Related electrical circuit diagram
York esuiumcot controller
FR2 (HD-46082)
TXW02453
20-450 0
WA1 200-3
T-37
TROUBLESHOOTING
T-37 f *
Short circuit in modulated
clutch outlet rotation
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.
2
Is resistance between C4 (female) (2) and chassis ground normal? ‘Min. 1 MR * Turn starting switch OFF. * Disconnect C4, M02B. and T16.
T-37 Related
YES
Is resistance betYES ween C4 (female) 1 (2) and (9) normal? _
NO *Min.lMR - Turn starting switch OFF. * Disconnect C4, M026, and T16. NO
electrical
Defective transmission controller
Replace
Short circuit in wiring harness between C4 (female) (21-T16 (female) (1) and between C4 (female) (9) -TIE (female) (21
Repair or replace
Short circuit with chassis ground in wiring harness between C4 (female) (2) T’16 (female) (1)
Repair or replace
circuit diagram
J L26 (LIT21 Tra con
Mod con
TXW02445
WA1 200-3
20-45 1 0
T-38
TROUBLESHOOTING
Disconnection
T-38 * Ir
in transmission
oil temperature
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
3 YES Is resistance betYE? ween T19 (female) (2) and chassis 2 ground normal?
Is resistance betYES ween C3A (female) (11)and T19 (female) (1) normal? 1 Is resiStancehetween T19 (male) (1) and (2) and between (1). (2) and chassis ground normal? * Between (1) - (2): 3.8 - 4.8 R (at 25W . Between (1). (2) chassis ground: 3.6 - 3.9 R * Turn starting switch OFF. . Disconnect T19.
T-38 Related
* Max. 1 R . Turn starting switch OFF. * Disconnect C3A and 119.
Max. 1 R * Turn starting switch OFF. - Disconnect C3A. l
NO
NO
electrical
circuit
NO
Remedy
Defective transmission controller
Reolace
Disconnection or defective contact in wiring harness between T19 (female) (2) -chassis ground
Repair or reolace
Disconnection or defective contact in wiring harness between C3A (female) (11) -T19 (female) (1)
Repair or replace
Defective transmission oil temperature sensor
?eplace
diagram
Transmission contr JT3 (LIT261
temperature
20-452 0
sensor
WA1 200-3
T-39
TROUBLESHOOTING
T-39 * *
Fl (Forward
1st gear) 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.
r _
between C2 (female) 16) and chassis ground normal? L Min. 1 MQ * Turn starting switch OFF. * Disconnect C2 and M02.A. IS reStStSnCe
* Max. 1 Q * Turn starting switch OFF. - Disconnect C2 and M02A.
T-39 Related
L
Replace
II
normal?
NO - Stan engine. . Set FNR switch in ‘F” and shift-down switch to ‘Fl”: Max. 1 V Other setting than above: 17 - 30 V NO
Repair or replace
Shortcircuit
with chassis ground in wiring harness between M02A (female) (13) - C2 (female) (6)
Repair or replace
Disconnection or defective contact in wiring harness between M02A (female) (13) - C2 (female) (6)
NO
electrical
Defective transmission controller
circuit diagram
h Transmission steering joystick controller FI signal
Modulated control I
c2 ~YIC21) 518
6
clutch
p. 5fW
TXW02466
WA1 ZOO-3
20-453 0
T-140
TROUBLESHOOTING
T-40 * * *
Abnormality
in auto shift indicator
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. Perform diagnosis steps 2 - 6 when all of the lst, 2nd, and 3rd auto shift indicator lamps are defective. Remedy
CaUSe
1YES
YES 3
r
Is resistance beYES tween L69 (male) (6) and chassis 2 ground normal? If L69 is replaced with another relay, is operation normal?
*Max.lD * Turn starting switch OFF. Disconnect L69.
.
Is resistance between ~92 (male) (1) and (2) normal?
* 5 - 6.2 Id2 NO . Turn starting switch OFF. . DisconnectW2. NO
* Turn starting switch ON. . _ IJO - Turn auto/manual selector switch OFF (Auto shift mode). * Turn starting switch
lyE! kmktawbrtweaaL95
YES haleImadI.87 h!& Ill.temen L96 Ifemak) (21 _
ON.
6Is voltagebatweanL55 tfemafe)(1).I.% (female)11).I.97 (female)(1) andL66 lfemalell2)normal?
yEs -
From A -
5
-
andL86ImaW (11.and klwemL97WrcidOland LBS ImaIell11 lbxrf?al? *Max.lQ N( *Turn startingawitch OFF. . Disconnect lJ5, LS6,L67, l.57.L56,andI.%
-Max.lD Turn starting NO switch OFF. . Disconnect L95, L96, L97. and L69. l
NO
10 YE!
a From 8,~~
Is voltage between YES C2 (female) (5). (4). (10) and chassis 9 ground normal? b resaance be 1 j tween C2 (female) - Max. 1 V N( - *Turn starting switch OFF - (5). (4). (10) and chassis ground * DisconnectCZ. L62, L63. nounal) and L64 . Turn starting switch ON. . Min. 1 MD -Turn starting NO switch OFF. = Disconnect C2, L82, L83, and L84.
*MaxlD *Turn starting switch VO OFF. * Disconnect C2, L92, L83, and L84.
20-454 0
A.
Defective resistor V-92)
Replace
Disconnection or defective contact in wiring harness between L69 (female) (6) -chassis ground
Repair or replace
Defective illumination relay (L69)
Replace
Defective auto shift indicator lamp (1st. 2nd, or 3rd)
Replace
GotoB
-
l
*Turn starting switch ON. * Turn auto/manual NO selector switch OFF (Auto shift mode). * Turn startina switch ON.
_ Is resistance between L69 (female) (5) and chassis ground normal7 -5-6.2 kcz * Turn starting switch OFF. . Disconnect L69.
Go to
Disconnection or defect% contactintiring haineaa betweanLWfemale) (2) - L67 Imale)(1). betweenL96(female) (2) - L66lmale)(1). or between U7 ffemale)I21- L65(male)(1)
Repair or replace
Disconnectionor defective contact in wiring harness between W5 (female) (1). L96 (female) (1L LS7 (female) (1) - L69 (female) 121
qepair or Pplace
Disconnection or defective contact in wiring harness between L&9 (female) (5) chassis ground
Repair or replace
Defective transmission controller
Replace
Shortcircukwithcower s.wce in tiring harnessbetweenQ 6emale)(5)- L62(male)(1). batweenCL(female)(4)- L63 (male)(1t, or Mwaen Q (female)DO)- L64Imale)(1)
3epair or Fplace
I Shortdrcuk with chassisground in wiringharnessbetweenQ Repair or (female)f5)- L62(male)(11. replace baween Cz Ifemale)14)- L63 (male)(1). or bahwaenC2 Hamale)110)- L64hnale)11)
Disconnectionor defective contact in wiring hamesa batwaen C2 (female) f5)- L62 (male) (1). between C2 (female1(41 - L63 (male) (1). or between C2 (female) (10) L64 (male1 (1)
Repair or .eplace
WA1 200-3
T-40
TROUBLESHOOTING
T-40 Related electrical circuit diagram Auto shift indicator
Transmission controller
51
T
FS2 (St2 Blue)
illumination
TXW02563
WA1 200-3
20-455 0
TROUBLESHOOTING OF MODULATED CLUTCH CONTROLLER SYSTEM (MC MODE)
Judgement table for modulated clutch control system related parts .............................................. 20-502 Operations of controller against abnormality and conditions of machine caused by abnormality ................................................................................................................................. 20-504 Electric circuit diagram of modulated clutch control system .......................... .................................. 20-510 MC- 1 Error code [701 (Disconnection in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system) is displayed ............................................................................... 20-512 MC- 2 Error code 1721 (Abnormality in accelerator pedal sensor system) is displayed ............ 20-514 MC- 3 Error code 1731 (Short circuit in F/R ECMV fill switch system) is displayed.. .................. 20-515 MC- 4 Error code 1741 (Disconnection in Ist, 2nd, or 3rd ECMV fill switch system) is displayed .......................................................................................................................... 20-516 MC- 5 Error code 1751 (Short circuit with chassis ground in lst, 2nd, or 3rd ECMV fill switch system) is displayed ......................................................................................... 20-517 MC- 6 Error code 1761 (Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system) is displayed ............................................................................................... 20-518 MC- 7 Error code 1771 (Short circuit or disconnection in drive force control dial system) is displayed ........................................................................................................... 20-519 MC- 8 Error code [781 (Short circuit or disconnection in travel speed control dial system) is displayed ........................................................................................................... 20-520 MC- 9 Error code 1801 (Short circuit or disconnection in wheel rotation sensor system) is displayed ........................................................................................................... 20-521 MC-10 Error code 1811 (Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation sensor system) is displayed ................................ .20-522 MC-11 Error code 1821 (Short circuit, disconnection, or short circuit with power source in engine speed sensor system) is displayed .................................................................. 20-523 MC-12 Error code 1831(Short circuit or disconnection in travel speed sensor system) is displayed .......................................................................................................................... 20-524 MC-13 Error code [841 (Short circuit, disconnection, or short circuit with power source in neutral cut solenoid system) is displayed ................................................................... 20-526 MC-14 Error code 1851 (Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system) is displayed ............................................ 20-527 MC-15 Short circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system ................................................................................................................................ 20-528 -20-529 MC-16 Disconnection in F ECMV fill switch system ....................................................................... 20-529 MC-17 Disconnection in R ECMV fill switch system ....................................................................... MC-18 Disconnection in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system. .................... 20-530 MC-19 Abnormality in electronic governor voltage command system ........................................ -20-531 MC-20 Abnormality in transmission cut-off signal system ............................................................. 20-532 MC-21 Abnormality in modulated clutch ECMV fill switch system .............................................. .20-533 20-534 MC-22 Abnormality in right brake pedal switch system ................................................................. MC-23 Abnormality in travel speed control ON/OFF switch system ............................................. 20-535 MC-24 Abnormality in RPM-SET ON/OFF switch system ............................................................... 20-536 MC-25 Abnormality in engine rotation output signal system ........................................................ 20-537 MC-26 Abnormality in power supply system of modulated clutch control system ................... 20-538 20-539 MC-27 Abnormality in network system ............................................................................................ MC-28 Abnormality in Fl (Forward 1st gear) input signal system ............................................... -20-539
WA1 200-3
20-501 0
JUDGEMENT TAB .E FOR MODULATED CLUTCH corn OL SYSTEM RELATED PARTS
TROUBLESHOOTING
JUDGEMENT TABLE FOR MODULATED CLUTCH CONTROL SYSTEM RELATED PARTS Self-diagnosis
-
display
;;E
Location of failure
2 3 m
P E 8
-0 ii
,P T
2 z .E
5 ._ z I
2 :: s 8 .% 2
.k
E
I% -
Failure mode
Bte
78 -
1
Machine cannot travel
2
Travel speed cannot be controlled
3
Travel speed control system operates while travel speed control ON/OFF switch is OFF
4
1
Travel speed control system operates while gear speed is F3 or R3
5
Travel speed control system operates while travel speed is below 1.5 km/h
6
Travel speed control system does not follow up travel speed control dial
7
Drive force does not change even if drive force control dial is turned
8
Drive force control system operates while gear speed is not Fl
9
Tire slip control system does not work
11
Tire slip control system works while tire slip control switch is “OFF”
13
0 -
Drive force control system does not follow up drive force control dial
10
12
0 -
( 1
Tire slip control system works while gear speed is not Fl Tire slip control system works while work equipment
is not operated
14
Engine speed does not rise even if accelerator
15
Shock timelag
16
Engine speed does not change even if RPM SST ON/OFF switch is operated
17
Engine speed can be set while RPM SET ON/OFF switch is OFF
pedal is pressed
is made when F & R gear is shifted
18
RPM-SET IDLE-UP/RESUME
19
Travel speed, drive force, and tire slip control system operates while cut-off switch is OFF
20
Multi-hydraulic
21
IDLE-DOWN
switch does not work
control system does not work
Rising speed of work equipment
is low
22
1
Display of engine speed is abnormal
23
1
Main monitor does not display modulated clutch control system information Diagnosis code when failure coda is displayed
20-502 0
0 E 8
WA1 200-3
1
TROUBLESHOOTING
WA1 200-3
JUDGEMENT TABLE FOR MODULATED CLUTCH CONTROL SYSTEM RELATED PAFiTS
20-503 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY / M~nlII ._.___-
ATFD .._- CLLITCH ___. _.. CONTROL ----. .---
-ailure code
SYSTEM - - - _-__.
Contents of abnormality
Abnormal system 1) 2) 3) 4) 5) 6)
70
Disconnection in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system
7) 8) 9) 10)
72
73
Defective bucket DUMP pressure switch Defective bucket TILT pressure switch Defective boom RAISE pressure switch Defective boom LOWER pressure switch Disconnection or defective contact in wiring harness between HR3, HR4, HRIZ, HR13 (female) (2) - chassis ground Disconnectionor defective contact in wiring harness between modulated clutch controller M02A (female) (5) - HR4 (female) (1) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (6) HR3 (female) (1) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (7) HR12 (female) (1) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (8) HR13 (female) (1) Defective modulated clutch controller
Abnormality in accelerator pedal sensor system
1) Defective accelerator pedal potentiometer 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (19) - L25 (female) (1) 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (10) - L25 (female) (3) 4) Short circuit of wiring harness between modulated clutch controller M02A (female) (19) - L25 (female) (1) with wiring harness between modulated clutch controtler M02A (female) (10) - L25 (female) (3) 5) Defective modulated clutch controller
Short circuit in F/R ECMV fill switch system
1) Defective F ECMV fill switch 2) Defective R ECMV fill switch 3) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (4) T14 (female) (1) 4) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (3) T12 (female) (1) 5) Defective modulated clutch controller 1) 2) 3) 4)
74
75
20-504 0
Disconnection in lst, 2nd, or 3rd ECMV fill switch system
Short circuit with chassis ground in 1st. 2nd, or 3rd ECMV fill switch system
Defective 1st ECMV fill switch Defective 2nd ECMV fill switch Defective 3rd ECMV fill switch Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (2) T4 (female) (1) 5) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (1) T6 (female) (1) 6) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (14) - T8 (female) (1) 7) Defective modulated clutch controller I) 2) 3) 4)
Defective 1st ECMV fill switch Defective 2nd ECMV fill switch Defective 3rd ECMV fill switch Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (2) - T4 (female) (1) 5) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (I) - T6 (female) (I) 6) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (14) - T8 (female) (I) 7) Defective modulated clutch controller
WA1 200-3
_
OPERATIONS OF CONTROLLER AGAINST TROUBLESHOOTING
Normal
(Voltage,
CONDITIONS
condition
current,
resistance)
1) Voltage between M02A (8) - chassis ground
When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in boom RAISE position: 15 - 30 V 2) Voltage between M02A (7) - chassis ground When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in boom LOWER position: 15 - 30 V 3) Voltage between M02A (6) - chassis ground When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in bucket TILT position: 15 - 30 V 4) Voltage between M02A (5) - chassis ground When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in bucket DUMP position: 15 - 30 V Note: Move each lever a little (to degree that work equipment does not move actually) (for detection of PPC pressure signal).
Operation
OF MACHINE
of controller
against abnormality 1) NC solenoid
= OFF
1) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V 2) Voltage between M02A (19) - M02A (9): 0.5 - 4.75 V 3) Voltage between M02A (19) - M02A (9) fat low idling): 0.5 - 1.6 V 4) Voltage between M02A (19) - M02A (9) (at high idling): [Voltage at low idling + 2.1) - 4.75 V Note: Above table shows standard potentiometer voltage by which controller can recognize dial area normally. When adjusting potentiometer again, leave margin to error judgment area. Adjust voltage in range from 1.3 to 1.6 V at low idling. (Error judgment area is as follows; Potentiometer voltage < 0.5 V or Potentiometer voltage x- 4.5 V)
1) Controls idling.
1) Resistance between F ECMV fill switch T14 (male) (1) chassis ground: When forward switch is set to measuring point: Max. 1 R When forward switch is set out of measuring point Min. 1 MC 2) Resistance between I? ECMV fill switch T12 (male) (1) - chassis ground: When reverse switch is set to measuring point: Max. 1 R When reverseswitch is set out of measuring point Min. 1 MR t Start engine, turn transmission cut-off switch OFF, turn parking brake OFF, and press brake pedal.
1) Engages modulated clutch directly. 2) NC so)enojd = OFF
1) Resistance between lstJ2nd/3rd ECMV fill switch T4, T6, T6 (male) (I) - chassis ground: . $r;_n,se; to measunng point with shrft-up/down switch:
1) Engages modulated clutch directly. 2) NC solenoid = OFF
for
low
When set out of measuring point with shift-up/down switch: Min. 1 MR Start engine, set forward/reverse lever in N, and turn manual switch ON. Note: Default when engine is started is 2nd. If shift-down switch is pressed and held, gear is shifted down to 1st. If shift-up switch is pressed and held, gear is shifted up to 3rd.
t
WA1 200-3
Condition
ABNORMALITY
AND
BY ABNORMALITY
of machine
caused by abnormality 1) Machine condition does not change particularly. 2) Hydraulic loss is increased if machine travels at speed of 10 km/h or below in F3 gear.
Diagnosi!
code
C-l
Engine speed does not rise even if accelerator pedal is pressed.
c-2
When set out of measuring point with shift-up/down switch: Min. 1 MR It Starl engine, set forward/reverse lever in N, and turn manual switch ON. Note: Default when engine is started is 2nd. If shift-down switch is pressed and held, gear is shifted down to 1st. If shift-up switch is pressed and held, gear is shifted up to 3rd.
1) Resistance between lstf2nd/3rd ECMV fill switch T4, T6, T8 (male) (1) - chassis ground:. KzF;;t to measurmg pomt wrth shrft-up/down switch:
CAUSED
1) Engages modulated clutch directly. 2) NC solenoid = OFF
1) Drive force doesnot changeevenif driveforce controldial is operated. 2) Tire slip control system does not work. 3) Shock time lag is made when travel direction is changed. 1) Drive force does not change even if drive force control dial is operated. 2) Shock time lag is made when travel direction is changed.
C-3
c-4
1) Drive force does not change even if drive force control dial is operated. 2) Shock time lag is made when travel direction is changed.
c-5
20-505 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Failure code
76
77
78
80
81
20-506 0
Abnormal
system
Short circuit in RPM-SET IDLE-UP/RESUME IDLEDOWN switch system
Short circuit or disconnection in drive force control dial system
Short circuit or disconnection in travel speed control dial system
Contents
of abnormality
1) Defective RPM-SET/IDLE-UP switch, RESUME/IDLE-DOWN switch 2) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (15) - LllO (female) (1) 3) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (16) - LIIO (female) (3) 4) Defective modulated clutch controller
I) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (I) - F06 (female) (2) 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (10) - F06 (female) (1) 3) Short circuit of wiring harness between modulated clutch controller M02B (female) (1) - F06 (female) (2) with wiring harness between modulated clutch controller M02A (female) (IO) - F06 (female) (1) 4) Defective drive force control dial 5) Defective modulated clutch controller
I) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (10) - F07 (female) (2) 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (10) - F07 (female) (1) 3) Short circuit of wiring harness between modulated clutch controller M02B (female) (10) - F07 (female) (2) with wiring harness between modulated clutch controller M02A (female) (10) - F07 (female) (1) 4) Defective travel speed control dial 5) Defective modulated clutch controller
Short circuit or disconnection in wheel rotation sensor system
1) Defective wheel rotation sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (I I) - F15 (female) (2) 3) Disconnection or defective contact in wiring harness between F15 (female) (3) - chassis ground 4) Short circuit of wiring harness between modulated clutch controller M02B (female) (1 I) - F15 (female) (2) with wiring harness between VHMS controller Vl (female) (3) - F15 (female) (1) 5) Defective modulated clutch controller
Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation sensor system
I) Defective modulated clutch outlet rotation sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (4) - T16 (female) (I) 3) Disconnection or defective contact in wiring harness between modulated clutch controller M02B (female) (12) - T16 (female) (2) 4) Short circuit with power source in wiring harness between modulated clutch controller MOZB (female) (4) -chassis ground 5) Defective modulated clutch controller
WA1 200-3
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal
condition
(Voltage, current, resistance)
Operation of controller against abnormality
Condition of machine caused by abnormality
I) Turns off RPM-SET I) Voltage between M02A (15) - chassis ground: IDLE-UP/RESUME When RPM-SET IDLE-UP/RESUMEIDLE-DOWNswitch IDLE-DOWN is set to RESUME IDLE-DOWN position: Max. 1 V function. When RPM-SET IDLE-UP/RESUME IDLE-DOWN switch is set to SET IDLE-UP position: 15 - 30 V !I Voltage between M02A (16) - chassis ground: When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch is set to RESUME IDLE-DOWN position: 15 - 30 V When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch is set to RPM SET IDLE-UP position: Max. 1 V
Engine speed does not change even if RPMSET switch is operated.
I) Voltage between M02A (IO) - M02A (9): 4.75 - 5.25 V !) Voltage between M02A (I) - M02A (9kO.5 - 4.75 V 3) Voltage between M02A (I) - M02A 19) (Min.): 0.5 - 1.6V 1) Voltage between M02A (19) - M02A (9) (Max.): [Min. voltage + 2.11 - 4.75 V Jote: Above table shows standard potentiometer voltage by which controller can recognize dial area normally. When adjusting potentiometer again, leave margin to error judgment area. Adjust voltage in range from 1.3 to 1.6 V at low idling. (Error judgment area is as follows; Potentiometer voltage c 0.5 V or Potentiometer voltage > 4.5 VI
I) Slip ratio by drive force control dial = 100%
1) Drive force does
I) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V !) Voltage between M02A (10) - M02A (9): 0.5 - 4.75 V $1Voltage between M02A (10) - M02A (9) (Min.): 0.5 - 1.6 V 1) Voltage between M02A (IO) - M02A (9) (Max.): [Min. voltage + 2.71 - 4.75 V rlote: Above table shows standard potentiometer voltage by which controller can recognize dial area normally. When adjusting potentiometer again, leave margin to error judgment area. Adjust voltage in range from 1.3 to 1.6 V at low idling. (Error judgment area is as follows; Potentiometer voltage e 0.5 V or Potentiometer voltage > 4.5 VI
I) Slip ratio by travel speed control dial = 100% 2) Max. travel speed = 12 km/h
I) Resistance between wheel rotation (male) (2) - (3): 100 - 500 R
1) Turns off tire slip control.
sensor PI5
I) Modulated clutch outlet rotation sensor Resistance between T16 (male) (I) - (2): 500 - 1000 R Resistance between T16 (male) (I), (2) - chassis ground: Min. 1 MS2
WA1 200-3
Diagnosb code
C-6
not change even if drive force control dial is operated. 2) Tire slip control system does not
work.
c-7
3) Travel speed cannot be controlled.
I) Turns off modulated clutch control (Engages clutch directly).
I) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled.
I) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled.
I) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled.
C-8
c-9
C-IO
20-507 0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Failure code
82
83
84
85
20-508 0
Abnormal system
Short circuit, disconnection, or short circuit with power source in engine speed sensor system
Short circuit or disconnection in travel speed sensor system
Short circuit, disconnection, or short circuit with power source in neutral cut solenoid system
Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system
Contents of abnormality 1) Defective engine speed sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller C4 (female) (1) - T17 (female) (1) 3) Disconnection or defective contact in wiring harness between modulated clutch controller C4 (female) (9) - T17 (female) (2) 4) Short circuit of wiring harness between modulated clutch controller MO28 (female) (51- T17 (female) (1) with wiring harness between modulated clutch controller M02B (female) (12) - T17 (female) (2) 5) Short circuit with power source in wiring harness between modulated clutch controller M02B (female) (5) - T17 (female) (1) 6) Defective modulated clutch controller
1) Defective travel speed sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (13) - T15 (female) (1) 3) Disconnection or defective contact in wiring harness between modulated clutch controller M02B (female) (12) - T15 (female) (2) 4) Short circuit of wiring harness between modulated clutch controller M02B (female) (13) - T15 (female) (1) with wiring harness between modulated clutch controller MOZB (female) (12) - T15 (female) (2) 5) Defective modulated clutch controller
1) Defective neutral cut solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between modulated clutch controller MO1 (female) (21) - HRl (female) (1) 3) Disconnection or defective contact in wiring harness between HRl (female) (2) - chassis ground 4) Defective modulated clutch controller
1) Defective modulated clutch ECMV solenoid 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller MO1 (female) (16) - T9 (female) (2) 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller MO1 (female) (7) - T9 (female) (1) 4) Short circuit of wiring harness between modulated clutch controller MO1 (female) (16) - T9 (female) (2) with wiring harness between modulated clutch controller MO1 (female) (7) - T9 (female) (1) 5) Defective modulated clutch controller
WA1 200-3
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal
1
condition
(Voltage, current, resistance)
1)1Engine speed sensor
Resistance between T17 (male) (1) - (2): 500 - 1000 R Resistance between T17 (male) (I), (2) - chassis ground: Min. 1 MD 2) Voltage between M02B 6) - (12): Min. 0.5 V Note) Measure in AC range.
I
1) Travel speed sensor
Resistance between T15 (male) (1) - (2): 500 - 1000 R Resistance between T15 (male) (11, (2) - chassis ground: Min. 1 MR
Voltage between MO1 (female) (21) - chassis ground When work equipment control lever is operated: 17-3ov When work equipment control lever is in neutral: Max. 1 V lte) Move the lever a little (to degree that work equipment does not move actually) (for detection of PPC pressure signal).
Modulated clutch ECMV solenoid Resistance between TS (male) (I) - (2): 5 - 15 R Resistance between TS (male) (11, (2) - chassis ground: Min. 1 MR
WA 1200-3
OPeratbn
of COntrOller
against abnormality 1) Turns off modulated clutch control (Engages clutch directly).
Condition of machine caused by abnormality 1) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled. 4) Engine speed is not displayed normally.
I) Turns off tire slip control. 2) Turns off modulated clutch control (Engages clutch directly). 3) NC solenoid = OFF
1) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled.
1) NC solenoid output OFF (When short circuit
Work equipment does not rise quickly. (When short CkCUit with power source is made) Neutral cut control system does not work (Machine condition does not change particularly). (When disconnection or short circuit with chassis ground is made)
with power source is made, NC solenoid output cannot be turned off.)
1) Operates emergency spool. 2) Turns ON emergency operation switch. 3) Cannot work (when short circuit with power source is made on CNI (7) side).
1) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled. 4) Machine cannot travel in any gear speed.
Diagnosi
code
c-11
c-12
c-13
c-14
20-509 0
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF MODULATED CLUTCH CONTROL SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF MODULATED CLUTCH CONTROL SYSTEM
20-510 0
WA1 200-3
ELECTRIC CIRCUIT DIAGRAM OF MODULATED CLUTCH CONTROL SYSTEM
TROUBLESHOOTING
IMP-SET IDLE-UP/ RESUME
Boom LOWER switch
1st Ii
I-
I rmitcb
0uMTuY
TXW02470
WA1 200-3
20-511 0
TFtOUBLESHOOTlNG
MC-l
*
* *
MC1
Error code [70] (Disconnection in boom RAISE/LOWER TILT/DUMP pressure switch system) is displayed
or bucket
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
4M!
Is resistance YES 3 Is resistance YES between HR13 - (female) (1) and 2 (2) normal? ‘IsYES between HR3 - (female) (1) and 1 (2) normal? Is resistance between HRb (female) (1) and (2) normal? * Start engine. operation When lever is operated a little: Max. 1 R When lever is in neutral: Min. 1 MR
.
l
-
_ * Start engine. . Bucket TILT NO operation When lever is operated a little: Max. 1 R When lever is in neutral: Min. 1 MR
NO
7YEs YES 6
Is resistance - Max. 1 Q YES between MO24 NO * Turn starting switch (female) (5) and HR4 5 OFF. _ (female) (11normal? - DisconnectMO2and - Max. 1 R _ HR3. Turn starting HR13 (female)(2) and 7 NO switch OFF.. ._* Disconnect MO2 - Max. 1 R and HRb. Turn starting NO switch OFF. * Disconnect HR3, HRb, HR12, and 9 YES HR13. Is resistance II l
8
*Turn starting switch OFF. . Disconnect MO2 and HR12.
20-512 0
resistance between M02A (female)6) and HR3 (female1(1) normal?
-
Defective boom LOWER pressure switch
Replace
Defective boom RAISE pressure switch
Replace
Defective bucket TILT pressure switch
Replace
Defective bucket DUMP pressure switch
Replace
Go to
B.
-
Is
l
From
Start engine.
-Start engine. *bornLOWER operation NC Whenleveris operated aliie:Max.lQ Whenleverisin neutral:Min. 1 MQ
NO * ‘Oorn RA’SE operation When lever is operated a little: Max. 1 R When lever is in neutral: Min. 1 MR
-
From A
-
between HR12 (female) (1) and (2) normal?
GotoA
Remedy
NO
Disconnection or defective contact in wiring harness between M02A (female) (6) - HR3 (female) (1)
contact in wiring harness between M02A (female) (5) - HR4 (female) (1)
Repair or replace
Repair or replace
Disconnection or defective contact in wiring harness between HR3, HR4, HR12, HR13 (female) (2) -chassis ground
Repair or replace
Defective modulated clutch controller
Replace
Disconnection or defective contact in wiring harness between MO% (female) (8) - HR13 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between M02A (female) (7) - HR12 (female) (1)
Sepair or replace
WA1 200-3
MCI
TROUBLESHOOTING
MC-1 Related electrical circuit diagram RA5 Modulated controller
clutch
2L
(DTI)
3 boocf
(
RAIO (DTHD4) 11000
Wor con
switch
WA1 200-3
20-513 0
TROUBLESHOOTING
MC-2
MC-2 Error code [721 (Abnormality in accelerator pedal 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. Jr 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. ChUSe
3 YES Is resistance yEs between M02A - Ifemale) (10) and 2 _ L25 (female) (3) Is resistance normal? YES between MWA Max. 1 R NO - (female) (19) and * Turn starting chassis ground 1 switch OFF. normal? * Disconnect MO2 and l.25. * Min. 1 MR Turn starting NO switch OFF. Disconnect MO2 and l.25. l
- Is resistance between MOZA (female) (19) and LZ5 (female) (1) normal?
l
l
- Max.
1Q *Turn starting switch OFF.
NO
and l-25.
6 YES YES
n 4
1
I Is resistance Fro~~j;~d
]
* Min. 1 MR * Turn starting switch OFF. Disconnect MO2 and L25.
Is voltage
- between I_25 (1) 5 _ and (2) normal? Isrssistsncebetween ~ ._ *At low idling: ; M02A (female)110). NO 0.5-1.6V (19) and chassis At high idling: groundnormal? ~ (Low idling voltage + 2.1 VI - 4.75 V -Turn staning switch ON. - Min. 1 MQ * Turn starting NO switch OFF. * Disconnect MO2 and L25.
uo
l
GotoA
Remedy
-
Disconnection or defective contact in wiring harness between MOZA (female) (10) - L25 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (19) -L25 (female) (1)
Repair or replace
Disconnection or defective contect in wiring harness between M02A (female) (19) - L25 (female) 41)
Repair or replace
Defective modulated clutch controller
Replace
Defective accelerator pedal potentiometer
Replace
Short circuit of wiring harness between MO2A (female) (10) - L25 (female) (3) with wiring harness between M02A (19) - L25 (female) 11)
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (10) - L25 (female) (3)
Repair or replace
MC-2 Related electrical circuit diagram
Accelerator Pedal Madulated con
clutch
ri+r TXW02472
20-514 0
WA1 ZOO-3
TROUBLESHOOTING
MC-3
MC-3 Error code [73] (Short circuit in F/R ECMV fill 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.
Call!%
Is resistance YES -
2 -
between MO2A (female) (4) and
between
T12 (male)
-
_jzy
1
11ground
normal?
L
between T14 (male) (1) and chassis
*Min. 1 MR *Turn starting switch OFF. Disconnect T14.
- Min. . fur”
1 M!3 .__
.-. ..na switch OFF* Disconnect T12.
_
1 MQ
NC
*Turn starting switch chassisground OFF. noma~‘~~ - DisconnectMOZA.C3B. Min. 1 MD _ andT14. * Turn starting NO switch OFF. * Disconnect M02A. C3B. and T14. l
YES
- Min.
etrrrti
NO
NO
Remedy
Defective modulated clutch controller
Replace
Short circuit with chassis ground in wiring harness between M02A (female) (3) -Tl2 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (4) -T14 (female) (1)
Repair or replace
Defective R ECMV fill switch
Replace
Defective F ECMV fill switch
Replace
l
MC-3 Related electrical circuit diagram
Transnission
TXWO2456
WA1 200-3
20-5 15 0
TROUBLESHOOTlNG
MC-4
in lst, 2nd, or 3rd ECMV fill
MC-4 Error code [741 (Disconnection 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.
* It
Cause
4YE If T4 (female) (1) is grounded to chassis, is ‘74” displayed?
YES 3Is resistance YES between MOZA (female1 (14) and T8 2 (female) (1) normal? between
1
(female) (1) and T6 (female) (1) normal?
Is resistance between M02A (female) (2) and T4 (female) (1) normal?
-
MOZA
Max. 1 R * Turn starting switch OFF. Disconnect C3B. TS, M02A.
l
OFF.
* Discomen 14. -Start engine. *Setf0WwdlmmrselsvsrinN
-
Is resistance fis
-TUT” starting Switch
-
*SOt~~~ShiilOV~illlSt.
*Max.lR * Turn starting switch OFF. * Disconnect C5, TB, M02A.
NO
NO
N(
Remedy
Go to A.
Defective 1st ECMV fill switch
Replace
Disconnection or defective contact in wiring harness between M02A (female) (14) - T8 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between MO24 (female) (1) -T6 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between M02.A (female) (2) - T4 (female) (1)
Repair or replace
l
*MaxlR * Turn starting switch OFF. * Disconnect UB, T4, M02k
NO
6 If T8 (female) (1) YES is grounded to 5 chassis, is ‘74” If T6 (female) (1) , displayed? *T$;; starting switch is grounded to chassis, is ‘74” * Disckct T8. * Stan engine. displayed?
From A -
-
* Set forward/reverse
YES
NO
Defective 3rd ECMV fill switch
lever in N.
. Set gear shift lever in 3rd. Turn starting switch OFF. NO * Disconnect T6. Start engine. * Set forward/reverse lever in N. Set gear shift lever in 2nd. *
Defective modulated clutch controller
Defective 2nd ECMV fill switch
l
l
MC-4 Related electrical circuit diagram Transniarion
TXW0.2457
20-5 0
16
WA1 200-3
TROUBLESHOOTING
MC-5
MC-5 Error code 1751 (Short circuit with chassis ground in Ist, 2nd, or 3rd ECMV fill 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 Drooerly inserted. Always connect any disconnected connectors before going on to the next step. ’
CaUSe
4YE! YES_
NC
*Turn starting switCh OFF. * DisconnactM&U, 635, and TO.
l
NO
l
* Min. 1 MD *Turn starting switch OFF. Disconnect T4.
(21 and
-Min.1 MQ
l
-
[ (female)
Is resistance YES between ~8 (mate) (1) and chassis 2 _ ground normal? Is resistance Min. 1 MD YES between T6 (male) Turn starting (1) and chassis switch OFF. 1 ground normal? * Disconnect T8. Is resistance Min. 1 MR between T4 (male) * Turn starting (1) and chassis NO switch OFF. ground normal? * Disconnect T6.
GotoA
Remedy
Short circuit with chassis ground in wiring harness between M02A (female) (2) -T4 (female) (1)
Repair or replace
Defective 3rd ECMV fill switch
Replace
Defective 2nd ECMV fill switch
Replace
Defective 1st ECMV fill switch
I NO
l
6 Is resistance between MOZA (female) (14) and chassis ground normal?
yes 5
From A
Is resistance between M02A (female1(1) and I&a~.sground
* Min.
1 MR Turn starting switch OFF. * Disconnect M02A. C3B, and T6.
l
MC-5 Related
WA1 200-3
electrical
1
YES
NO
Replace
Short circuit with chassis ground in wiring harness between M02A (female) (14) - T8 (female) (1)
Bepair or replace
Short circuit with chassis ground in wiring harness between MOZA (female) (1) -T6 (female) (1)
?epair or *eplace
-
* Min. 1 MD NO * Turn starting switch OFF. * Disconnect M02A. C5, and T8.
I
Defective modulated clutch controller
circuit diagram
20-517 0
TROUBLESHOOTING
Mt?A
MC-6 Error code [76] (Shot-t circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN 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. Remedy
CaUSt?
3 YES Isresistance between MOZA resistance between MO2A (female) (15) and chassisground
-
11
rhazground
Is
yES
-
1 _IS resistance between LllO (male) (1). (2) and (3) as shown in -Table 17 * Disconnect LllO. *Turn starting switch OFF.
-
* Min. 1 MR *Turn starting switch OFF. - Disconnect M02A and LllO.
-
* Min. 1 MQ NO *Turn starting switch OFF. Disconnect MOZA and LllO.
l
NO
NO
Defective modulated clutch controller
Replace
Short circuit with chassis ground in wiring harness between M02A (female) (16) - LllO (female) (3)
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (15) - LllO (female) (1)
Repair or replace
Defective SET IDLE-UP /RESUME IDLE-DOWN switch
Replace
Table 1 RPM-SET
UP
switch
IDLE-
ON
RESUMEJDLE-
DOWN
switch
ON
Between LllO (female) (1) - (2)
Min. 1 MR
Max. 1 R
Between LllO (female) (3) - (2)
Max. 1 R
Min. 1 MC?
MC-6 Related electrical circuit diagram
Modulated con
RPM-SET
I OLE-UP/RESUME IDLE-DOWN switch
clutch
LR7
(DTI)
RAlO
(DTHD4)
Battery
TXW02473
20-518 0
WA1 200-3
TROUBLESHOOTING
MC-7
MC-7 Error code 1771 (Short circuit or disconnection control dial system) is displayed *
* *
in drive force
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. . Remedy
-
GotoA
Is yEs
-
resistance
-
belweenM02A (female) (10) and FO6 (female) (1) - normal?
Ihaha;round
-
2 pIs resistance *Max.lQ YES between MOZB - (female) (1) and - *Turn starting chassis ground switch OFF. 1 ‘ * Disconnect M02A normal? Isresistance * Min. 1 MO and F06. between MOZB *Turn starting (female) (1) and F06 NO switch OFF. (female) (2) normal? * Disconnect M02B and F06. *Max.10 *Turn starting switch OFF. * Disconnect M02B and F06.
*Min. 1 MR NO *Turn starting awitch OFF. * C&connect MOZA and FO6.
‘i
NO
NO
6
Is resisance
YEs Is voltage - between F06 (2) 5 and (3) normal?
between MOZA From
1
A -
(female) (10) and MOZB (female) (1)
normal? Min. 1 MR + Turn starting switch OFF. * Disconnect M02A. M02B. and F06. l
-
’ Drive
force
YES
Short circuit with chassis ground in wiring hamesa between M02A (female) (10) - F06 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between M02A (female) (10) -H)6 (female) (1)
Repair or replace
Shon circuit with chassis ground in wiring harness between M02B (female) (1) - FO6 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between MOZB (female) (1) - F06 (female) (2)
Repair or replace
Defective modulated clutch controller
Replace
Defective drive force control dial
Replace
Short circuit of wiring harness between M02A Ifemale) (10) - FO6 liemale) 11) with wiring harness between MO28 (female) (11 - FO6 (female) (2)
Repair or replace
-
NO
control dial At204’4V AtlOO%:lV *Turn starting switch ON. NO
I I
MC-7 Related electrical circuit diagram Modulated con
clutch
Dial controlline the driving force
fi
WA1 200-3
TXW02474
20-519 0
TROUBLESHOOTING
MC-8
MC-8 Error code 1781 (Short circuit or disconnection control dial system) is displayed *
* *
in travel weed .
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. Remedy
-
GotoA
IS
yes
- IS resistance YES between MO26 - (female) (10) end chassis ground 1 normal? * Min. 1 MR
-
2
-
Is resistance between MO26 - *Turn starting (female) (10) and switch OFF. F07 (female) (2) * Disconnect M02B normal? and F07. lMax.lf2 * Turn starting I NO switch OFF. * Disconnect M02B and F07.
resistance
[;;z;ground
-
between MOZA (female) (10) and Fo7 (female) (1) normal? -
-
.Max.lR Turn starting switch OFF. * Disconnect M02A and F07.
*Min. 1 MD NC *Turn starting switch OFF. * Disconnect MOZAand F07. NO
l
NO
YES
6
I Isvoltaae
II
From A normal? Min. 1 MR * Turn starting switch OFF. * Disconnect M02A, M02B. and F07. l
1
At12km/h:lV At3km/h:4V *Turn starting switch ON. NO
11
Disconnection or defective contact in wiring harness between M02A (female) I101 - F07 (female) (1)
Repair or replace
Disconnection or defective contact in wiring hamess between M02A (female) (10) - F07 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between MOZB (female) (10) - F07 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between MOZB (female) (10) - F07 (female) (2)
Repair or replace
Defective modulated clutch controller
Replace
Defective travel speed control dial
Replace
Short circuit of wiring harness between M02A (female) (10) - F07 (female) (1) with wiring harness between M02B (female) (10) - F07 (female) (2)
Repair or peplace
MC-8 Related electrical circuit diagram Modulated controller -
clutch
speed
Vehicle MOZA (04020)
rffr
20-520 0
TXW02475
WA1 200-3
TROUBLESHOOTING
MC-9
MC-9 Error code [801 (Short circuit or disconnection sensor system) is displayed
in wheel rotation
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting connector and inserting the T-adapter, or when removing the T-adapter and returning the connector if the error code is no longer displayed on the monitor display, the to its original position, 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
I
GotoA
Is raaktance between MOZB (female) (11) and
yes
-
2
chassis ground ,normal? Min. 1 MR Disconnect M02B and F15. * Turn starting switch OFF.
- Is resistance ES between M02B - (female) (11) and FlS (female) (2) normal? -Max.1 R _ *Disconnect M02B , NO and F15. *Turn starting switch OFF. l
l
*loo-500R * Disconnect F15. *Turn starting switch OFF.
I&ss;ground -
’ Max*
’ a
Disconnect F15. *Turn starting switch OFF.
11 NO
Remedy
-
Disconnection or defective contact in wiring harness between F15 (female) (3) chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between M02B (female) (11) - F15 (female) (2)
Repair or replace
l
,
NO
/contact in wiring harness between M02B (female) (11) - F15 (female) (2)
Defective wheel rotation sensor
L
N10
Repair or replace
Replace
Replace From A -I
between MOZB (female) (11) and Vl (female) (3) normal?
H
MS2 ’- Min. 1..- Disconnect M02B Vl, and F15. *Turn starting switch OFF.
MC-9 Related
WA1 200-3
electrical
circuit diagram
I
Short circuit of wiring harness between M02B Repair or replace
TROUBLESHOOTING
MC-10
MC-IO
Error code [81] (Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation 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 CaUSe Remedy related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
GotoA
resistence yRS between MO26 - (female) (4)and chassisgmund 2 normal? Is
-
Is resistance Min. 1 MR between M02B (female) (4) and T16 - .DisconnectT16, M02B, and C4. 1 (female) ~llnorrnal? P Turn starting Is resistance *Max. 1 R switch OFF. between T16 _ * Disconnect T16, (male) (1) and (2) M02B, and C4. ND normal? * Turn starting switch OFF. l600-1,OOOR * Disconnect T16. *Turn starting NO switch OFF.
'MaX.lQ NC * DisconnectTX, M02B. and C4. *Turn starting switch OFf
l
Eg
l
From*Jijg%jf 1normal?
*
*Max. 1 V * Disconnect T16, MOZB. and C4. *Turn starting switch ON.
MC-10 Related electrical circuit diagram
NO
-
Disconnection or defective contact in wiring harness between M02B (female) (12) -T16 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness betwean MOZB (female) (41 -T16 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between MO26 (female) (4) -TN (female)(1)
Repair or replace
Defective modulated clutch outlet rotation sensor
Replace
Defective modulated clutch controller
Replace
Short circuit with power source in wiring harness between M02B (female) (4) -chassis ground
Repair or replace
JL26 (OT2)
Transmission controller
TXW02445
20-522 0
WA1 200-3
TROUBLESHOOTING
MC-11
MC-11
Error code 1821 (Short circuit, disconnection, or short circuit with power source 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.
*
Cause
-
GotoA yES
‘Is resistance yes
between -
! -
-
3 -
(female) (12) and T17 (female) (2)
-
*MaX.1R * Disconnecr C4, T17, L07, and MOZB.
-Turn starting switch Min. 1 MR OFF. NO *Disconnect C4, T17, L07, and M02B. *Turn starting switch OFF. l
-
I
1 (female) (1) normal?
lMax.lR *Disconnect C4, T17, L07, and MOZB. * Turn starting 1 switch OFF.
(male) (1) and (2)
NO
I
*500-1,ooon * Disconnect T17. Turn starting switch OFF.-
6 YES YES 5 Is resistance between M02B (female) (5) and (12) normal?
From A _
* Min. 1 MR * Disconnect C4, T17, L07, and M02B. * Turn starting switch OFF.
MC-11
Related
electrical
_
Is voltage between M02B (female) (5) and chassis ground normal? *Max.lV NO * Disconnect C4, T17, L07, and M02B. *Turn starting switch ON.
NO
circuit diagram
Transmission controller
Modulated controller
-
N(
Disconnection or defective contact in wiring harness between C4 (female) (9) T17 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between C4 (female) (1) T17 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between C4 (female) (1) T17 (female) (1)
Repair or replace
Defective engine speed jensor
NO
l
MOZB
normal?
MOZB
(female) (5) and chassis ground normal? -
between
Remedy
Iefective modulated :lutch controller Short circuit
with
source in wiring
power harness
M02B (female) (5) - T17 (female) (1) xtween
short circuit of wiring larness between M02B female) (5) -T17 (female) 1) with wiring harness xlween M02B (female) 12) - T17 (female) (2)
Repair or replace
qepair or ‘eplace
Main monitor
clutch MOZB (040 16)
d
TXW02454
WA1 200-3
20-523 0
TROUBLESHOOTING
MC-12
MC-12
Error code 1831 (Short circuit or disconnection sensor system) is displayed
in travel speed
f
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. Sr 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.
C.WSB
4YE! Is resistance yRG
-
3
Is resistance yes
between -
? -
M02E
(female) (13) and chassisgmund Pnormal?
-
-
Ifemale) (12) and T15 (female) (2) normal? *Max.lQ
*Disconnect Cf. T15, L07, and M02B. *Turn starting switch OFF. NO
I
l
NO normal?
1
*5oo-wo0R * Disconnect T15. l
M02B. *Turn starting switch OFF. NO
Turn starting switch OFF.
6 YES
figi%Jj-
-
between MO25
Min. 1 MR lDisconnectC5, T15, L07, and M02B. Turn starting switch OFF. l
GotoA
Remedy
-
NC
Disconnection or defective contact in wiring harness between M02B (female) (12) - T15 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness betwesn M02B (female) (13) -T15 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between MOZB (female) (13)-T15 (female) (1)
Repair or replace
Defective travel speed sensor
Replace
Defective modulated clutch controller
Replace
Short circuit with power source in wiring harness between M02B (female) (13) - T15 (female) (11
Repair or replace
n ES 5
I From A
-I
Is resistence between MOZB (female) (13) and 1112) normal? *Min. 1 MR * Disconnect C5, T15, L07, and M02B. *Turn starting switch OFF.
20-524 0
I
Max. 1 V NO Disconnect C5, T15, L07, and M02B. *Turn starting switch ON.
l
nIO
Short circuit of wiring harness between M02B (female) (13) - T15 (female) 11) with wiring harness between MO25 (female) (141- T15 (female) (2)
Repair or replace
WA1 200-3
TROUBLESHOOTING
MC-12 Related
electrical
MC-12
circuit diagram
RT2(HD-850861
Transmission
I
T15 IDTZ)
SDeed S~"SO~
II
TXW02453
WA1 200-3
20-525 0
TROUBLESHOOTING
MC-13
MC-13
Error code [841 (Short circuit, disconnection, or short circuit with power source in neutral cut solenoid 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.
Ir
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
[Is resistance
Yf
OYE! lr-
Remedy
-
GotoA
Disconnection or defective contact in wiring harness between HRl (female) (2) chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between MO1 (female) (21) - HRl (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between MO1 (female) (21) - HRl (female) (1)
Repair or replace
Defective neutral cut solenoid
Replace
Defective modulated clutch controller
Replace
Short circuit with power source in wiring harness between MO1 (female) (21) - HRl (female) (1)
Repair or replace
2 Is rssistance YES between MO1 - (female) (21) and HRl (female) (11 1 normal? ’ Is resistancebetween *Max.lR HRl (male) (1) and (2) and between (1). - ‘Turn atarting switch OFF. (2) and chassis * Disconnect MO1 mound normal? and HRl. + Between (1) - (2):
-
*Turn starting mitch OFF. * Disconnect Mol. HRI, and HR2.
NO
10
5-15Q I NO (1). (2) chassis ground: Min. 1 MR *Turn starring switch OFF. 5 YES * Disconnect HRl. Is v&age between MO1 (female) (21) From A and chassis ground l-l -I normal?
* Between
I
- Max.
1V NO * Turn starting switch OFF. * Disconnect Mol. HRl, and HR2. *Turn starting switch ON.
MC-13
Related
electrical
circuit diagram JR3 (DTl)
Modulated controller
clutch
Nuetral solenoid
cut
HRZ (DTZ) R2D
20-526 0
TXW02477
WAIZOQ-3
.
MC-14
TROUBLESHOOTING
MC-14
*
* *
Error code 1851 (Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system) is displayed
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting 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. check that all the related Before carrying out troubleshooting, CaUSe inserted. connectors are properly Always connect any disconnected connectors before going on to the next step. 4YEI
II-
resistance YES_ between MO1 (female) (7) and T9 3 (female1(1) normal?
GotoA
-
Is
PIs resistance between MO1 yes - (female) (16) and chassis ground 2 _
*Max.lR *TurnStarting switch OFF.
-
*Disconnect
normal) + Min. 1 MD Turn starting switch OFF. Disconnect MO1 and T9.
Ifemale) (16) and T9 (female) (2) normal? *Max. 1 R * Turn starting NO switch OFF. * Disconnect MO1 1 and T9.
N(
MO1 and T9.
NO
l
Disconnection or defective contact in wiring harness between MO1 (female) (7) T9 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between MO1 (female) (16) -T9 (female) (2)
Repair or replace
l
T9 (male)(1) and (2) and between (1). (2)
contact in wiring harness between MO1 (female) (16) - T9 (female) (2)
. Between (1) - (2): I 5-15s2 NO * Between (1). (2) chassis ground: Min. 1 MR *Turn ataning switch OFF. * Disconnect T9.
1 YEZ Is voltage
MO1 (female) (7) and chassisground normal?
YES
6 -
batween MO1 (female) (7) and
From A
* Min. 1 MD *Turn starting switch OFF. * Disconnect MO1 and T9.
MC-14
Related
electrical
Hodulated clutch CO”
Is resistance YES batween MOT (female) I71and (16) 5 normal? _ l5-15n * Turn starting switch OFF. * Disconnect MOZ.
NO
between
*Max.lV NC *Turn starting switch OFF. *DiaconnactMO1 and T9. *Turn starting switch ON. NO
Repair or replace
Defective modulated clutch ECMV solenoid
Replace
Defective modulated clutch controller
Replace
Short circuit with power source in wiring harness between MO1 (female) (7) - T9 (female) (1) Short circuit of wiring harness between MO1 (female) (7) - T9 (female) (1) with wiring harness between MO1 (female) (16) - T9 (female) (2) Short circuit with chassis ground in wiring harness between MO1 (female) (7) - T9 (female) (1)
Repair or replace
Repair or peplace
Repair or .eplace
circuit diagram
solenoid
TXW02478
WA1 200-3
20-527 0
TROUBLESHOOTING
MC-15
* *
MC-15
Shot-t circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
4YE Is resistance YES between M02A - (female) (81 and 3 chassis ground “O”Tlel? 1 MR -
Is resistence YES between MO2A - (femele) (7) end chassis ground 2 - normal? *Disconnect MO24 HR13, and i27. * Min. 1 MD Turn starting NO switch OFF. I Disconnect MOZA, HR12. and L27.
,
PIs resistance between MOZA (female) (6) and chassis ground normal?
between M02A (female) (5) and
L
Short circuit with chassis ground in wiring harness between M02A (female) (8) - HA13 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (7) - HR12 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness beween M02A (female) (6) - HR3 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (5) - HR4 (female) (1)
Repair or replace
Defective modulated clutch controller
Replace
-
* Min. 1 MD *Turn starting awitch OFF. * Disconnect MOZA and HR4.
l
I
l
I NO
5 YES
From A -
-
GotoA
Min. 1 MD *Turn starting NO switch OFF. * Disconnect MOZA and HR3. l
Remedy
r
*Min. .T;;;.mning &t,.hN’
YES
inserted.
Is resistance II between M02A (female) (5). 16).(71, and (8) normal?
Short circuit of wiring harness between M02A (female) (5) - HR4 (female) (1). between MOZA(female) (6) - HR3 (female) (1). between MONA(female) (7) HR12 (female) (1). and bsrween MONA(female) (8) HR13 (female) (1) with each other
* Min. 1 MR NO *Turn atatting switch OFF. * Disconnect M02A. U7, HR3, HR4, HR12, and HR13
Repair or replace
MC-15 Related electrical circuit diagram RAS (DTI) Modulated controller
clutch
2L
31000
RAtO (DTHD4)
(
Bucket switch Wor con
Bucket switch
37 dump tilt
Boom raise switch
TXW0247 1
20-528 0
WA1 ZOO-3
TROUBLESHOOTING
MC-16 *
Disconnection
MC16,
in F ECMV fill 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.
*
Cause
r
Is voltage between T14 (1) and chassis ground normal?
YES 1 -
2 YES Is resistance between M02A 13) and Tl4 (female) (1) normal? NO . Max. 1 R - Disconnect C3B. M02A. and T14. * Turn starting switch OFF.
* *20-30V Turn starting NO switch OFF. * Disconnect T14. . Start engine. * Turn transmission cut-off switch OFF (Put out lamp) * Turn parking brake switch OFF. * Press brake. l
MC-17 * *
MC-17
Disconnection
Remedy
Defective modulated clutch controller
Replace
Disconnection or defective contact in wiring harness between M02A (female) (3) - T14 (female) (1)
Repair or replace
Defective F ECMV fill switch
in R ECMV fill 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. Remedy
Is voltage between T12 (1) and chassis ground normal?
YES 1 -
2 YES Is resistance between M02A (4) and T12 (female) (I) normal? NO *Max. 1 R * Disconnect C3B, M02A. and T12. . Turn starting switch OFF.
p*20-30V * Turn starting NO switch OFF. * Disconnect T12. * Start engine. Turn transmission cut-off switch OFF (Put out lamp) * Turn parking brake switch OFF. Press brake.
Defective modulated clutch controller
Replace
Disconnection or defective contact in wiring harness between M02A (female) (4) - T14 (female) (1)
Repair or replace
Defective R ECMV fill switch
l
l
MC16,
MC-17 Related electrical circuit diagram Transmission _
R fill
switch
TXW0’2456
WA1 200-3
20-529 0
MC18
TROUBLESHOOTING
Disconnection in RPM-SET IDLE-UP/RESUME switch system
MC-18 f t
IDLE-DOWN
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.
Remedy
4YE!
Is resistsnce YES between M02A - (female) (16) and LllO (female) (3) 2 mrma,‘,
n 1
(male) (11,(2) and (3) as shown in
Is resistance YES between LllO - (female) (21 and 3 chassis ground IlOrlllsl?
Max. 1 R ; between M02A - (female) (15) and - *Turn starting LllO (female) 11) switch OFF. n0rHlal? * Disconnect MOZA - Max. 1 R and L110. Turn starting NO switch OFF. Disconnect MOZA and LllO. l
-
Defective modulated clutch controller
Replace
Disconnection in wiring harness between LllO (female) (2) -chassis ground
Repair or replace
Disconnection in wiring harness between MOZA (female) (16) - LllO (female) (3)
Repair or replace
Disconnection in wiring harness between MOZA (female) (15) - LllO (female) (1)
Repair or replace
Defective RPM-SET IDLE -UP/RESUME IDLEDOWN switch
IReplace
-
NC
* Max. ’ R Turn starting switch OFF. Disconnect LllO. l
l
NO
l
l
- Disconnect Lll 0. * Turn starting switch OFF.
Table 1 RPM-SET IDLEUP switch ON
RESUMEJDLEDOWN switch ON
Between LllO (female) (1) - (2)
Min. 1 MR
Max. 1 R
Between LllO (female) (3) - (2)
Max. 1 R
Min. 1 MR
MC-18 Related
Modulated
.
electrical
RPM-SET IDLE-UP/RESUME IDLE-DOWN switch
circuit diagram
clutch
LR7 (DT~) 4-j
RA5 (DTI)
RAI 0 (DTHD4)
Battery
2 000
7
TXW02473
20-530 0
WA1 200-3
MC-19
TROUBLESHOOTING
MC-19 + +
Abnormality
in electronic governor voltage command
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.
3 YES
Is resistan between MO1 - (female) (14) and chassis ground 1 normal? * Min. 1 MR
Is voltage between YES MO1 (female) (14) _ and chassis 2 ground nOrmal?
yes
-
system
Is resistance b&wean MO1 (female) (14) and (12 (female) (5) normal?
c
1
Max. 1 R * Turn starting switch OFF. * Disconnect MO1 and Q2. *
MC-19
‘T”rn
Related
l
I
aaning
-
* At low idling: NO Max. 0.5 V * At high idling: 3.8 - 5 V * Turn starting switch ON. NO
switch OFF. Disconnect MO1 and Q2.
NO
electrical
Modulated clutch controller
Short circuit with power source in wiring harness between MO1 (female) (14) - 02 (female) (5)
Repair or replace
Defective modulated clutch controller
Replace
Short circuit with chassis ground in wiring harness between MO1 (female) (14) - Cl2 (female) (5)
Repair or replace
Disconnection or defective contact in wiring harness between MO1 (female) (14) - 02 (female) (5)
Repair or replace
circuit diagram
NO1 (NIC21)
LRI (HD-95066)
OUANTUM
)ELc.0”.*01 W1..1 1355( I TXW02479
WA1 200-3
20-531 0
TROUBLESHOOTING
MC-21 * *
Abnormality
MC-21
in modulated clutch ECMV fill 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.
* )
;I’“” resistance yes between M02A - (female) (12) and 2 T10 (female) (11 Is resistance normal? YES between MOZA Min. 1 MR NO - (female) (12) and *Turn starting T10 tfemale) (1) 1 switch OFF. _ normal? Is resistance * Disconnect M02A and TlO. *Max. 1 R between TlO (male) - * Turn starting NO (1) and chassis switch OFF. ground normal? Disconnect MO24 * Turn starting and TlO. I switch OFF.No Disconnect TlO. -Turn starting switch ON (Do not start engine): Min. 1 MR When engine speed is above 500 rpm: Max. 1 Q Is
l
Defective modulated clutch controller
Replace
Short circuit with chassis ground in wiring harness between M02A (female) (12) -TlO (female) (1)
Repair or replace
Disconnection in wiring harness between M02A (female) (12) -TlO (female) (1)
Repair or replace
Defective modulated clutch ECMV fill switch
Replace
l
l
MC-21 Related electrical circuit diagram
Modulated rnntrnlIPr __ . _
_
clutch RT2 (HD-85086)
T10 (011) 11’1711 - __-
lLLl
MOO/C f i switch
II
=FE TXWO2480
WA1 200-3
20-533 0
TROUBLESHOOTING
MC22
MC-22 Abnormality
in right brake pedal switch system
f Check that fuse l(9) is normal. f Before carrying out troubleshooting, check that all the related connectors are properly inserted. or Always connect any disconnected connectors before going on to the next step.
Cause
4YE! ISvoltage between YES_ MOZA (female) (18) _ and chassisground 3 normal?
ES 2 Is resistance YES b-en M02A - (female) (18) and chassis ground 1 pnormal? * Min. 1 MS1
-
Is r&Stance between M02A (female) (18) and Ll 11 (female) (2) normal? * Max. 1 R * Turn starting switch OFF. * Disconnect M02A and Llll.
MC-22
Related
Modu lated cant
I
*Turn star%J switch OFF. * Disconnect M02A and Llll.
electrical
clutch
-
Is resistance * Press right brake between Llll pedal: Max. 1 V (female) (1) and FS2 Release right brake (female) (8) normal? _ pedal:17-30V. * Max. 1 R * Turn starting NO switch OFF. * Disconnect Ll 11 and FSZ. NO
NC
Remedy
Defective modulated clutch controller
Replace
Defective right brake pedal switch
Replace
Disconnection or defactive contact in wiring harness between Ll 11 (female) (1) FS2 (female) (8)
Repair or replace
Short circuit with chassis ground in wiring harness between MOZA (female) (18) - Llll (female) (2)
Repair or replace
Disconnection or dafactive contact in wiring harness batwaen M02A (female) 118) - Llll (female) (2)
Repair or replace
circuit diagram
Fuse (I 1
i
20-534 0
TXW0248 I
WA1 200-3
TROUBLESHOOTING
MC-23 * *
MC-23
Abnormality
in travel speed control ON/OFF
switch system
Before carrying out troubleshooting, check that all the related connectors are properly inset-ted. Always connect any disconnected connectors before going on to the next step.
4YE!
I Isresistance YES -
3 ~-
2
YE
L24 (female)
1
1
I Is resistance
‘Isresiaance between M02A (femaleI (20) and
-
(3)
normal? *Max.lR *Turn starting switch OFF. . Disconnect M02A and L24.
.
between M02A Ifemale) (201 and chassis ground
“crme’7 ~*Min. 1 MR *Turn starting switch OFF. * Disconnect M02A and l.24.
L24 (4) and
-
chassis ground normal?
Is resistance YES -
between (female)
lr-
-
’ Maxe * Turn
’ *
starting switch OFF. * Disconnect K4. NO
NO
* Travel speed control ON/OFF 0 switch ON: Max. 1 R OFF: Min. 1 MR * Disconnect f-24. Turn starting switch OFF.
NC
Defective modulated clutch controller
Replace
Disconnection in wiring harness between I24 (female) (4) -chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between M02A (female) (20) - L24 (female) (3)
Repair or replace
Disconnection in wiring harness between M02A (female) (20) - I24 (female) (3)
Repair or replace
Defective travel speed control ON/OFF switch
Replace
l
MC-23 Related
electrical
Modulated
circuit diagram
clutch
.
M02A (04020)
LR7 IDTI)
WA1 200-3
RA5 (DTI
1
Speed set switch
RAlO (DTHD4)
Battery
20-535 0
TROUBLESHOOTING
MC-24 * + *
MC-24
Abnormality
in RPM-SET ON/OFF
switch system
Check that fuse I(101 is normal. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
YES Is voltage YES
2 Is resistance between
yf
(female) (2) and chassis ground normal?
1
(female1
(1) and (2)
L108
*Max. 1 R *Turn starting switch OFF. Disconnect L108.
-
Replace
ON/OFF
ground, disconnection, defective contact, or short circuit with powersource in NO
OFF: Max. 1 V ON:l?-3av . Turn starting switch OFF.
NO
Defective modulated clutch controller Short circuit with chassis
(female) (3) and chassis ground normal? switch
Remedy
between
M02B
* RPM-SET
inserted.
wiring harness between M02B (female) (3) - L108 (female)
(1)
Disconnection or defective contact in wiring harness between
Repair or replace
L108 (female)
(2) -
Repair or replace
chassis ground
l
RPM-SET ON/OFF switch b ON: Max. 1 R OFF: Min. 1 MS2 * Turn starting switch OFF. * Disconnect L108.
*
MC-24
Related
Nodu cant
20-536 0
electrical
Defective RPM-SET ON/OFF switch
Replace
circuit diagram
RPM-SET
WA1 200-3
TROUBLESHOOTING
MC-25 * *
MC-25
Abnormality
Before carrying Always connect
in engine rotation output
signal system
out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step.
YES
d
1and
chassis ground normal?
* Start engine. : Min. 0.5 V
Defective modulated clutch controller
r NO
I
Shon circuit with chassis ground, disconnection, defective contact, or short circuit with power source in wiring harness between MO25 (female) (14) - L28 (female) (4) or V3A (female) (7)
inserted.
Replace
Repair or
MC-25 Related electrical circuit diagram
Modulated con
clutch
VHMS controller
Work eauiDment controller
L28 1040 16) TXW02484
WA1 200-3
20-537 0
TROUBLESHOOTING
MC-26
* * * *
MC-26
Abnormality in power supply system of modulated control system
clutch
Check that fuse I (9) 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 Tadapter (or socket).
I YES 1 I
Cause
Defective modulated clutch controller Disconnection or defective contact in wiring harness between MO1 (female)(8),(17). (18)-MO1 W,M02A(9)
- Max.
1R . Turn starting switch OFF. - Disconnect MO1 and M02A.
MC-26
Related
electrical
Modulated con
NO
Disconnection or defective contact in wiring harness between MO1 (female) (91, M02A (female) (9) - chassis ground
Remedy
Replace
Repair or replace
Repair or replace
circuit diagram
clutch
TXW02485
20-538 0
WA1 200-3
MC-27, MC-28
TROUBLESHOOTING
MC-27 *
in network
system
See “T-34 Network system” in troubleshooting
MC-28 *
Abnormality
Abnormality
in Fl (Forward
for transmission
controller system.
1st gear) input signal system
See “T-39 Fl (Forward 1st gear) signal system” in troubleshooting system.
WA1 200-3
for transmission
controller
20-539 0
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER (JOYSTICK STEERING CONTROL) SYSTEM (J MODE)
Judgement table for work equipment control system related parts ...............................................
.20-602
Operations of controller against abnormality and conditions of machine caused 20-604
by abnormality ................................................................................................................................. Electrical circuit diagram for joystick steering system .....................................................................
.20-608
in travel speed sensor system) is displayed.. ....................... 20-609
J- 1
Error code I551 (Abnormality
J- 2
Error code 1561 (Disconnection or short circuit with chassis ground in 20-610
caution buzzer relay system) is displayed ....................................................................... J- 3
Error code 1571 (Disconnection or short circuit with chassis ground in 20-611
steering lever angle sensor system) is displayed ........................................................... J- 4
Error code [581 (Deviation of steering lever angle sensor and frame 20-612
angle sensor potentiometer signals ................................................................................. J- 5
Error code I591 (Disconnection or short circuit with chassis ground in 20-613
frame angle sensor system) is displayed. ........................................................................ J- 6
Error code 1611 (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed ..............................................
J- 7
Error code [621 (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed .....................................................
J- 8
20-614
20-615
Error code [631 (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed ...........................................................................................
20-616
J- 9
Short circuit with chassis ground in travel speed sensor system ......................................... 20-617
J-10
Steering speeds in both directions are different ..... ................................................................
J-l 1
Abnormality
J-12
in console switch (adjustment of steering lever angle sensor
and frame angle sensor is impossible) ............................................................................
20-619
in power source and voltage ...............................................................................
20-620
Abnormality
WA1 200-3
20-618
20-60 1 0
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL SYSTEM (JOYSTICK CONTROL SYSTEM) RELATED PARTS
TROUBLESHOOTING
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL SYSTEM (JOYSTICK CONTROL SYSTEM) RELATED PARTS ielf-di,
nosis disp
Ialy (Display of abnormal-m
Location of failure
Failure mode
63 Refer to G mode
1 1 Engine cannot be started 2 1 Steering speed is heightened 3 1 Steering speed ir_lowered 4
-
_
H-6
Response of steering system is heightened
5
Response of steermg system IS lowered
6
Steering speeds in both directions are different
7
Steering speed is heightened even at high travel speed
8 ( Machine is steered suddenly after engine is started 9 1 Engine can be started while machine is steered IO ) Caution buzzer does not sound or keeps sounding
M-16
Diagnosis code when failure code is displayed
20-602 0
WA1 200-3
OPERATIONS OF CONTROLLER AGAINST ABNORMALllY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY -ailure code
55
56
57
58
59
20-604 0
Abnormal
system
Abnormality in travel speed sensor system
Disconnection or short circuit with chassis ground in caution buzzer relay system
Disconnection or short circuit with chassis ground in steering lever angle sensor (potentiometer) system
Deviation of steering lever angle sensor and frame angle sensor potentiometer signals
Disconnection or short circuit with chassis ground in frame angle sensor (potentiometer) system
Contents
of abnormality
I) Defective travel speed sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L28 (female) (5) - T15 (female) (1) 3) Disconnection or defective contact in wiring harness between work equipment controller L28 (female) (12) T15 (female) (2) 4) Defective joint connector (JLI9, JL6, JL12, JM4) 5) Defective work equipment controller
I) Defective caution buzzer relay 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L28 (female) (13) - L65 (female) (I) 3) Disconnection or defective contact in wiring harness between caution buzzer relay L65 (female) (2) - chassis ground 4) Defective work equipment controller
I) Improper installation (Misalignment) of steering lever angle sensor 2) Defective steering lever angle sensor 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L27 (female) (20) - JS2 (female) (1) 4) Defective work equipment controller
I) Improper installation (Misalignment) of steering lever angle sensor 2) Defective steering lever angle sensor 3) Improper installation (Misalignment) of frame angle sensor 4) Defective frame angle sensor 5) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between L27 (female) (20) - JS2 (female) (1) 6) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between L28 (female) (I) - L30 (female) (1) 7) Defective work equipment controller
I) Improper installation (Misalignment) of frame angle sensor 2) Defective frame angle sensor 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between L28 (female) (I) - L30 (female) (I) 4) Defective work equipment controller
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Normal condition (Voltage, current, resistance)
Operation of controller against abnormality
Condition of machine caused by abnormality
1) Resistance between travel speed sensor T15 (male) (1) - (2): 500 - 1,OOOQ
Turns off steering main pressure control EPC solenoid.
Steering speed is heightened even at high travel speed.
Diagnosi code
J-l
11 Voltage between relay L65 (1) - chassis ground when caution buzzer is turned on: 20 - 30 V 2) Resistance between work equipment controller L28 (15) - chassis ground, caution buzzer relay: 200 - 4OOQ 3) Resistance between work equipment controller L28 (female) (15) - L65 (female) (1): Max. 1 R 4) Resistance between caution buzzer relay L65 (female) (2) - chassis ground: Max. 1 R
Does not operate at all.
I) Voltage between work equipment controller L27 (20) - (9): 0.5 - 4.5 v !I Resistance between steering lever angle sensor JS2 (male) (1) - (2): 0 - 5 kS2
1) Turns off steering main pressure control EPC solenoid output. 2) Controls steering lever angle sensor signal voltage as input voltage.
Steering speeds in both directions are different.
I) Voltage between work equipment controller L27 (20) - (9): 0.5 - 4.5 v 2) Voltage between work equipment controller L28 (1) - L27 (9): 0.5 - 4.5 V 3) Resistance between steering lever angle sensor JS2 (male) (1) - (2): 0 - 5 kQ 4) Resistance between frame angle sensor L30 (male) (1) - (2): 0 - 5 kD
Turns off steering main pressure control EPC solenoid output.
Steering speeds in both directions are different.
1) Voltage between work equipment controller L28 (1) - L27 (9): 0.5 - 4.5 V 2) Resistance between frame angle sensor L30 (male) (1) - (2): 0 - 5 kQ
1) Turns off steering main pressure control EPC solenoid output. 2) Controls frame angle sensor signal voltage as input voltage.
WA1 200-3
Caution buzzer does not sound or keeps sounding.
J-2
J-3
J-4
Steering speeds in both directions are different. J-5
20-605 ‘0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
‘ailure
61
62
63
20-606 0
code
Abnormal
system
Disconnection or short circuit with chassis ground in steering lever lock pressure switch system
Disconnection or short circuit with chassis ground in steering neutral interlock relay system
Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system
Contents
of abnormality
1) Defective steering lock pressure switch 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L27 (female) (1) - STL (female) (1) 3) Disconnection or defective contact in wiring harness between work equipment controller L27 (female) (2) chassis ground 4) Defective work equipment controller
1) Defective steering neutral interlock relay 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L26 (female) (21) - L127 (female) (1) 3) Disconnection or defective contact in wiring harness between L127 (female) (2) - chassis ground 4) Defective work equipment controller
1) Defective steering main pressure control EPC solenoid system 2) Disconnection, defective contact, short circuit with chassis ground, short circuit, or short circuit with power source in wiring harness between work equipment controller L26 (female) (2) - L29 (female) (2) 3) Short circuit with chassis ground in wiring harness between work equipment controller L26 (female) (16) L29 (female) (1) 4) Defective work equipment controller
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALlTY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
Normal condition (Voltage, current, resistance)
Operation of controller against abnormality
Voltage between work equipment controller L27 Turns on caution buzzer. (female) (1) - chassis ground: When steering lock lever is in LOCK: 20 - 30 V . When steering lock lever is in FREE: Max. 1 V l
Condition of machine caused by abnormality (In case of disconnection} I) Transmission is kept in N. 2) Steering system is operable normally. (In case of short circuit with chassis ground) 1) Machine can travel although steering system is locked. 2) Gear is shifted in F or R. 3) Gear is shifted in F or R.
Voltage between work equipment controller L26 (female) (21) - chassis ground: When steering lock lever is in NEUTRAL: Max. 1 V
Does not operate at all.
l
Current flowing between work equipment controller L26 (2) - (16): 600 & 80 mA (Check on CGC monitor.)
WA1 200-3
Turns off steering main pressure control EPC solenoid output.
Diagnosis code
1) Engine can be started while machine is steered. 2) Machine is steered suddenly after engine is started 3) Engine cannot be started.
I) Response of steering system is lowered. 2) Steering speed is lowered. 3) Response of steering system is heightened 4) Steering speed is heightened
J-6
J-7
J-8
20-607 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM SYSTEM
FOR JOYSTICK STEERING SYSTEM
FOR JOYSTICK
ram anell mtentioaetsr
STEERING
Stssrino switch lock
TXW02486
WA1 200-3
J-l
TROUBLESHOOTING
Error code 1551 (Abnormality displayed
J-1
in travel speed sensor system) is
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or T-adapter, the inserting and connector on the monitor display, the to its original position, if the error code is no longer displayed 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
4YE
1 ye I
1 *Turn starting switch ON.
Is resistance between T15
NO * Disconnect L28
NO
* Max. * Turn l
1R starting switch OFF. Disconnect JL19, JL6, JL12, and JM4.
J-l
Related
I NO
electrical
Remedy
Defective work equipment controller Short circuit with power source in wiring harness between L26 (female) (5) JL19 (3), (5) - JL6 (3). (6) FR2 (7) - T15 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between L26 (female) (5) JL19 (3). (5) - JL6 (3). (61FR2 (7) - T15 (female) (1)
Repair or replace
Defective travel speed sensor
Replace
Defective joint connector (JL19, JL6, JL12, JM4)
Replace
circuit diagram
TXW02453
WA1 200-3
J-2
TROUBLESHOOTING
J-2
Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay 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. When the joystick steering lever is not being used, leave it at the neutral position. Always connect any disconnected connectors before going on to the next step.
Replace
yes
-
2 Is resistance YES between L65 - (female) (2) and chassis ground 1 - normal?
-
-
Is resistance * Max. 1 R between L65 _ * Turn starting (male) (1) and (2) switch OFF. normal? * Disconnect LG. 1 .200-400R Lo ‘Turn starting switch OFF. * Disconnect L65.
J-2 Related
electrical
Fuse
-
Is rssistance between I.28 (female) (15) and L65 Ifemale) (1) normat?
11 withc&as$sis;md&
l;;ha;ground -
* Mi”-’ MC2
NO
* Turn starting . D~~~~nor.U8 and L65.
- Max. 1 R -Turn starting switch OFF. - Disconnect L28 and L65.
NO
NO
L28 (female) (15) - L66 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between L28 (female) (15) L65 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between L65 &male) f21chassis ground
Repair or replace
1r
caution buzzer
Rep,ace
circuit diagram
(II
Power source
Caution FS2 (S 12)(B1ue) >
I 91A
9
0.75fY
I Work eauipment~ controller J/S caution
L28 (04016) relay
252
15
”
5fY
m m
OlOAV
0.5fB
124AB OIOAU 252
0.5fL 0.5fB 0.5fY
L65 6
: :
Jovst ick taut ion buzzer relay
TXW024137
20-610 0
WA1 200-3
TROUBLESHOOTING
J-3
J-3
Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle 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. When the joystick steering lever is not being used, leave it at the neutral position. Always connect any disconnected connectors before going on to the next step.
* *
Remedy
Replace or adjust neutral position
neutral position) Disconnection,
defective
contact,short circuitwith
(female) (20) and
chassis ground, or short circuti with power source
in wiring
Repair or replace
harnessbetween L27 ffemale) (20) - JS2 (female)(1) (female) (10) and
left (0.5 - 4.5 V) * Lean steering lever to right or left (0.2 - 5 kc11
Defective steerintg lever angle sensor
Replace
Replace
J-3 Related Work
electrical
circuit diagram
eauiwnent
Pontentionetcl
TXWO.2488
WA1 200-3
20-611
0
TROUBLESHOOTING
J-5
J-5
Error code 1591 (Disconnection or short circuit with chassis around in frame angle sensor system) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or T-adapter, the connector and inserting if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed. check that all the related connectors are properly inserted. Before carrying out troubleshooting, 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
l
I
J
-4.9-5.1 v *Turn starting switch ON.
Change frame angle (0.2 - 5 kQ)
IO
J-5 Related Work
electrical
NO
Remedy
Improper installation of frame angle sensor (Deviation of neutral position)
Replace or adjust neutral position
Disconnection, defective contact short circuit with chassis ground, or short circuit with power source in wiring harness between LZ8 (female) (1) - WO (female) 11)
Repair or replace
Defective frame angle sensor
Replace
Defective work equipment controller
Replace
circuit diagram
eauiDment
Pontentioncter
rotentiometer
Txw024aa
WA1 200-3
20-613 0
J-6
TROUBLESHOOTING
J-6
Error code [611 (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed
f
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or connector and inserting the T-adapter, 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 ail the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Ir
cause
4YE:
,
YES between STL (1) .dl”““““h L ground normal? Is voltage between L27 (1) and chassis ground normal?
YES _1 _ (male) (1) and (2)
lo-2v -
. Turn starting switch OFF. . Disconnect L27 and STL
~20-3ov Turn starting NO switch ON. Turn steering lock pressure switch ON. l
fZ!Z&-H
Remedy
Defective work equipment controller
Replace
Disconnection or defective contact in wiring harness between L27 (female) (2) chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between L27 (female) (1) STL (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between L27 (female) (1) - STL (female) (1)
Repair or replace
Defective steering lock pressure switch
Replace
l
* Max. 1 R * Disconnect STL NO Start engine. When steering lock lever is in FREE: Max. 1 R When steering lock lever is in LOCK: Min. 1 MR l
J-6 Related
electrical
Work eou iDment ler control
circuit diagram
STL
Steering switch
CDT21
lock
#
ry
WA1 200-3
TROUBLESHOOTING
J-7
J-7
Error code 1621 (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed
j,
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.
+
F
Cause
I
YES
4YEs
1 yes 3
If L127 relay is replaced, is system
-
normal?
Is volt& *
Replace L127 with normal relay.
YES
Max. 1 R . Turn starting switch OFF. * Disconnect U6 and L127. l
J-7 Related
electrical
~261female) ~1) and chassis ground
2 Is resistance between l.26 (21) NO and L127 (female) (1) normal?
between
normal?
- Max.
-
1V * Turn starting switch OFF. * Disconnect l26 and L127.
Is resistance between L127 (female)
(2) and
-
chassis ground Il0rHIel7
i
NO _ - Max. 1 R * Turn starting I switch OFF. * Disconnect L127. NO
NO
Remedy
Defective steering neutral relay
Replace
Defective work equipment controller
Replace
Disconnection or defective contact in wiring harness between L127 (female) 12) chassis ground
Repair or replace
Short circuit with chassis ground in wiring harness between l26 (female) (21) - L127 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between L26 (female) (21) - L127 (female) (1)
Repair or replace
circuit diagram
Work equipment controller
L26 J/S
neutral
lock
relay
(MIC21) 573
21
‘.
573 OlOBT
5fY
m nr) < 0
0.5fY 0.5fB
L127 ; 3
5 6
Steer ins neutral relay
TXW02490
WA 1200-3
20-615 0
TROUBLESHOOTING
J-8
*
+ f *
J-8
Error code [631 (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid 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. When the joystick steering lever is not being used, leave it at the neutral position.
CalIS
4YE! 5 YES 3
1Is resistance
y~5 i! -
lfamalelf6l and
*Turn starting switch OFF. * Replace with other same EPC solenoid. *Turn starting switch ON. From A -
-
NO
YES
5
* Max. 1 V . Disconnect L26 and l-29. *Turn starting switch ON.
* Min. 1 MD * Turn starting switch OFF* Disconnect I_26 and l29.
I
* Min. 1 MQ *Turn starting switch OFF. . Disconnect l-26 and US.
is resistance between L26 (female) (6) and chassisground normal?
pIs resistance betweenl.26 (female) (16) and chassis gmund normal?
-
Is resistance between L26 (female) (6) and (16) normal? * Min* ’ MR * Turn starting switch OFF. * Disconnect L26.
NO
Remedy
GotoA.
Short circuit of wiring harness betwean I_26 (female) (6) - L2S (female) (2) with wiring harness NC1 between U6 (female) (16) and L29 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between L26 (female) (16) US (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between L26 (female) (6) US (female) (2)
Repair or replace
Defective steering main pressure control EPC solenoid
Replace
Defective work equipment controller
Replace
Short circuit with power source in wiring harness between l.26 (female) (6) - L29 (female) (2)
rlepair or aplace
-
NO
J-8 Related electrical circuit diagram
Joust
Work equiDment controller
ick
EPC L29 (DT2) 111901 2 I191
solenoid
I TJW02491
20-6 16 0
WA1 200-3
J-9
TROUBLESHOOTING
J-9 * Ir
Short circuit with chassis ground 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 2 YES YES 1 Is resistancebetween L28 (female) (51 and chassisground normal?
-
. Min 1 R * Turn starting switch OFF. * Disconnect L28 and 115.
J-9 Related
Is resistance between U8 (female) (12) and (5) normal?
-
j NO * Max. 1 R * Turn starting switch OFF. . Disconnect L28 and T15.
NO
electrical
Remedy
Defective travel speed sensor
Replace
Shon circuitof wiring harness between L28 ifemale) (5) JL19 13).(5) - JL6 (3) , (6) FR2 (7)-T15 (female) (1) with wimg harnessbetween L28 (female) (12) - L19 (11,(6) JL6 (1). (81- JL12 (3). (1) - FR2 (8) -T15 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between L28 (female) (5) L19 (3). (5) - JL6 (31, (6) - FR2 (7) - T15 (female) (11
Repair or reolace
circuit diagram
Transmission
TXW02453
WA1 200-3
20-617
J-IO
TROUBLESHOOTING
J-IO *
Steering
speeds in both directions
are different
If an error code is displayed, check the parts corresponding
to it. Cause
Deviation of steering lever angle sensor or frame angle sensor potentiometer
20-618 0
Repair or replace
WA1 200-3
TROUBLESHOOTING
J-II
* *
J-l 1
Abnormality in console switch (adjustment of steering angle sensor and frame angle sensor is impossible)
lever
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.
Remedy
4y~S Is voltage between YES L27 (female) (14) and chassis ground I normal?
Is resistance YES batweenC3A (female) 16) and JS3 2 (female) (1) normal? Is resistance YES betwaen L27 - (female) 114)and JS4 (male) (1) 1 - normal?
Is resistance between console switchJS3 (male) (1) and JS4 (female) _(l) normal? .
*Max. 1 R * Turn starting switch OFF. * Disconnect I_27 and JS4.
-
* Max. 1 R * Turn starting switch OFF. * Disconnect C3A and JS3. NO
* When left armrest is at rearmost position , kwitch is ON): NO Max. 1 R . When left armrest is not at rearmost position kwitch is OFF): Min. 1 MR * Turn starting switch OFF. . DisconnectJLlS, JL6, JL12, and JM4.
J-l 1 Related
electrical
ND . Max. 1 V -Turn starting switch OFF. - DisconnectL27 and JS4. -Turn starting switch ON NO
Defective work equipment controller
Replace
Short circuit with power source in wiring harness between L27 (female) (14) JS4 (male) (1)
Repair or replace
Disconnection or defective contact in wiring harness between C3A (female) (6) JS3 (female) (1)
Repair or replace
1 Disconnection or defective contact in wiring harness between L27 (female) (14) JS4 (male) (1)
Replace
Defective console switch
circuit diagram
Work equipment controller
L27 (04020)
Cons0 I Transmission h joystick steering controller
WA1 200-3
20-619 0
J-12
TROUBLESHOOTING
J-12 * * J, j:
Abnormality
in power source and voltage
Before carrying out troubleshooting, check that all the related connectors are properly Check that fuse I (10) is normal. When the joystick steering lever is not being used, leave it at the neutral position. Always connect any disconnected connectors before going on to the next step.
I
Defective work equipment controller
1 YES Is voltage between L26 (female) (81, (18) and chassis ground normal?
l20-3ov l
Disconnection or defective contact in wiring harness between L26 (female) (8). (181, (17) -FS2(10)-fuseI
NO
Turn starting switch ON.
J-12 Related
electrical
Work eau i Pment controller \
1
Cause
/
inserted.
Remedy
Replace
Repair or repiace
circuit diagram
Fuse ( I ) LLO
Power INPUTt Power INPUTS t 2.1
\MILZII
1.25fW
1.25fW
FS2 (Sl 2 Blue 1 11. 25fW
101 58AI
TJW02493
20-620 0
WA1 200-3
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROL) SYSTEM (W MODE)
Judgement table for work equipment controller related parts .........................................................
20-652
Action taken by controller when abnormality occurs and problems on machine.. ....................... 20-654 Electrical circuit diagram for work equipment controller system .....................................................
w-
1
w- 2
20-656
Failure code [431 (Shot-t circuit, disconnection in damping solenoid) is displayed.. ........ 20-658 Failure code 1441 (Short circuit in power source at hot end of damping 20-659
solenoid) is displayed ......................................................................................................... w- 3
Failure code [451 (Short circuit in power source at return end of damping solenoid) is displayed .........................................................................................................
w- 4
20-659
Failure code [491 (Short circuit, disconnection in boom lever kick-out relay system) is displayed ...........................................................................................................
w- 5
20-660
Failure code 1511 (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed ............................................................................................................
W- 6
w- 7
20-661
Failure code 1521 (Short circuit, disconneciton in boom angle potentiometer system) is displayed ...........................................................................................................
20-662
Sensor cannot be adjusted ......................................................................................................
20-663 20-663
in engine speed signal system ..........................................................................
W- 8
Abnormality
w- 9
Remote positioner RAISE, LOWER LEDs do not light up .....................................................
W-IO
Remote positioner RAISE stop lamp (CGC monitor) does not flash
20-664
20-665
(for 2.5 seconds) ................................................................................................................. w-11
Remote positioner LOWER stop lamp KGC monitor) does not flash 20-665
(for 2.5 seconds) .................................................................................................................
20-666
w-12
Buzzer for switch operation does not sound .........................................................................
w-13
Shock when stopping boom (abnormality in boom lever detent switch) ......................... 20-667
w-14
Short circuit in boom RAISE, LOWER pressure detection switch.. ......................................
WA1 200-3
20-668
20-65 1 0
TROUBLESHOOTING
JUDGEMENT ABLE FOR WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROLLER SYSTEM) RELATED PARTS
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROLLER SYSTEM) RELATED PARTS
Location of failure
Failure mode
20-652 0
WA1 200-3
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE IEMOTE
B(
-ailure code
DM POSITIONER
CONTROL
ER SYSTEM Nature of abnormality
Abnormal system
Defective damping solenoid
:; Short circuit in wiring harness between work equipment controller L26 (female) (51, (15) and HRS (female) (11, (2) defective contact, or 3) Short circuit with ground, disconnection in wiring harness between work equipment controller L26 (female) (5) - HRS (1) defective contact, or 4) Short circuit with ground, disconnection in wiring harness between work equipment controller L26 (female) (15) - HRS (2) 5) Defective work equipment controller
43
Damping solenoid system
44
Short circuit with power source in damping solenoid system
I) Defective damping solenoid 2) Short circuit with power source in wiring harness between work equipment controller L26 (female) (5) - HRS (1) 3) Defective work equipment controller
45
Short circuit with power source at return end of damping solenoid system
1) Defective damping solenoid 2) Short circuit with power source in wiring harness between work equipment controller L26 (female) (15) - HRS (2) 3) Defective work equipment controller
49
Boom kickout relay system
1) Defective boom relay 2) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L26 (female) (20) boom relay L45 (1) 3) Defective contact or disconnection in wiring harness between boom relay L45 (female) (2) - chassis ground 4) Defective work equipment controller Defective boom RAISE/LOWER switch contact or disconnection in wiring harness between work equipment controller L27 (female) (5) - HR13 (female) (1) Defective contact or disconnection in wiring harness between HR13 (female) (2) - chassis ground Defective contact or disconnection in wiring harness between work equipment controller L27 (female) (6) - HR12 (female) (1) Defective contact or disconnection in wiring harness between HR12 (female) (2) and chassis ground Defective work equipment controller
:; Defective 3) 51
Boom RAISE/LOWER switch system
4)
5) 6)
Defective boom angle potentiometer
:; Short circuit with power source, short circuit with ground,
52
20-654 0
Boom angle potentiometer system
defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (19) F04 (female) (1) 31 Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (9) - F04 (female) (2) 4) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (10) F04 (female) (3) 5) Defective work equipment controller
WA1 ZOO-3
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Rr$l&;$“n’,a$~;;rs
1) Resistance between work equipment controller L26 (female) (5) and (15): 10 - 20 12 2) Voltage between work equipment controller L26 (female) (5). (15) and chassis ground: Less than 1 V 3) Resistance of wiring harness between work equipment controller L26 (female) (51, (15) - HR9 (11, (2): Less than 1 Q
Damping solenoid output: OFF
There is shock when stopping boom in remote positioner mode
Voltage between work equipment controller L26 (female) (5) and chassis ground: Less than 1 V
Damping solenoid output: OFF
Condition when normal (voltage, current, resistance)
Voltage between work equipment controller L26 (female) (15) and chassis ground: Less than 1 V
there is abnormality
,‘,r;EgF code
W-l
Damping solenoid output: OFF
1) Resistance of relay coil: 200 - 400 R 2) Resistance of wiring harness between work equipment controller L26 (female) (20) - boom relay L45 (1): Less than 1 R 3) Resistance of wiring harness between boom relay L45 (female) (2) and chassis ground: Less than 1 R
Boom lever kickout output: OFF
1) When boom lever is at neutral, resistance becomes as follows. 2) Resistance between work equipment controller L26 (female) (5) and chassis ground: Less than 1 R and resistance between work equipment controller L26 (female) (3) and chassis ground: Less than 1 R
Damping solenoid output: OFF
Voltage between work equipment controller L26 (female) (19) and L27 (9): 0.3 - 4.8 V
Remote positioner function: OFF
There is shock when stopping boom in remote positioner mode
There is shock when stopping boom in remote positioner mode
Boom does not stop at desired position in remote positioner mode (boom lever detent is not canceled)
w-2
w-3
w-4
There is shock when stopping boom in remote positioner mode w-5
Remote positioner function does not work
W-6
WA1 200-3
20-655 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROLLER SYSTEM Fuse
(I)
Fuse
M
20-656 0
FS2
(S12Xeluel
WA1 200-3
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROLLER SYSTEM
TROUBLESHOOTING
Positioner raise indicator (Green1
Boom kick solenoid
out
Bucket positioner solenoid
FLI
(HD-26086)
Bucket sositioner
Boom
sensor FR2 (HD-46082)
RT2 (HD-85086)
T15 (DT2)
I R20
angle
Boom lever detent switch Boom lower switch
I// Boom dump solenoid Boom dumv solenoid
TXW02495
WA1 200-3
20-657 0
W-l
TROUBLESHOOTING
Failure code M31 (Short circuit, disconnection solenoid) is displayed
W-l
in damping
*
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or T-adapter, the connector and inserting if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed.
*
Before Always Always socket
f f
carrying out troubleshooting, check that all the related connectors are properly inserted. connect any disconnected connectors before going on to the next step. turn the starting OFF before disconnecting any connector to connect the T-adapter (or adapter).
Cause
YES 2
YE
1 I Is resistance between L26 (female) (5) and (15) normal?
I
I
Is resistance between L26 (female) (5) and chassis normal? Disconnect L26. * Min. 1 MS2
l
Is resistance between HR9 NE (male) (1) and chassis normal?
_
* Disconnect HR9. Min. 1 MR l
t
* Disconnect L26. l15-2552
3 YES
4 YES
N
Is resistance between HR9 (female) (1) and (2) normal?
Related
electrical
circuit
Defective work equipment controller
Replace
Short circuit with chassis ground in wiring harness between I26 (female) (5), (15) - HR9 (female) (l), (2)
Repair or replace
Defective damping solenoid wiring harness Short circuit, defective contact. or disconnection in wiring harness between L26 (female) (5). (15) - HR9 (female) (1). (2)
Repair or replace
Defective damping solenoid
* Disconnect HR9. .15-25R
W-l
NO
Remedy
diagram
Work equipment cant rol ler DUMP ins solenoid TJW02496
20-658 0
WA1 200-3
w-2,
TROUBLESHOOTING
W-2
w-3
Failure code [441 (Short circuit in power source at hot end of damping 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. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter). Cause
Is voltage between L26 (female) (5)
* Disconnect L26. Turn starting switch ON. - Max. 1 V
NO
l
w-3
Remedy
Defective work equipment controller
Replace
Short circuit with power source in wiring harness between L26 (female) (5) and HR9 (female) (1)
Repair or replace
Failure code 1451(Short circuit in power source at return end of damping solenoid) is displayed CaUSe
Remedy
Defective work equipment controller
Replace
Short circuit with power source in wiring harness between L26 (female) (15) and HRg (female) (2)
Repair or replace
L26 (female) (15)
1
l
NO
W-2, 3 Related
electrical
Disconnect U6. * Turn starting switch ON. - Max. 7 V
Work cant
circuit diagram
equipment Dumping solenoid TJW02496
WA1 200-3
20-659 0
w-4
TROUBLESHOOTING
W-4
in boom lever kick-
Failure code [491 (Short circuit, disconnection out relay system) is displayed
*
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting 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 Always Always socket
* *
carrying out troubleshooting, check that all the related connectors are properly inserted. connect any disconnected connectors before going on to the next step. turn the starting OFF before disconnecting any connector to connect the T-adapter (or adapter).
Cause
Remedy
Defective work equipment controller Disconnection in wiring harness between U6 (female) (20) - L45’ (female) (1)
* Disconnea L46. - Min. 1 Mf2
W-4 Related Work coni
electrical
NO
Short circuit with chassis ground in wiring harness between L26 (female) (20) - L45 (female) (1)
Replace
Repair or
Repair or replace
circuit diagram
equipment
Booim kit k-out SOI enoid
FS2
(Sl2
10 58A
Blue
1
(
R20
20-660 0
TJW02497
WA 1200-3
w-5
TROUBLESHOOTlNG
Failure code [511 (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed
W-5 *
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting 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. (Or Always turn the starting OFF before disconnecting any connector to connect the T-adapter socket adapter). Cause
YES
Defective work equipment controller
3 Is resistance between L27 (female) (6) and (9) normal?
YI
2 Is resistance
I
YI
W-5 Related Work
.Max.lR * Turn startingswitch0% * DisconnectHR12. * Boom lever: Neutral.
5
YES
l
l
3
electrical
Defective contact disconnection in harness between (female) (6). (9) (female) (1). (2)
Replace
or wiring L27 HR12
Defective boom LOWER switch Defective contact disconnection in harness between (female) (5). (9) (female) (lb, (2)
or wiring I27 HR13
Repair or replace
Replace
Repair or replace
PIP - Max. 152 NO * Turn starting switch OFF. Disconnect HR13. Boom lever: Neutral.
- Max.
1D -Turn starting switch OFF. - Disconnect HR12, HR13.
4YE
is resistance between HR12 NO (male) (1) and (2) nomtal?
- Max. 1 R - Turn starting switch OFF. * Disconnect U7. * Boom lever: Neutral.
- Max.
1R * Turn starting switch OFF. * Disconnect L27. n - Boom lever: Neutral.
-
Remedy
Defective boom RAISE switch
Replace
Xsconnection or fefective contact in wiring harness between iR12 (female) (2). HR13 female) (2) - JR15 (5). 3). 16) -chassis grqund, x defective joint connector JR15
Repair or replace
circuit diagram
eauipment
WA1 ZOO-3
pressure
switch
Pressure
switch
20-66 1 0
TROUBLESHOOTING
W-6 *
* * *
W-6
Failure code 1521(Short circuit, disconneciton system) is displayed potentiometer
in boom angle
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. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
F
YES
Defective work equipment controller
1
Is voltage
- 0.3 - 4.8 V * Turn starting switch ON.
YES
3
between L27 (female) (9) and (19) normal?
YES 2 _ Is resistance between F04 (female) (1) and (2). (2) and (3) normal?
~6
Remedy
Is resistance between F04 (female) (19). (9). (10) -chassis nl%Tnal?
-
NO * Min. 1 MR -Turn starting switch OFF. * Disconnect L27 and F04.
- Between (1) and NO (2): 0.2 - 5 kR Between (2) and (3):4-5M . Turn starting switch OFF. * Disconnect F04.
Replace
Short circuitwith power source in wiring harness between L27 (female)(9) FO4(female) (2). L27 (female) (10) - F04 (female) (3). L27 (female) (19) - FO4(female) (1 Shcrf circuit in wiring hames! between L27 (female) (9) F04 (female) (2) and between L27 (female) (10) - FO4 (female) (3). between L27 (female) (19) - F04 (female) I1
Repair or replace
Replace
Repair or
Defective boom angle potentiometer
l
W-6 Related electrical circuit diagram Work cant
eauipment
JL24
(DT2)
Boom angle Potentiometer
LR~ (DTI)
RA5 (DTI)
RAtO
(DTHD4)
Battery
TJWO2499
20-662 0
WA1 200-3
w-7,
TROUBLESHOOTING
W-7 * f * * *
Sensor cannot be adjusted
For details of the method of operation, see STRUCTURE AND FUNCTION. 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 OFF before disconnecting any connector to connect the T-adapter (or socket adapter). If the set switch display flashes in the set mode, check the installation of the boom angle potentiometer.
1
* Turn remote positioner RAISEAOWER set switch ON.
W-8
L
ZYES
Remote positioner Is remote RAISE, LOWER _ positioner set LEDS does not signal system light up of flash normal?
* * *
W-8
l
See troubleshooting W-10.
Abnormality
Defective work equipment controller
Replace
Defective remote positioner RAISEROWER set switch or LED s&em
RezaFeor
_
NO
’I
in engine speed 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 OFF before disconnecting any connector to connect the T-adapter (or socket adapter). Cause
_ Is resistance between L28 (female) (4) and chassis normal? - Disconnect L28 and MOZB. * Min. 1 MD
W-8 Related Work con
WA1 200-3
2 YES Is resistanceberween MS I28 (female)(41and - chassisnormal when 1 MO28Wemale)(141is grounded to chassis? , _
DisconnectL28. * Max. 1 R
l
NO
NO
electrical
equipment
Remedy
Defective work euqipment controller
Replace
Defective contact or disconnection in wiring harness between US (female) (4) and M02B (female) (14)
Repair or replace
Short circuit with chassis ground in wiring harness between L28 (female) (4) and MOZB (female) (14)
Repair or replace
circuit diagram Modulated . .
.
20-663 0
TROUBLESHOOTING
w-9
W-9 Remote positioner RAISE, LOWER LEDs do not light up * * Jc * *
Check that CGC works 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. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket). If fuse I-(11) is broken, check the wiring harness between the fuse and L136 (female) (1) and L136 (female) (I) for short circuit with chassis ground.
Defective work euqipment controller
Replace
D&connectionor defective contactin wiring harness Repair or betweenI26 (female)(61Ll37 (male) (1). or betweenL28 recdace (female)(14) - L13S(male)(1)
nale) (1) 1and chassis ground normal7 -2O-30V * ~isxnn
L136
H
II
with chassis groundin wiring harness betweenU8 (female)(8) Ll37 (male) (1). or betweenI26 (female)(141-LES (male)(1) Short circuit
,____.___.. male) (1).
- Disconnect L28, L137, and L139. * Min. 1 MR
NO
NO
- Turn starting switch ON.
I
Diinnection, defective contact.or short circuitwith chassisground in wiring harnessbeween fuse I (11) L136(female) (1). L136 (female)(1)
Repair or
Repair or
W-9 Related electrical circuit diagram
Work esuiDment controller
Positioner RAISE indicator (a reen) Positioner LOWER indicator (green) TJW02501
20-664 0
WA1 200-3
w-10, w-11
TROUBLESHOOTING
W-IO
Remote positioner RAISE stop lamp (CGC monitor) flash (for 2.5 seconds) Cause
Defective CGC
W-II
does not Remedy
Repair or replace
Remote positioner LOWER stop lamp (CGC monitor) does not flash (for 2.5 seconds) Cause
Defective CGC
WA1 200-3
Remedy
Repair or replace
20-665 0
w-12
TROUBLESHOOTING
W-12 * * * *
Buzzer for switch operation does not sound
Check that the main monitor and alarm buzzer 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. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause
Is
resiincebetween
chassisnormalwhen
chassis normal? and LO8. .5-6kQ
NO
Remedy
Defective work euqipment controller
Replace
Defective contact or disconnectionin wiring harness between L28 (female) MI- JL16 (1). (6) LO8(female) (6)
Repair or replace
. Defective contact or disconnacitonin wiring harness between L28 (female) (16!- RES2 (1). (2) - JL6 (5). (6) -chassis - Short circuit with chassis ground in tiring harness between L28 (female) WIJL16 (1). (6) - LO8(female) (6)
Repair or replace
W-12 Related electrical circuit diagram
Work epu i Pment controller
R20 TJW02502
20-666 0
WA1 200-3
w-13
TROUBLESHOOTING
W-13 * * * *
Shock when stopping boom (abnormality switch)
in boom lever detent
Check that the failure mode [491 is not displayed. 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 boom lever is at neutral, [GNDI is input to the controller when the boom detent switch is closed. Remedy
cause
4YE: *S 3 Is resistance ;zEl%E9,MS HRll (fern&) (1). 2 (2) normal? pIs resistancebetween I.27 (female)(8). (9) * Min. 1 MD YES_ and chassis normal _ Turn starting when HI31 1 (female) switch OFF. (IokA$$ grounded 1 s c Disconnect L27 Is resistance * Max. 1 R and HRll. between HRll - * Turn starting NO (male) (1) and (2) switch OFF. normal? * Disconnect l27 l
-
Is resistance between I_27 (female) (8) and (9) nom-rat? * Min. 1 MQ NC * Turn starting switch OFF. * Disconnect L27 and HRll.
Defective work equipment controller
Replace
Short circuit in wiring harness between L27 (female) (8) - HRll (female)
(1) and between L27 (female) (9) - HRl 1 (female1(2) Short circuit with chassis ground in wiring harness between L27 (female) (8) -
HRll (female) (11, or between L27 (female) f91HRl 1 (female) (2) Defectivecontact or disconnectionin wiring harnessbetween LZ7 (female) (8) - HRll (female) (1). or between L27 (female) (91HRl 1 (female) (2)
NO
l
and HRll. * At boom lever neutral: Max. 1 52 NO . Other than neutral: Min. 1 MR Turn starting switch OFF. . Disconnect HRll
Repair or replace
Defective boom lever detent switch
Repair or replace
Repair or replace
Replace
l
W-13 Related electrical circuit diagram
Work uipment Intro1 ler
L27 (04020)
3 (HD-76086) JL21
(DTt)
Boom I ever detent switch
(DTIE)
JR13 (DTlB)
JLll
(DTl)
,,
LR~ (~~11
I
RAlO
(DTHD4)
Battery
A7 TJW02503
WA1 200-3
20-667 0
TROUBLESHOOTING
W-14 * *
w-14
Short circuit in boom RAISE, LOWER pressure detection
switch
Before carving out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
cause
4YE c
is resistance L27 (female) (5). (61, and (9) normal?
Is resistance YES_ between ~27 3 (female) (6) and (9) normal?
n j between
Yl
i/OE,,i
* Min. 1 MR Turn starting switch OFF. Disconnect K7, HR12, and HR13. l
1
l
between HFi12 (male) 11) and HR73 (male) (1) -chassis Min. 1 M~z *Turn starting switch OFF. * Disconnect HR12 and HR13. l
W-14 Work cant
Min. 1 MR Turn starting switch OFF. * Disconnect U7, HR12, and HR13. l
l
;0
NO
Defective work equipment controller Short circuit in wiring harness between L27 (female) (6) - LRl 1 (2) - F22 (female) (1) and between L2i (female) (9) - LRll (6) - F22 (female) (2) Short circuitin wiring harness betweenL27 (female)(6) HR13(female)(1) and betweer l27 (female)(6) - HR12 (female)(l), or between l27 (female)(5) and HR13(female) (11,HR12 (female)(1) Shortdr& withchassisgrow, in wiringharnessbetweenL27 (female)(5) - HRl3 (female)(1) or betwell L27wemale)(6)HRl2 (female)(1). or between I27 Ifemale (9)- HR13(female) (2). HR12(female)12) Defective boom RAISE switch or boom LOWER switch
NO
Related
* Min. 1 MQ NC * Turn starting switch OFF. - Disconnect L27 and HRl
Remedy
electrical
Replace
Repair or replace
Repair or replace
Repair or replace
Replace
circuit diagram
esuipment
Dressure
switch
Dressure
switch
TJW02498
20-668
WA1 200-3
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) Trouble data display ,.................................,................
,.................. ........ .... ... ............i .................. ......... . 20-703
Electrical circuit diagram of main monitor system .......... .......... ................... ....... ...... .......... .............. 20-704 20-706 M- 1 Main monitor does not work ..................................................................................................... M- 2 When starting switch is turned ON (within 3 seconds) and engine is started all lamps stay lighted up ................................................................
20-707
display does not work properly ......................................................................... in shift indicator ....................................................................................................
20-708
(PRE-LUBE) immediately, M- 3 Speedometer
M- 4 Abnormality a) Displays N even when directional lever is at F ................................................................. b) Displays N even when directional lever is at R. ................................................................ c) Does not display N even when FNR (Forward-reverse) switch is set in N ...................
20-709 20-709 20-709 20-710
d) Does not display F even when FNR (Forward-reverse) switch is set in F.. ................... 20-710 e) Does not display R even when FNR (Forward-reverse) switch is set in R .................... 20-710 20-712 M- 5 Turn signal display does not light up ....................................................................................... .20-7X? a) L.H. turn signal display does not light up.. ....................................................................... 20-712
b) R.H. turn signal display does’not light up ......................................................................... M- 6 Abnormality in parking display .................................................................................................. a) Parking lamp display does not light up ............................................................................
20-713 .20-713
-20-713 Parking lamp display stays lighted up .............................................................................. 20-714 M- 7 Night lighting does not light up ................................................................................................ 20-715 M- 8 Abnormality in front working lamp. .......................................................................................... a) Neither monitor display nor front working lamp light up.. ............................................. .20-715 b) Working lamp lights up but monitor display does not light up.. ................................... .20-715 b)
c) Monitor display lights up but front working lamp does not light up ............................ M- 9 Abnormality in rear working lamp ............................................................................................ a) Neither monitor display nor rear working lamp light up.. .............................................. b) Rear working lamp lights up but monitor display does not light up ............................
20-715 20-717 .20-717
20-717 Monitor display lights up but working lamp does not light up ..................................... .20-717 20-719 M-10 Abnormality in transmission cut-off.. ........................................................................................ c)
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change . ... ................ .. .. .......... ...... .. .............. .............. . 20-719 b)
When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off function is actuated when pedal is depressed .. .. ............ ....._...... 20-719
c)
When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated ... ....... ...... .. ................ ... ..................... ........................... 20-719
d)
Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF) .... .. ... .. ................. ............ ...... .............................. 20-719
Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated .... ............. ...........**..*.................***............................... 20-720 M-l 1 Abnormality in emergency steering normal display ............................................................... 20-721 Emergency steering normal display does not light up ........................................................... 20-721 e)
20-722
a)
in emergency steering actuation display ........................................................... Emergency steering actuation display does not light up .................................................
b)
Emergency steering actuation display stays lighted up ..................................................
.20-722
M-12 Abnormality
WA1 200-3
20-722
20-701 0
M-13 Abnormality a)
in parking brake dragging warning .....................................................................
When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even when directional lever is at N ...........................................
20-723 20-723
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 .................. 20-723 M-14 Abnormality in parking brake dragging warning (When joystick steering mode). ............. 20-725 a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even when directional lever is at N ...........................................
20-725
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 .................. 20-725 M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously, or they are not actuated .............................................................. a) Actuated continuously .......................................................................................................... Not actuated .......................................................................................................................... M-16 Abnormality in buzzer.. ............................................................................................................... b)
a)
20-727 20-727 20-727 20-728
Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) .................................................................................................................
20-728
20-728 b) Buzzer always sounds .......................................................................................................... Condition of monitor switches is not stored in memory.. ..................................................... -20-730 M-18 Service meter does not advance or advances while engine is stopped .............................. 20-731 20-731 a) Service meter does not advance.. ....................................................................................... .20-731 b) Service meter advances while engine is stopped ............................................................ 20-732 M-19 Buzzer is not made to sound by transmission controller ....................................................... M-17
in auto-greasing system ....................................................................................... Forced greasing cannot be carried out .............................................................................. Monitor display flashes rapidly (2 times/set) .................................................................... Monitor display flashes slowly (1 time/r&. ......................................................................
M-20 Abnormality a) b) M-21
c) Failure code is not sent to main monitor (abnormality in network) .....................................
20-702 0
20-733 20-733 20-733 20-733 20-735
WA1 200-3
TROUBLE
TROUBLESHOOTING
DATA DISPLAY
TROUBLE DATA DISPLAY 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 dis-
7
ExamPle:When
I f
code
action
SPEED
CALL
is
\
play-
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. For failure that have occurred and been reset, the failure code and the time elapsed since failure are displayed to make it easy to check failures that are not occurring at present. The failure codes for failures that are now occurring flash, and the codes for failures that are not occurring light up. For details of the method of operating and transferring data to the trouble data display mode, see STRUCTURE AND FUNCTION for the main monitor. Note: If the engine is not stopped, it is impossible to switch to the trouble data display mode, so the codes for failures which can only be detected when the engine is operating light up. 4.
TDW01377
I
code failure ExamDle:When before 27 hours occurred Failure
I /
‘41’has code
/ SPEED
/\
TOW01378
Failure codes list See “Introduction”
WA1 200-3
of Troubleshooting.
20-703 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM SYSTEM
20-704 0
FOR MAIN
FOR MAIN MONITOR SYSTEM
MONITOR
WA1 200-3
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
TROUBLESHOOTING
l-l-%
-~~-~~-~~-_~-~~-_________= z z z 0
WA1 200-3
I
TROUBLESHOOTING
M-l Ir *
M-l
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.
YES 1 Is voltage between LO5 ll), (2) - (3) normal? *20-30V * Turn starting switch ON.
-
. -
NO
2 Is resisance between LO5 (female) (31 and chassis ground
Related
-
electrical
Replace
Defective contact or disconnection in wiring harness between LO5 (female) (1). (2) and FS2 (female) (9)
Repair or replace
Defective contact or disconnection in wiring harness between LO5 (female) (3) - JL5 (2). (8) and LR7 (male) (4)
normal7 -Turn starting switch OFF. * Disconnect L05. * Max. 1 R
M-l
YES
Defective main monitor
NO
Repair or replace
circuit diagram
Bat terv relay
Bat tery~Battery/A~
/I
TJW02506
20-706 0
WA1 200-3
M-2
TROUBLESHOOTING
M-2
* *
When starting switch is turned ON (within 3 seconds) and engine is started (PRE-LUBE) immediately, all lamps stay lighted up
1
Related
I
YES I
If L114 is replaced, do lamps operate normally? * Turn starting L switch OFF. NO * Replace Ll14 with normal relay of same type. * Turn starting switch ON.
M-2
1
check that all the reBefore carrying out troubleshooting, inserted. ,lated connectors are properly connectors before going Always connect any disconnected on to the next step.
2YEs engine is tined, is voltage between LO5 14) and chassisground normal?
When
.20-30V Start engine.
NO
l
re I ay WA1 200-3
PRE-LUBE
hold
Replace
Defective main monitor
Replace
Disconnection or defective contact in wiring harness between LO5 (female) (4) - JL15 (4). (3) - SJ2 (female) (3) - L57 (female) (1)
Repair or replace
circuit diagram
electrical
fl
;;;;;;;g
Defective PRE-LUBE HOLD relay (L114)
relay
Neutral relay
ml
Starting
switch
PRE-LUBE indicator (orange)
-1 1
1
swIt,ch
a Rear
ENG
frame TJW02507
20-707 0
M-3
TROUBLESHOOTING
M-3 * * * *
Speedometer
display does not work properly
When error code is not displayed. 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
1 YES Is resistance between LO7 (female) (1) - (2) normal?
NO
.500-lktl -Turn starting switch OFF. * Disconnect L07.
M-3
Remedy
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO7 (female) (1). (2) -115 (female)(11, (2)
Repair or replace
Related electrical circuit diagram
ewiment
Work controller
Modulated
128 hl4016)
clutch
Transmission
Main
I
monitor
TXW02453
20-708 0
WA1 200-3
TROUBLESHOOTING
M-4
Abnormality
M-4
in shift indicator
+ Ir * Ir +
Check that error code is not displayed. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. Check that the transmission shifts. The steering system must be in the steering wheel mode.
a)
Displays
N even when
directional
inserted.
lever is at F Cause
1 YES
Defective main monitor
Is voltage between LO8 (7) and chassis ground normal?
Defective contact or disconnection in wiring harness between LO8 (female) (7) and JSl (female) (2)
NO -2O-30V * Turn starting switch ON. * Directional lever: F
bl
Displays
N even when
directional
Repair or replace
lever is at R Cause
Remedy
I
1 YES Is voltage between LO8 63) and chassis ground normal? NO *20-30V Turn starting switch ON. * Directional lever: R l
WA1 200-3
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO8 (female) (8) and JSl (female) (4)
Repair or replace
20-709 0
TROUBLESHOOTING
c)
Does not display
M-4
N even when
FNR (Forward-Reverse)
switch
is set in N.
1 YES
Defective main monitor
Is voltage between LO8 (7) or (8) and chassis ground normal?
Short circuit with power source in wiring harness between LO8 (female) (7) and JSl (female) (2) or harness between LO8 [female) (8) and JSl (female) (4)
NO - Max. 1 V * Turn starting switch ON. * Set FNR (ForwardReverse) switch in N.
d)
Does not display
F even when
FNR (Forward-Reverse)
switch
Repair or replace
is set in F.
Cause
Remedy
f
r
1
YES
Defective main monitor
Is voltage betvveen LO8 (female) (7) and chassis ground normal?
Defective contact or disconnection in wiring harness between LO8 (female) (7) - JL16 (4). (3) and JSl (female) (2)
NO *20-30V * Turn starting switch ON. . Set FNR (FotwardReverse) switch in F.
e)
Does not display
1 Is voltagebetween LO8 (female) (8) and chassis ground normal?
Replace
I
R even when
FNR (Forward-Reverse)
switch
Repair or replace
is set in R.
Defective main monitor
Replace
Repair or
*20-30V Turn starting switch ON. * Set FNR (ForwarcfReverse) switch in R. l
20-710 0
WA1 200-3
1
M-4
TROUBLESHOOTING
M-4
Related electrical circuit diagram Transmissi controller
JLl8 (DT2l
Dn
on
d-l
JL16 (DT2)
h
i
WA1 200-3
TJWO2508
20-711 0
M-5
TROUBLESHOOTING
M-5
Turn signal display does not light up
* * *
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. check that the lamp bulb of the turn signal indicator on the Before starting troubleshooting, blown. monitor is not T
al
L.H. turn signal display
does not light up
1 YES Is voltage between LO6 (14) and chassis 1ground normal? NO * Repeats 0 V and 20-30V. * Turn starting switch ON. -Turn L.H. turn signal ON.
Cause
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO6 (female) (14) and L144 (male) (1)
Repair or replace
Cause b1 R.H. turn signal display
1 YES
NO -RepeatsOVand 20-30v. *Turn starting switch ON. * Turn R.H. turn signal ON.
Related
electrical
circuit
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO6 (female) (15) and L142 (male) (1)
Repair or replace
diagram R. H. turn signal I amp(25W) -
F20
20-712 0
Remedy
does not light up
Is voltage between LO6 (15) and chassis ground normal?
M-5
Remedy
L. H. turn signal
I amp (25W)
TJW02509
WA1 ZOO-3
M-6
TROUBLESHOOTING
M-6
in parking display
Abnormality
* *
Before carwing out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
al
Parking
lamp display
does not light up
Cause
3 YES
Defective main monitor
Is resistance YES .B
r
1gyfrl9rc”hc
L.
Is voltage between LO6 (11) and chassis 1 ground normal? _ P Is resistance -2O-30V between T18 - * Turn starting (male) (1) and (2) switch ON. normal? * Turn parking switch ON. * Max. 1 R NO * Disconnect T18. *Turn starting switch ON. * Turn parking switch ON.
- Max.
1R * Turn starting switch OFF. - Disconnect Tl8.
YES
b)
Parking
(male) (1) and (2) - Min. 1 MD * Disconnect T18. * Turn starting switch ON. * Turn parking switch OFF.
Related
NO
Defectivecontact or disconnectionin wiring harness between LO6 (fernale)(FR2ill)-RT2 (N) and T18 (female) (1)
Defective parking brake indicator switch
2
I-
Defective contact or disconnection in wiring harness between T18 (female) (2) - JMl (21, (7) and chassis ground
-
11
NO
lamp display stays lighted
Is voltage YE ; between T18 (1) and chassis 1 1ground normal?
M-6
between T18 (female) (2) and
Cause
up
YES
11 I
,
NO *o-2v -Turn starting switch ON. * Turn parking switch OFF.
electrical
Replace
Repair or replace
Repair or replace
Replace
Remedy
Defective main monitor
Replace
Short circuit with power source in harness between LO6 (female) Ill)-FR2(11)-RT2(N) T18 (female) (1)
Repair or replace
Defective parking brake indicator switch
Replace
circuit diagram
Ma i n Parking brake indicator
RT2 (HO-85086)
Tl
WA1 200-3
TJW02510
20-713 0
TROUBLESHOOTING
M-7 * * * *
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 LO5 (female) (16).
1 YES I Is valtaae between LO5 (16) and chassis ground normal? *20-3ov * Turn starting switch ON. * Turn small lamp switch ON.
M-7
Related
Defective main monitor Defective contact or disconnection in wiring harness between LO5 (female) (16) and FSZ (female) (5)
I
NO
electrical
Repair or replace
circuit diagram
Main
monitor
LO5 (04020) 0.5fY
Small lamp relay
1 25fP :___
IIIIIII
LR1 (HD-QKnRfi, k
n i
/, 1
I”0
04 I 25fP .,A.', lL,D
nCIs,
asp
m
R.H. clearance
JHDIDTI)
rance
(5W)
G14 TJW02511
20-714 0
WA1 ZOO-3
M-8
TROUBLESHOOTING
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.
al
Neither monitor display nor front working lamp light up Cause
YES
YES between L60 (1)
1
Max. 1 V -Turn starting switch ON.
YE S
l
2
NO 4
.20-30V * Turn starting switch ON.
b)
Defective contact or disconnsction in wiring harness between L60 (female) (1) - LO5 (female) 117). L75 (female) (5). CL6 (female) (1)
Repair or replace
Defective front working lamp relay
Replace
Defective main monitor
Replace
between L66 (6)
1 l
Is voltage between L60 f2), (4), (5) and chassis ground normal?
Remedy
between LO6 (1)
Max. 1 V
switch ON.
Defective contact or disconnection in wiring harness between LO6 (female) (1) and L60 (female) (6)
I
l20-30V * Turn starting switch ON.
Defective contact or disconnection in wiring harness between L60 (female) (21, (4), (5) and FS5 (female) (1)
N
Working lamp lights up but monitor display does not light up
Repair or replace
Repair or replace
_
3
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO5 (female) (17) and L60 (female) (1)
Repair or replace
Is voltage between LO5 (17) and chassis ground normal? *20-30V + Turn starting switch ON.
c)
NO
Monitor display lights up but front working lamp does not light up
I
WA1 200-3
20-715 0
M-8
TROUBLESHOOTING
M-8
Related Ma i n In onito
r
electrical
r
diagram
circuit
eht I amp
Fuse (II,
3
eft
amp
j FL1 (HD-26066)
I.25fBr
I
I. 25fY I I
a FZO
D
!34
t
L60
Front working lam0 relay
20-716 0
L61
Rear working I amp relay
5
Front working lamp relay
lamp (R. H. 1
I amp
ine
(L. H. )
--
Working I amp
TJW02512
WA1 200-3
M-9
TROUBLESHOOTING
M-9
Abnormality
in rear working lamp
* * *
Before carrying out troubleshooting, check that all the related connectors are properly 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
I
CaUSe
Remedy
Defective contact or disconnection in wiring harness between L61 (female) (1) - LO5 (female) (18). LRI (female) (13) YES
)
Is voltage between L61 (6) and chassis ground normal?
YES *20-30V *Turn starting switch ON.
2
,
* Max. 1 V Turn starting switch ON.
l
l20-30V * Turn starting switch ON.
4YES -
Rear working
Replace
Defective contact or disconnection in wiring harness between LO6 (female) (2) and L61 (female) (6)
NO
Repair or replace
Defective contact or disconnection in wiring harness between L61 (female) (2). (41, (5) and FS5 (female) (2)
NO
b)
Replace
Defective main monitor
between LO6 (2) NO and chassis ground normal? *Max.lV -Turn starting switch ON.
t
I
- Is voltage
Repair or replace
I Defective rear working lamp relay
3 between L61 (I
Repair or replace
lamp lights up but monitor display does not light up Remedy
CaUSe
I YES Is voltage between LO5 (18) and chassis ground normal? .20-30v - Turn starting switch ON.
cl
NO
Monitor display lights up but rear working lamp does not light up
I .
WA1 200-3
inserted.
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO5 (female) (18) and L61 (female) (1)
Repair or replace
Glse Defective contact or disconnection in wiring harness between L61 (female) (1) - GO3 (female) (1). GO7 (female) ULor L61 (female) (3) - GO2 (female) (1). GO8 (female) Cl), or blown working lamp bulb
I
Remedy
Repair or
20-717 0
TROUBLESHOOTING
M-9
M-9
Related electrical circuit diagram Main
monito r
aht iamp
Fuse (II)
7 L
J
I-88-b
eft lamp
LRI MD-95086)
FLItHO-26066)
Im
lr ” Y 0
a
c
i 34
0
i L60
Front *
worixlna lamp relay
20-718 0
L61
Rear
worklna lamp relay
L75
Front
:
worklna IamP relay
Worki ne It lamp (R. H. )
lamp
(L. H. )
k
lamp
TJWO2512
WA1 200-3
M-10
TROUBLESHOOTING
M-l 0 Abnormality
in transmission
cut-off
* *
check that all the related connectors are properly Before carrying out troubleshooting, 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
Defective main monitor
bl
disconnection in wiring harness between L66 (female) (3) - C3A (female) (10) and M02A (female) (11)
Replace
Defective main monitor
Repair or replace
Replace
NO
*MaxlV * Turn starting switch ON. * Disconnect L12.
When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated
2
YES
(female) (‘2)and
switch OFF.* Disconnect L12.
*Max.152 * Turn starting switch OFF. + Disconnect L12.
dl
Remedy
cut-off switch) is OFF, When monitor switch (transmission monitor display goes out but cut-off function is actuated when pedal is depressed
between LO6 (3) and chassis ground normal?
cl
inserted.
NO
CaUSt2
Defective contact or disconnection in wiring harness between L12 (female) (1) and C3A (female) (10)
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
Defective transmission controller
Replace
Cut-off function is always actuated regardless of monitor cut-off switch ON or OFF) display (transmission
1 YES Is voltage between C3A (10) and chassis ground normal? WMaxlV
WA1 200-3
NO
Defective contact or disconnection in wiring harness between C3A (female) (10) and LO6 (female) (3). L12 (female) (1)
Repair or replace
20-719 0
TROUBLESHOOTING
e)
Monitor display ON), but cut-off
M-10
lights up (transmission cut-off switch function is not actuated
turned
Cause
Remedy
Defective transmission cut-off switch
function work
YES
I
r) ‘
disconnected? * Disconnect L12. -Turn starting switch ON.
1Does
cut-off
Replace
Defective main monitor
II
N
Defective transmission controller
Replace
Short circuit with chassis ground in harness - Disconnect L12. . Turn starting switch ON. *20-30V
M-10
Related Madulated controloer
Transmission
controller
electrical
between LO6 (female) (3) - M02A (female) (1 l), C3A (female) (10) and L12 (female) (1)
NO
Repair or
circuit diagram Main monitor
clutch H02A (040201
LO6 (040
16)
I
Transmission cut-off switch (OPEN at left brake
dePressed)
TJW02513
20-720 0
WA1 200-3
M-l 1
TROUBLESHOOTING
M-II * *
in emergency steering
Abnormality
normal display
check that all the related connectors are properly Before carrying out troubleshooting, before going on to the next step. connectors Always connect any disconnected
Emergency
steering
normal
display
inserted.
does not light up
* 1 YES Is voltage between LO5 (10) and chassis ground normal? *20-30V - Turn starting switch ON.
NO
M-l 1 Related
electrical
circuit
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO5 (female) (10) -chassis
Repair or replace
diagram
Main LR2 (HD-85086)
TJW02514
WA1 200-3
20-721 0
M-12
TROUBLESHOOTING
M-12
Abnormality
in emergency
steering
actuation
display
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always co&e6t any disconnected connectors before going on to the next step.
al
Emergency steering actuation display does not light up I-
2
YES
Short circuit with chassis ground in harness between Lo5 (female) (11) and Rll (female) (1)
* Min. 1 MS2 NO -Turn starting switch OFF. * Disconnect LO5 and R12.
Repair or replace
Defective emergency steering indicator switch
I
* Min. 1 MD starting switch ON. Disconnect Rll, R12.
* Turn
Remedy
Defective main monitor
Is resistance YES between LO5 , r Wemale)(11) and
(male) (1) and Rll
Cause
NO
l
b1 Emergency steering actuation display stays lighted up
2 YES
Defective main monitor
Is voltage YES between LO5 (11) _ 1 r and chassis
I l
(male) (2) normal? I.
-Max.lR - Start engine. - Disconnect Rll, R12.
M-12
1
Turn starting switch ON.
NO
Defective contact or disconnection in wiring harness between LO5 (female) (11) and chassis ground
Repair or replace
Defective emergency steering indicator switch
Replace
Related electrical circuit diagram
Main
l-h? R20
20-722 0
TJW02514
WA1 200-3
TROUBLESHOOTING
M-13 * *
Abnormality
M-13
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.
al When parking brake is applied, buzzer sounds (intermittently)
and CAUTION lamp flashes even
when directional lever is at N
F Is voltage between LO5 (female) (8) and chassis ground normal? NO *20-30V * Turn starting switch ON. * Directional lever: N
Cause
I
Remedy
Defective main monitor
Replace
Defective contact or disconnection in wiring harness between LO5 (female) (8) - JSl (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 Ir
Check that the synchronous flash is normal. CaUSe
YES Is voltage between LO5 (female) (8)
2
YES
II
switch ON. * Directional lever: Other than N
WA1 200-3
I *3kQ-4k,s2 . Turn starting switch OFF. * Disconnect LO5
Remedy
Defective main monitor
Replace
Short circuit with power supply in wiring harness between LO5 (female) (8) - JSl (female) (3). or defective directional lever
Repair or replace
Defective main monitor
Replace
NO
20-723 0
TROUBLESHOOTING
M-13
M-13
Related electrical circuit diagram
Transmission controller
JSl LsWP12)
Joust ick lever switch
TJW02515
20-724 0
WA1 200-3
M-14
TROUBLESHOOTING
M-14
Abnormality in parking brake dragging warning steering mode)
(When joystick
* *
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.
a1
When parking brake is applied, when directional lever is at N
buzzer
sounds (intermittently)
and CAUTION
lamp flashes even
: 1 YES
See troubleshooting of transmission controller system CTmode)
Is S-NET has any trouble? Defective main monitor *20-30V *Turn starting switch ON. *Joystick lever switch: N
bl
NO
When parking brake is applied, buzzer does not sound and CAUTION when directional lever is at position other than N *
Repair or replace
lamp does not light up even
Check that the synchronous flash is normal.
Remedy
1 YES
See troubleshooting of transmission controller system CT mode)
Repair or replace
Defective main monitor
Replace
Is S-NET has any trouble? * Max. 1 V *Turn starting switch ON. * Joystick lever switch: F or R
WA1 200-3
NO
20-725 0
TROUBLESHOOTING
M-14
M-14 Related electrical circuit diagram
VHMS controller
Work esuipment controller
a a
.
JLI
Modulated clutch controller
_I
Transm ission contra I ler
Main monitor
Jovst lever
ck switch
I
5 (IIT
I 1:
TJW02516
20-726 0
WA1 200-3
M-15
TROUBLESHOOTING
M-15 f
When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously, or they are not actuated
-k
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
YES 1 Does buzzer stop and lamp go out? *Turn starting switch ON. * Connect LO7 (male) (6) to chassis ground.
b)
NO
Does buzzer stop and lamp go out? *Turn starting switch ON. - Connect Vl (female) (13) to chassis ground.
NO
Remedy
Defective main monitor
Replace
Defective VHMS controller
Replace
Defective contact or disconnection in wiring harness between LO7 (female) (6) and Vl (female) (13)
Repair or replace
Not actuated
Cause
- IIefective
-Turn starting switch ON. * Disconnect Vl
NO
Remedy
main monitor
Replace
Defective VHMS controller
Replace
Short circuit with power source in harness between LO7 (female) (6) and Vl (female) (13)
Repair or replace
:
M-15
Related
Main
electrical
circuit diagram VHMS
TJW02517
WA1 200-3
20-727 0
M-16
TROUBLESHOOTING
M-16
Abnormal’rty
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
Does buzzer sound? * Turn starting switch ON. * Contact L43 (female) to chassis ground.
2 YES Is voltage between L42 (female) (1) and chassis ground nonnat?
NO
*20-30V Turn starting switch ON.
NO
l
Remedy
Defective contact or disconnection in wiring harness between LO6 (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
b1 Buzzer always sounds CaUSe
YES
Remedy
Defective main monitor
1 If LO6 is
II
3 * Turn starting switch OFF. * Disconnect L99.
If L89 is
Replace
Defective emergency parking brake reset switch
Replace
I Defective buzzer
’
. Min. 1 MR. * Turn starting switch OFF. * Disconnect L06, L89, L99, and . L43.
20-728 0
Defective caution buzzer relay
NI
Short circuit with chassis ground in wiring harness between L43 (male) (1) LO6 (female) (8) - I_89 (female) (3) - L99 (female) (female) (3)
Repair or replace
WA1 200-3
M-16
TROUBLESHOOTING
M-16
Related
electrical
circuit diagram Emergency Darkins brake cancel switch
Main
monitor
LO6
(04016)
Buzzer OUTPUT 124A
8
0.5fL
VHMS
I-#7
WA1 200-3
TJW02518
20-729 0
M-17
TROUBLESHOOTING
M-17 Condition * *
Before carrying Always connect
switches is not stored in memory
of monitor
inserted.
check that all the related connectors are properly out troubleshooting, connectors before going on to the next step. any.disconnected
cause
1 YES
Remedy
Defective main monitor
Replace
Defective contact or disconnection in wiring harnessbetweenL07 (female) (10) and LO9 (female) (2)
Repair or replace
Is voltage between LO7 (10) and chassis ground normal? NO
*20-30V * T&n starting switch ON.
M-17
Related electrical circuit diagram Battery
Main
monitor
relay
LO7 (04012)
Starting
switch 66AC 10
0.5fY
-
R03 (DT2)
JR3 (DTl)
Start
20-730 0
ina
switch
R20
TJW02519
WA1 200-3
TROUBLESHOOTING
M-18 *
M-18
Service meter does not advance or advances while engine is stopped
*
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
a)
Service
meter
does not advance
1 YES Is voltage between LO5 (5) and chassis ground normal? NO
*20-30V * Start engine.
b1
Service
meter
advances
while
engine
1 YES
Related
Alternator
Defective contact or disconnection in wiring harness between LO5 (female) (5) -alternator terminal L, or defective alternator
Repair or replace
Cause
Short circuit with power source in wiring harness between LO5 (female) (5) -alternator terminal L, or defective alternator
NO
electrical
Replace
Defective main monitor
Is voltage between LO5 (5) and chassis ground normal?
M-18
Defective main monitor
is stopped
I
*o-5v * Turn starting switch ON.
inserted.
I
Remedy
Replace
Repair or replace
circuit diagram
psg~
TJW02520
WA1 200-3
20-73 1
M-20
TROUBLESHOOTING
Abnormality
M-20
in auto-greasing
system
* *
check that all the related connectors are properly Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step.
a)
Forced greasing cannot be carried out
2 1
NO * Turn starting switch ON. *Turn auto-greasing switch ON.
Defective main monitor
Remedy
-
Repair or replace
Replace
NO
l
b1 Monitor
Defective contact or disconnection in wiring harness between LO6 (female) (5) and GREl (female) (1)
. Max. 3 V
_
*Max.3V Turn starting switch ON. * Turn auto-greasing switch ON.
See “Handling autcgreasing system” in Operation and Maintenance Manual
YES
mvoitage_ between GREl (1) and chassis ground normal?
YES Is voltage between LO6 (5) and chassis ground normal?
Cause
inserted.
display flashes rapidly (2 times/set)
A YES
Defective main monitor
1 Is voltage between LO8 (5) and chassis ground normal?
l20-3ov -Turn starting switch ON.
2 YES _
between GREl NO
(2)and chassis ground normal? .20-3ov * Turn starting switch ON.
c1
’
Is voltage -
Defective contact or disconnection in wiring harness between LO8 (female) (5) and GREl (female) (2) See “Handling autogreasing system” in Operation and Maintenance Manual
NO
Monitor
display flashes slowly (1 time/set)
Confirm
that
Cause
Repair or replace
-
Remedy
grease is not empty. See “Handling autogreasing system” in Operation and Maintenance Manual
Table
Replace
1 (Relationship
between
-
input signal and display)
)
WA1 200-3
20-733 0
TROUBLESHOOTING
M-20
Related
electrical
M-20
circuit diagram
Main m
TJW025.22
20-734 0
WA1 200-3
M-21
TROUBLESHOOTING
M-21 * Ir *
Failure code is not sent to main monitor network)
(abnormality
in
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. Set dipswitch 3 at the rear of the main monitor to “F”. Cause
M-21
Related
electrical
Remedy
circuit diagram
1 VHMS
lort
wi PIE
coatrillle /
Transmission ontrol
ler
TWW02601
WA1 200-3
20-735 0
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (V MODE)
Operations of VHMS controller against abnormality and conditions of machine caused by abnormality .................................................................................................... 20-804 List of alarm items displayed on CGC monitor .................................................................................. 20-820 Electrical circuit diagram for VHMS system ....................................................................................... 20-822 V- 1
[E901] (Engine oil level below LOW level) is displayed ........................................................ 20-824
V- 2
[E902] (Engine oil pressure below specified pressure) is displayed ...................................20-824
V- 4
[E904] (Engine coolant temperature above specified temperature) is displayed .............. 20-824
V- 5
[E905] [Fuel level below specified level (before engine starts)] is displayed .................... 20-825
V- 6
[E906] [Fuel level below specified level (While engine is running)] is displayed ............. 20-827
V- 7
[E907] (Torque converter oil temperature above 120°C) is displayed .................................20-829
V- 8
[E908] (Torque converter oil temperature above 130°C) is displayed .................................20-830
V- 9
[E911] (Hydraulic oil temperature above 105°C) is displayed .............................................. 20-831
V-10
[E912] (Low front or rear brake oil pressure) is displayed ................................................... 20-832
V-11
[E913] (Low front brake oil pressure) is displayed ................................................................ 20-834
V-12
[E915] (Low rear brake oil pressure) is displayed ................................................................. 20-836
V-13
[916] (Disconnection or short circuit with chassis ground in battery fluid level sensor “1”) is displayed ............................................................................ 20-838
V-14
[917] (Disconnection or short circuit with chassis ground in battery fluid level sensor “2”) is displayed ............................................................................ 20-839
V-15
[918] (Disconnection or short circuit with chassis ground in battery fluid level sensor “3”) is displayed ............................................................................ 20-840
V-16
[E925] [Brake fluid level below specified level (before engine starts)] is displayed ......... 20-841
V-17
[E926] [Brake fluid level below specified level (While engine is running)] is displayed .. 20-842
V-18
[E927] [Coolant level below LOW level (before engine starts] is displayed ...................... 20-843
V-19
[E928] [Coolant level below LOW level (While engine is running)] is displayed .............. 20-844
V-20
[E931] (Clogging of transmission oil filter) is displayed ....................................................... 20-845
V-21
[E932] [Clogging of air cleaner (1)] is displayed .................................................................... 20-847
V-22
[E933] [Clogging of air cleaner (2)] is displayed .................................................................... 20-849
V-23
[E934] [Clogging of air cleaner (3)] is displayed .................................................................... 20-850
V-24
[E935] [Clogging of air cleaner (4)] is displayed .................................................................... 20-851
V-25
[E937] (Abnormal charge by alternator) is displayed ............................................................ 20-852
V-101 [E811] (Abnormality in NSW power source system) is displayed in history..................... 20-853 V-102 [E812] (Short circuit with chassis ground in 24-V circuit of sensor power supply) .......... 20-854 V-103 [E813] (Short circuit with chassis ground in 12-V circuit of sensor power supply) .......... 20-856 V-104 [E814] (Short circuit with chassis ground in 5-V circuit of sensor power supply) ............ 20-857 V-105 [E818] (Wrong connection of connector) is displayed in history ......................................... 20-858
WA1200-3
20-801 (8) 2
V-107 [E824] (Communication with CGC and engine controller is impossible) is displayed in history .............................................................................................................. 20-859 V-108 [E825] (Abnormality in S-NET communication between VHMS – transmission controller) is displayed in history ............................................................................................ 20-860 V-109 [E826] (Abnormality in S-NET communication between VHMS – modulated clutch controller) is displayed in history ................................................................................ 20-862 V-110 [E827] (Abnormality in S-NET communication between VHMS – work equipment controller) is displayed in history ........................................................................ 20-864 V-111 [E828] (Abnormality in S-NET communication between VHMS – main monitor) is displayed in history .............................................................................................................. 20-866 V-113 [E841] (Short circuit with power source in buzzer output system) is displayed in history .............................................................................................................. 20-869 V-114 [E843] (Short circuit with power source in check lamp system) is displayed in history .............................................................................................................. 20-870 V-115 [E844] (Short circuit with power source in flash synchronizing signal system) is displayed in history .............................................................................................................. 20-871 V-116 [E861] (Disconnection or short circuit with chassis ground in boom bottom pressure sensor system) is displayed in history ........................................... 20-872 V-117 [E862] (Disconnection or short circuit with chassis ground in boom head pressure sensor system) is displayed in history............................................... 20-874 V-118 [E863] (Disconnection or short circuit with chassis ground in rear brake oil pressure sensor system) is displayed in history ........................................... 20-876 V-119 [E864] (Disconnection or short circuit with chassis ground in work equipment relief pressure sensor system) is displayed in history ........................... 20-878 V-120 [E865] (Disconnection or short circuit with chassis ground in front brake oil pressure sensor system) is displayed in history .......................................... 20-880 V-121 [E866] (Disconnection or short circuit with chassis ground in transmission main relief pressure sensor system) is displayed in history ........................ 20-882 V-122 [E867] (Disconnection or short circuit with chassis ground in steering relief pressure sensor system) is displayed in history ........................................... 20-884 V-123 [E868] (Disconnection or short circuit with chassis ground in torque converter outlet oil pressure sensor system) is displayed in history .................... 20-886 V-124 [E871] (Disconnection or short circuit with chassis ground in transmission modulation pressure sensor system) is displayed in history....................... 20-888 V-125 [E872] (Disconnection or short circuit with chassis ground in transmission lubricating oil pressure sensor system) is displayed in history .................. 20-890 V-126 [E874] (Short circuit with chassis ground in torque converter oil temperature sensor system) is displayed in history ................................................................................... 20-892 V-127 [E875] (Short circuit with chassis ground and with power source in hydraulic oil temperature sensor system) is displayed in history ........................................................ 20-893 V-128 [E875] (Short circuit with chassis ground in ambient temperature sensor system) is displayed in history ................................................................................... 20-894
20-802 (8) 2
WA1200-3
v-129
IE8781 (Disconnection
or short circuit with chassis ground in
PPC relief pressure sensor system) is displayed in history ................................................ v-130
IE8841 (Disconnection
.20-896
or short circuit with chassis ground
in torque converter inlet oil pressure sensor system) is displayed in history.. ................ 20-898 v-201
Disconnection
or short circuit with power source in 24-V system
of sensor power supply ............................................................................................................ v-202
Disconnection
20-900
or short circuit with power source in 12-V system 20-902
of sensor power supply ............................................................................................................ V-203
Disconnection
or short circuit with power source in 5-V system 20-903
of sensor power supply ............................................................................................................
or short circuit with chassis ground in buzzer output system.. ................. 20-904
V-204
Disconnection
V-205
Disconnection
or short circuit with chassis ground in check lamp system.. ..................... 20-905
V-206
Disconnection
or short circuit with chassis ground in
flash synchronizing
signal system ..........................................................................................
20-906
V-207
Short circuit with power source in boom bottom pressure sensor system ...................... 20-907
V-208
Short circuit with power source in boom head pressure sensor system .......................... 20-908
v-209
Short circuit with power source in rear brake oil pressure sensor system.. ..................... 20-909
v-210
Short circuit with power source in front brake oil pressure sensor system ..................... 20-910
v-21 1 Short circuit with power source in work equipment relief pressure sensor system.. ...... 20-911 relief pressure sensor system.. ............ 20-912
v-212
Short circuit with power source in transmission
V-213
Short circuit with power source in steering relief pressure sensor system ...................... 20-913
V-214
Short circuit with power source in torque converter outlet oil pressure sensor system 20-914
V-215
Short circuit with power source in transmission
V-216
Disconnection
modulation pressure sensor system.. . 20-915
or short circuit with power source in
torque converter oil temperature sensor.. ..............................................................................
20-916
V-217
Disconnection
in hydraulic oil temperature
sensor system .................................................
20-917
V-218
Disconnection
in ambient temperature sensor system .........................................................
20-918
v-219
Short circuit with power source in PPC relief sensor system ............................................. .20-919
v-220
Short circuit with chassis ground in fuel level sensor system ............................................
v-221
Short circuit with power source in battery fluid level sensor “1” ....................................... 20-921
v-222
Short circuit with power source in battery fluid level sensor “2” ....................................... 20-922
V-223
Short circuit with power source in battery fluid level sensor “3”. ..................................... .20-923
V-224
Short circuit with chassis ground or power source in brake fluid level sensor.. ............. 20-924
V-225
Short circuit with power source in coolant level sensor ......................................................
V-226
Short circuit with chassis ground or power source in transmission
oil filter clogging sensor ...................................................................................
20-920
20-925
20-926
V-227
Short circuit with power source in air cleaner clogging (I) relay system ......................... 20-927
V-228
Short circuit with power source in air cleaner clogging (2) relay system ......................... 20-928
v-229
Short circuit with power source in air cleaner clogging (3) relay system ......................... 20-928
V-230
Short circuit with power source in air cleaner clogging (4) relay system.. ....................... 20-929
V-231
Abnormal charge by alternator ...............................................................................................
WA1 200-3
20-930
20-803 0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALrrY
TROUBLESHOOTING
OPERATIOF IS OF VHMS CONTROLLER AGAINST ABNORMALITY AND COND TIONS OF MACHINE CAUSED BY ABNORMALITY List of alarm items displayed on CGC monitor: See page 20-820. I
*
40. -
Abnormal system
Failure mode
-ailur ‘e Action code code
Contents of abnormality
1
pv$ne oil
E901
---
1) Low engine oil level 2) Abnormality related to engine controller (CENSE) * See alarm items displayed on CGC monitor
2
Engine oil pressure
E902
---
1) Low engine oil pressure 2) Abnormality related to engine controller (CENSE) + See alarm items displayed on CGC monitor
Engine coolant temperature
E903 E904
-
3
1) Engine coolant temperature above 102OC (E903) 2) Engine coolant temperature above 105X (E904) 3) Abnormality related to engine controller (CENSE) It See alarm items displayed on CGC monitor
-
4
Fuel level
-
5
Torque :onverter oil :emperature
iydraulic oil emperature
E905 E906
---
1) Low fuel level or defective fuel level sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (2) - R05 (female) (1) 3) Defective VHMS controller f See alarm items displayed on CGC monitor
Short circuit with chassis ground
---
--_
1) Defective fuel level sensor 2) Short circuit with chassis ground in wiring harness between V2A (female) (2) - R05-(female) (1) 3) Defective VHMS controller
Short circuit with power source
E905 E906
---
1) Low fuel level or defective fuel level sensor 2) Short circuit with power source in wiring harness between V2A (female) (2) - R05 (female) (1) 3) Defective VHMS controller + See alarm items displayed on CGC monitor
Disconnection
___
---
1) Defective torque converter oil temperature sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (3) - T24 (female) (1) 3) Defective VHMS controller
Sensing is impossible.
z E874
__-
1) Torque converter oil temperature above 120°C (E907) 2) Torque converter oil temperature above 130°C fE908) 3) Defective torque converter oil temoerature sensor ’ 4) Defective VHMS controller * For E907 and E908, see alarm items displayedon CGC monitor
Input voltage < 0.3 v
Short circuit with power source
_--
___
1) Defective torque converter oil temperature sensor 2) Short circuit with power source in wiring harness between V2A (female) (3) - T24 (female) (1) 3) Defective VHMS controller
Sensing is impossible.
Disconnection
_--
-__
1) Defective hydraulic oil temperature sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (11) - HS (female) (1) 3) Defective VHMS controller
Sensing is impossible.
5911 f875
_--
1) Hydraulic oil temperature above 105°C (E911) 2) Defective hydraulic oil temperature sensor 3) Short circuit with chassis ground or with pcwer scurce in wiring harness between V2A (female) (11)- HSl (female) (1) 4) Defective VHMS controller * For E911, see alarm items displayed on CGC monitor
E875
___
1) Defective hydraulic oil temperature sensor 2) Short circuit with power source in wiring harness between V2A (female) (11) - HSl (female) (1) 3) Defective VHMS controller
Sensing is impossible.
Low front brake oil pressure (E912, E913) Defective front brake oil pressure sensor Defective joint connector JR14, JL2: or JR13 Disconnection or defective contact m wiring harness between Vl (female) (2) - HR15 (female) (2) 5) Disconnection or defective contact in wiring harness between V2A (female) (7) - HR 15 (female) (3) 6) Defective VHMS controller t For E912 and E913, see alarm items displayedon CGC monitor
Input voltage c 0.5 v
Short circuit with chassis ground
Short circuit with chassis ground Short circuit with power source
-
Disconnection
7
1) 2) 3) 4)
E912 ::z
Brake oil pressure (F) Short circuit with chassis ground
-
20-804 0
___
Disconnection
-
6
--_
E3 E865
__-
1) Low front brake oil pressure (E912, E913) 2) Defective front brake oil pressure sensor 3) Short circuit with chassis ground in wiring harness between Vl (female) (2) - HR15 (female) (2) 4) Short circuit with chassis ground in wiring harness between V2A (female) (7) - HR15 (female) (3) 5) Defective VHMS controller f For E912 and E913, see alarm items displayed on CGC monitor
Sensing is impossible.
Fg<
Tltage
Input voltage < 0.5 v
WA1 200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal condition
Condition of machine caused by abnormality
Alarm buzzer
Failure history Saved: fi Other: x
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
Resistance (between R05 (1) – (2)) FULL (100%): 10 Ω 1/2 (50%): 32 Ω 1/4 (25%): 49.5 Ω EMPTY (0%): 85 Ω (Max. power consumption: 0.5 W)
Resistance (between T24 (1) – (2)) Normal temperature (25°C): Approx. 40 kΩ 130°C: Approx. 1.7 kΩ
Resistance (between HS (1) – (2)) 100°C: Approx. 3.5 – 4.0 kΩ 25°C: Approx. 37 – 50 kΩ
Phenomena under abnormal condition Insufficient engine oil level Cummins engine controller (CENSE) defective Low engine oil pressure or Cummins engine controller (CENSE) defective Engine coolant temp. above 105°C, or Cummins engine controller (CENSE) defective
Resetting method
Diagnosis code
Refill engine oil or see Cummins Service Manual. Check or see Cummins Service Manual.
V-1
V-2
Check or see Cummins Service Manual.
V-4
Gauge keeps indicating EMPTY. Low fuel level alarm is output wrongly.
–––
V-5 V-6
–––
Gauge keeps indicating FULL. Low fuel level alarm cannot be output.
–––
V-220
–––
–––
Gauge keeps indicating EMPTY. Low fuel level alarm is output wrongly.
–––
V-5 V-6
–––
–––
–––
Gauge keeps indicating 25°C. Alarm screen cannot be output.
–––
V-216
–––
–––
fi
Gauge keeps indicating 130°C. Alarm screen is output wrongly.
When left is not satisfied.
V-7 V-8 V-126
–––
–––
–––
Gauge keeps indicating 25°C. Alarm screen cannot be output.
–––
V-216
–––
–––
–––
Gauge keeps indicating 25°C. Alarm cannot be output.
–––
V-217
–––
–––
fi
Gauge keeps indicating 130°C. Alarm is output wrongly.
When left is not satisfied.
V-9 V-127
–––
–––
–––
Gauge keeps indicating 25°C. Alarm cannot be output.
–––
V-127
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 MPa {0 kg/cm2})
When left is not satisfied.
V-10 V-11 V-120
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 kg/cm2)
When left is not satisfied.
V-120
–––
–––
fi
Voltage (between V2A (7) – (3)): 0.7 – 5.3 V –––
WA1200-3
–––
fi
20-805 (8) 2
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALJTY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Abnormal
Failure
Failure
Action
system
mode
code
code
Brake oil pressure (F)
Short circuit with power source
VO. 7
Disconnection
a
Brake oil pressure (R)
Battery fluid level (1)
E912 E915 E863
---
---
1) Low rear brake oil pressure (E912, E915) 2) Defective rear brake oil pressure sensor 3) Defective joint connector JR14, JL?, or JR13 41 Disconnection or defective contact In wiring harness between Vl (female) (2) - HR16 (female) (2) 5) Disconnection or defective contact in wiring harness between V2A (female) (8) - HR 16 (female) (3) 6) Defective VHMS controller + For E912 and E915, see alarm items displayed on CGC monitor
Input voltage < 0*5V
Input < o 5v voltage
E912 Eg15 E863
- _ _
Short circuit with power source
---
---
1) Short circuit with power source in wiring harness between WA (female) (8) - HR16 (female) (3) 2) Defective VHMS controller
---
1)Defective battery fluid level sensor (1) or inscfricientcharge of battery 2) Disconnection or defective contact in wiring harness between WA (female) (1) - RA7 (female) (1) 3) Defective VHMS controller f See alarm items displayed on CGC monitor
E916
- - -
1) Defective battery fluid level sensor (1) or insufficientcharge of battery 2) Short circuit with chassis ground in wiring harness between WA (female) (1) - RA7 (female) (1) 31 Defective VHMS controller + See alarm items displayed on CGC monitor
---
---
1) Short circuit with power source in wiring harness between V2B (female) (1) - RA7 (female) (1) 2) Defective VHMS controller
Short circuit with chassis ground Short circuit
with power source
lo
Battery fluid level (21
6-v cel, voltage
c 2 V
6-v cell voltage
< 2 V
Sensing is impossible.
E917
---
Short circuit with chassis ground
E917
- - -
1) Defectivebatteryfluidlevelsensor(2) or insufficientcharge of battery 2) Short circuit with chassis ground in wiring harness between V2B (female) (2) - RA6 (female) (1) 3) Defective VHMS controller f See alarm items displayed on CGC monitor
6-V cell voltage < 2 V
---
---
1) Short circuit with power source in wiring harness between V2B (female) (2) - RA9 (female) (1) 2) Defective VHMS controller
Sensing is impossible.
E918
---
1) Defective battery fluid level sensor (3) or insufficientcharge of bsttery 2) Disconnection or defective contact in wiring harness between V2B (female) (3) - RA9 (female) (1) 3) Defective VHMS controller * See alarm items displayed on CCC monitor
voltage
E918
- - -
1) Defective battery fluid level sensor (3) or insufficientcharge of battery 2) Short circuit with chassis ground in wiring harness between V2B (female) (3) - RA9 (female) (1) 3) Defective VHMS controller rt See alarm items displayed on CGC monitor
---
---
1) Short circuit with power source in wiring harness between V2B (female) (3) - RA9 (female) (1) 2) Defective VHMS controller
Sensing is impossible.
1) Low front brake fluid level or defsctive front brake fluid level sensor 2) Low rear brake fluid level or defective rear brake fluid level sensor 3) Disconnection or defective contact in wiring harness between V3A (female) (5) - HR6 (female) (1) 4) Disconnection or defective contact in wiring hamess between V3B (female) (5) - HRlO (female) (1) 5) Defective VHMS controller t See alarm items displayed on CGC monitor
Sensing is impossible.
Short circuit
Disconnection
11 Banery fluid
Short circuit
level (3)
with chassis ground Short circuit with power
source
20-806 0
-_-
1) Defective battery fluid level sensor (2) or insufficientcharge of battery 2) Disconnection or defective contact in wiring harness between V2B (female) (2) - RA6 (female) (1) 3) Defective VHMS controller t See alarm items displayed on CGC monitor
source
Brake fluid level
__-
Disconnection
with power
l2
condition
1)Shon circuit with power source in wiring harness between V2A (female) (7) - HR15 (female) (3) 2) Defective VHMS controller
Short circuit with chassis ground
E916
Abnormal
of abnormality
1) Low rear brake oil pressure (E912, E915) 2) Defective rear brake oil pressure sensor 3) Short circuit with chassis ground in wiring harness between Vl (female) (2) - HR16 (female) (2) 4) Short circuit with chassis ground in wiring harness between V2A (female) (8) - HR16 (female) (3) 5) Defective VHMS controller * For E912 and E915, see alarm items displayed on CGC monitor
Disconnection
g
---
Contents
6V
cell
voltage
< 2 V
6-V cell < 2 V
6-V cell voltage < 2 V
Disconnection
E925 E926
- - -
Short circuit with chassis ground
- - -
- - -
1) Short circuit with chassis ground in wiring harness between V3A (female) (5) - HR6 (female) (1) 2) Short circuit with chassis ground in wiring harness between V3B (female) (5) - HRlO (female) (1) 3) Defective VHMS controller
Sensing is impossible.
Short circuit with power source
- - -
- - -
1) Short circuit with power source in wiring harness between V3A (female) (5) - HR6 (female) (1) 2) Short circuit with power source in wiring harness between V3B (female) (5) - HI?10 (female) (1) 3) Defective VHMS controller
Sensing is impossible.
WA1 200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal condition Joltage (between V2A :7) - (3)): 0.7 - 5.3 v
Condition of machine caused by abnormality
Alarm buzzer
---
-_-
___
--_
F$‘lUeist$y
Phenomena under abnormal condition
Resetting method
Diagnosis code
---
Real-time monitor is displayed. Max. pressure is always sensed. Alarm cannot be output.
- - -
v-210
0
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 MPa {O kg/cm211
When left is not satisfied.
v-10 v-12 V-118
0
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 MPa {O kg/cm%
When left is not satisfied.
Real-time monitor is displayed. Max. pressure is always sensed. Alarm cannot be output.
- - -
v-209
Other: x
Voltage (between ;;A (;)3-J3)):
. - .
--_
Voltage (between RA7 (1) - chassis): 5.5 - 6.5 V
Voltage (between RA8 ( 1) - chassis): 5.5 - 6.5 V
--_
--_
-_-
___
---
0
Alarm is output wrongly.
When left is not satisfied.
v-13
-__
__-
0
Alarm is output wrongly.
When left is not satisfied.
v-13
___
__-
_-_
Alarm cannot be output.
___
v-221
_--
_-_
0
Alarm is output wrongly.
When left is not satisfied.
v-14
0
Alarm is output wrongly.
When left is not satisfied.
v-14
---
Alarm cannot be output.
-__
v-222
0
Alarm is output wrongly.
When left is not satisfied.
v-15
0
Alarm is output wrongly.
When left is not satisfied.
v-15
---
__-
--_
-_-
Voltage (between E (;)5-;hassrs):
. - .
v-10 v-12
V-118
---
_--
_-_
__-
___
---
Alarm cannot be output.
_-a
---
Alarm is always output (Wrong sensing). E925: Before engine is started. E926: After engine is started.
---
V-223
---
V-16 v-17
__-
V-224
---
V-224
Voltage (between HR6 (1) - chassis, HRlO (1) - chassis)
WA1 200-3
--_
---
-__
---
--_
---
Alarm cannot be output.
---
20-807 0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
JO.
Abnormal
Failure
Failure
Action
system
mode
code
code
Disconnection
13
Coolant
level
Short circuit with power source
14
!5
Differential pressure on transmission oil filter (clogging)
Clogging of air cleaner (1)
ES27 E928
---
---
---
1) Defective coolant level sensor 2) Short circuit with chassis ground in wiring harness between V3A (female) (10) - GO1 (female) (1) 3) Defective VHMS controller
---
---
circuit with power source in wiring harness between V3B (female) (10) - GO6 (female) (1) 2) Defective VHMS controller
1)Short
,8
9
Clogging of air cleaner (3)
Clogging of air cleaner (4)
Alternator terminal R voltage
20-808 0
Sensing is impossible.
Sensing is impossible. Sensing is impossible.
E931
---
Short circuit with chassis ground
- --
---
1)Short circuit with chassis ground in wiring harness between V3A (female) (11) - R02 (female) (1) 2) Defective VHMS controller
Sensing is impossible.
Short circuit with power source
---
---
1) Short circuit with power source in wiring harness between V3A (female) (11) - R02 (female) (1) 2) Defective VHMS controller
Sensing is impossible.
Sensing is impossible.
Disconnection
E932
---
1)Ciogging of air cleaner (1) or defective dust indicator (1) 2) Defective dust indicator relay (1) 3) Disconnection or defective contact in wiring harness between V3B (female) (1) - L132 (female) (6) 4) Defective VHMS controller * See alarm items displayed on CGC monitor
Short circuit withchassis ground
---
---
1) Short circuit with chassis ground in wiring harness between V36 (female) (1) - L132 (female) (6) 2) Defective VHMS controller
---
---
1) Short circuit with power source in wiring harness between V3B (female) (1) - L132 (female) (6) 2) Defective VHMS controller
Sensing is impossible.
Sensing is impossible.
Short circuit
,,
condition
1)Clogging of transmission oil filter or defective transmission oil filter sensor (ROl) 2) Cl ging of transmission oil filter or defective transmission oil filter sensor (ROZ) Sensing is 31 Dzective joint connector JR7 impossible. 4) Disconnection or defective contact in wiring harness between V3A (female) (11) - V2A (female) (1) 5) Defective VHMS controller
source
C!ogging of air cleaner (2)
Abnormal
Disconnection
with power
6
of abnormality
1) Coolant level below LOW or defective coolant level sensor 2) Defective joint connector JR2 or JR7 3) Disconnection or defective contact in wiring harness between V3A (female) (10) - GO6 (female) (1) 4) Defective VHMS controller * See alarm items displayed on CGC monitor
Short circuit withchassis ground
Contents
Sensing
is
impossible.
Disconnection
E933
---
1) Clogging of air cleaner (2) or defective dust indicator (2) 2) Defective dust indicator relay (2) 3) Disconnection or defective contact in wiring harness between V36 (female) (2) - L133 (female) (6) 4) Defective VHMS controller *See alam items displayed on CGC monitor
Short circuit withchassis ground
---
---
1)Short circuit with chassis ground in wiring harness between V3B (female) (2) - L133 (female) (6) 21 Defective VHMS controller
Sensing is impossible.
Short circuit with power source
---
---
1) Short circuit with power source in wiring harness between V3B (female) (2) - L133 (female) (6) 2) Defective VHMS controller
Sensing is impossible.
Sensing is impossible.
Disconnection
ES34
---
1) Clo ging of air cleaner (3) or defective dust indicator (3) . dust indicator relay (3) 2) De 3ectlve 3) Disconnection or defective contact in wiring harness between V3B (female) (3) - L134 (female) (6) 4) Defective VHMS controller f See alarm items displayed on CGC monitor
Short circuit withchassis ground
---
1) Short circuit with chassis ground in wiring harness between V3B (female) (3) - L134 (female) (6) 2) Defective VHMS controller
Sensing
---
Short circuit with power source
---
---
1) Short circuit with power source in wiring harness between V3B (female) (3) - L134 (female) (6) 2) Defective VHMS controller
Sensing is impossible.
Sensing is impossible.
is
impossible.
Disconnection
E935
---
1) Clogging of air cleaner (4) or defective dust indicator (4) 2) Defective dust indicator relay (4) 3) Disconnection or defective contact in wiring harness between V3B (female) (4) - 1135 (female) (6) 4) Defective VHMS controller f See alarm items displayed on CGC monitor
Short circuit with chassis ground
- --
1) Short circuit with chassis ground in wiring harness between V3B (female) (4) - L135 (female) (6) 2) Defective VHMS controller
Sensing
---
Short circuit with power source
---
---
1) Short circuit with power source in wiring harness between V3B (female) (4) - L135 (female) (6) 2) Defective VHMS controller
Sensing is impossible.
is
impossible.
Disconnection
E937
---
1) Defective alternator signal relay L152 2) Defective alternator 3) Disconnection or defective contact in wiring harness between V2A (female) (4) - L152 (female) (6) 4) Defective VHMS controller * See alarm items displayed on CGC monitor
Short circuit withchassis ground
---
---
1) Short circuit with chassis ground in wiring harness between V2A (female) (4) - L152 (female) (6) 2) Defective VHMS controller
___
Short circuit with power source
---
---
1)Short circuit with power source in wiring harness between V2A (female) (4) - L152 (female) (61 - El4 (female) (2). El5 (female) (2) 2) Defective VHMS controller
- - -
_ _ _
WA1 200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal condition
Voltage (between V3A (IO) - (9)) Coolant level normal: Max. 1 V Coolant level insufficient: 17 - 30 V
Voltage (between V3A (11) - (9)) Filter normal: Max. 1 V Filter clogged: 17 - 30 V
Condition of machine caused by abnormality
Alarm buzzer
F$keekt$y
Phenomena under abnormal condition
Other:’ x
Resetting method
Diagnos, code
_--
---
-__
Low coolant level alarm is output (E928 is sensed wrongly).
---
V-18 v-19
-_-
___
---
Low coolant level alarm is not output.
-_-
---
-_-
--_
---
---
_--
--_
---
---
---
---
---
-_-
_-_
---
_--
$I;;:)
---
- --
---
Alarm cannot be sensed.
---
--_
---
---
___
---
---
---
---
---
--_
_--
---
---
---
t;;yj
---
---
---
Alarm cannot be sensed.
-_-
--_
-__
_--
---
__-
g;;;j
---
---
---
Alarm cannot be sensed.
_--
--_
___
---
---
--_ ___
---
_--
v-225
Clogging alarm is output (E931 is sensed wrongly).
---
v-20
Low coolant level alarm is not output.
__ _
-__
V-226
-__
V-226
---
v-21
-__
--_
-__
V-227
;“:;;Tj is output wrongly
-_-
v-22
Alarm cannot be sensed.
--_
-__
_-_
V-228
-_-
V-23
_--
_--
is output wrongly
Voltage (between V3B (1) - chassis) Filter normal: Max. 1 V Filter clogged: 17 - 30 V
Joltage (between J3B (2) - chassis) :ilter normal: Max. 1 V ‘ilter clogged: 17 - 30 V
Voltage (between V3B (3) - chassis) Filter normal: Max. 1 V Filter clogged: 17 - 30 V
Voltage (between V3B (4) - chassis) Filter normal: Max. 1 V Filterclogged: 17-30V
rVhen generating: 24 V Criterion Min. 9.3 V (While Pngine is running and generating) Vlax. 9.3 V (While sngine is stopped)
WA1 200-3
___
___
is output wrongly
---
is output wrongly
---
v-229
-_-
V-24
-__
___
_--
-_-
V-230
---
Abnormal charge level alarm is output wrongly. (E937)
___
v-25
---
_--
Abnormal charge level alarm is output wrongly. (E937)
___
___
_--
Misjudgment ismadewhile engine is running. Engine stop alarm may te sensed wrongly while engine is running.
V-231
-__
___ --
--_
20-809 0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Abnormal system
No.
NSW power 20 source (+24 V) (Battery)
21
22
24-V output of sensor power source
12-V output of sensor power source
Failure mode
24
26
Defective communication with CGC, engine controller (CUMMINS CENSE)
20-810 (8) 2
Abnormal condition
E811
–––
1) Disconnection or defective contact in wiring harness between V1 (female) (6) – FS3 (5) – Fuse – FS3 (6) – battery relay terminal B – battery (+) 2) Defective VHMS controller
Below 12 V
Short circuit with chassis ground
–––
–––
1) Short circuit with chassis ground in wiring harness between V1 (female) (6), (7) – Fuse I (13) 2) Defective VHMS controller
Sensing is impossible.
Short circuit with power source
E811
–––
1) Short circuit with power source in wiring harness between V1 (female) (6) – FS3 (5) – Fuse – FS3 (6) – battery relay terminal B – battery (+) 2) Defective VHMS controller
Above 40 V
Disconnection
–––
–––
1) Disconnection or defective contact in wiring harness between V1 (female) (2) – MT1, 2, 3, 4, 5 (female) (2) or between V1 (female) (2) – HR15, 16 (female) (2), HS2, 3, 4 (female) (2) 2) Defective VHMS controller
Sensing is impossible.
Short circuit with chassis ground
E812
–––
1) Defective transmission main relief pressure sensor, torque converter outlet oil pressure sensor, torque converter inlet pressure sensor, transmission modulation pressure sensor, front brake pressure sensor, rear brake pressure sensor, work equipment relief pressure sensor, steering relief pressure sensor, or PPC pressure sensor 2) Defective joint connector JT2, JR14, or JL2 3) Short circuit with chassis ground in wiring harness between JT2 (female) (2), (3), (4), (5) – MT5 (female) (2), MT4 (female) (2), MT3 (female) (2), MT2 (female) (2) 4) Short circuit with chassis ground in wiring harness between JR14 Voltage is below 14 V (female) (2), (3), (4), (5), (6) – HS4 (female) (2), HS2 (female) (2), HS3 (female) (2), HR16 (female) (2), HR15 (female) (2) 5) Short circuit with chassis ground in wiring harness between JL2 (female) (4) – JT2 (female) (1) or between JL2 (female) (5) – JR14 (female) (1) 6) Short circuit with chassis ground in wiring harness between V1 (female) (2) – JL2 (female) (3) 7) Defective VHMS controller
Short circuit with power source
–––
–––
1) Short circuit with power source in wiring harness between V1 (female) (2) – MT1, 2, 3, 4, 5 (female) (2) or between V1 (female) (2) – HR15, 16 (female) (2), HS2, 3, 4 (female) (2) 2) Defective VHMS controller
Sensing is impossible.
Disconnection
–––
–––
1) Disconnection or defective contact in wiring harness between V1 (female) (3) – F15 (female) (1) 2) Defective VHMS controller
Sensing is impossible.
Short circuit with chassis ground
E813
–––
1) Defective wheel rotation sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (3) – F15 (female) (1) 3) Defective VHMS controller
Voltage is below 7 V
Short circuit with power source
–––
–––
1) Short circuit with power source in wiring harness between V1 (female) (3) – F15 (female) (1) 2) Defective VHMS controller
Sensing is impossible.
–––
1) Disconnection or defective contact in wiring harness between V1 (female) (4) – RES3 (female) (1) Sensing is 2) Disconnection or defective contact in wiring harness impossible. between V1 (female) (5) – MT1 (female) (2) 3) Defective VHMS controller
–––
1) Defective transmission lubricating oil pressure sensor 2) Defective fuel level sensor 3) Short circuit with chassis ground in wiring harness between V1 (female) (5) – MT1 (female) (2) 4) Short circuit with chassis ground in wiring harness between V1 (female) (4) – RES3 (female) (1) 5) Defective VHMS controller
Voltage is below 3.4 V
Sensing is impossible.
5-V output of Short circuit sensor power with chassis ground source
Wrong connection of connector
Contents of abnormality
Disconnection
Disconnection
23
Failure Action code code
–––
E814
Short circuit with power source
–––
–––
1) Short circuit with power source in wiring harness between V1 (female) (4) – RES3 (female) (1) 2) Short circuit with power source in wiring harness between V1 (female) (5) – MT1 (female) (2) 3) Defective VHMS controller
Disconnection
–––
–––
1) Disconnection or defective contact in wiring harness between V2A (female) (12), V3A (female) (9) – chassis ground 2) Defective VHMS controller
–––
–––
–––
1) Short circuit with chassis ground in wiring harness between V2A (female) (9) – V3B (female) (12) 2) Defective VHMS controller
–––
–––
–––
1) Short circuit with power source in wiring harness between V2A (female) (12), V3A (female) (9) – chassis ground 2) Defective VHMS controller
–––
E818
–––
1) Disconnection, short circuit with chassis ground, or short circuit in wiring harness between V2A (female) (9), (12), V3A (female) (9), V3B (female) (12) – chassis ground 2) Defective VHMS controller
–––
1) Defective joint connector JL1 2) Disconnection or defective contact in wiring harness between V4A (female) (6) – D1 (female) (G), C2 (female) (A) 3) Disconnection or defective contact in wiring harness between V4A (female) (14) – D1 (female) (H), C2 (female) (B) 4) Defective CGC, engine controller, or VHMS controller
Short circuit with chassis ground Short circuit with power source Wrong connection of connector
Disconnection
E824
GND is input
Data are not updated
WA1200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal condition
Voltage (between V1 (6), (7) – chassis): 20 – 30 V
Voltage (between V1 (2) – chassis): 22 – 25 V
Voltage (between V1 (3) – chassis): 11 – 13 V
Voltage (between V1 (4), (5) – chassis): 4–6V
Voltage V2A (9): 20 – 30 V V2A (12): 0 – 5 V V3A (9): 0 – 5 V V3B (12): 20 – 30 V
WA1200-3
Condition of machine caused by abnormality
Alarm buzzer
Failure history Saved: fi Other: x
–––
–––
–––
Data cannot be saved. (2 wires are set. Failure occurs only when both wires are disconnected.)
–––
–––
–––
Fuse may be broken.
–––
–––
–––
Failure does not occur.
–––
–––
–––
Abnormal value of power source sensor
Stops outputting.
–––
fi
Abnormal value of power source sensor
–––
–––
–––
Abnormal value of power source sensor
–––
V-201
–––
–––
–––
Abnormal value of power source sensor
–––
V-202
Stops outputting.
–––
fi
Abnormal value of power source sensor
–––
–––
–––
Abnormal value of power source sensor
–––
V-202
–––
–––
–––
Abnormal value of power source sensor
–––
V-203
Stops outputting.
–––
fi
Abnormal value of power source sensor
–––
–––
–––
Abnormal value of power source sensor
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
fi
Connected to connector CN3A wrongly.
When left is not satisfied.
V-105
–––
–––
fi
Communication with CGC and engine controller (CENSE) is impossible.
When left is not satisfied.
V-107
Phenomena under abnormal condition
Resetting method
Diagnosis code
When left is not satisfied.
V-101
––– When left is not satisfied. –––
Hold until turning starting switch OFF.
Hold until turning starting switch OFF.
Hold until turning starting switch OFF.
–––
––– V-101
V-201
V-102
V-103
V-104
V-203
20-811 (8) 2
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING Abnormal system
No.
Failure mode
Short circuit with chassis Defective communication ground 26
with CGC, engine controller (CUMMINS CENSE)
Short circuit with power source
Disconnection
27
Defective communication with transmission controller (SNET)
Short circuit with chassis ground
Short circuit with power source
Disconnection Defective communication with 28 modulated clutch controller (SNET)
Short circuit with chassis ground
Short circuit with power source
Disconnection Defective communica29 tion with work equipment controller (S-NET)
Short circuit with chassis ground
Short circuit with power source
Disconnection
Defective communica30 tion with main monitor (S-NET)
Short circuit with chassis ground
Short circuit with power source
20-812 (8) 2
Failure Action code code
E824
E824
E825
E825
E825
E826
E826
E826
E827
E827
E827
E828
E828
E828
Contents of abnormality
Abnormal condition
–––
1) Defective joint connector JL1 2) Short circuit with chassis ground in wiring harness between V4A (female) (6) – D1 (female) (G), C2 (female) (A) 3) Short circuit with chassis ground in wiring harness between V4A (female) (14) – D1 (female) (H), C2 (female) (B) 4) Defective CGC, engine controller, or VHMS controller
Data are not updated
–––
1) Defective joint connector JL1 2) Short circuit with power source in wiring harness between V4A (female) (6) – D1 (female) (G), C2 (female) (A) 3) Short circuit with power source in wiring harness between V4A (female) (14) – D1 (female) (H), C2 (female) (B) 4) Defective CGC, engine controller, or VHMS controller
Data are not updated
–––
1) Defective joint connector JL17, JL18. JL22, or JL23 2) Disconnection or defective contact in wiring harness between Received data V3A (female) (8) – C3B (female) (4) 3) Disconnection or defective contact in wiring harness between are not updated V3A (female) (18) – C3B (female) (12) 4) Defective transmission controller
–––
1) Defective joint connector JL17, JL18. JL22, or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) – C3B (female) (4) 3) Short circuit with chassis ground in wiring harness between V3A (female) (18) – C3B (female) (12) 4) Defective transmission controller
Received data are not updated
–––
1) Defective joint connector JL17, JL18. JL22, or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) – C3B (female) (4) 3) Short circuit with power source in wiring harness between V3A (female) (18) – C3B (female) (12) 4) Defective transmission controller
Received data are not updated
–––
1) Defective joint connector JL22 or JL23 2) Disconnection or defective contact in wiring harness between Received data V3A (female) (8) – M01 (female) (1) 3) Disconnection or defective contact in wiring harness between are not updated V4A (female) (18) – M01 (female) (12) 4) Defective modulated clutch controller
–––
1) Defective joint connector JL22 or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) – M01 (female) (1) 3) Short circuit with chassis ground in wiring harness between V4A (female) (18) – M01 (female) (12) 4) Defective modulated clutch controller
Received data are not updated
–––
1) Defective joint connector JL22 or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) –M01 (female) (1) 3) Short circuit with power source in wiring harness between V4A (female) (18) – M01 (female) (12) 4) Defective modulated clutch controller
Received data are not updated
–––
1) Defective joint connector JL22 or JL23 2) Disconnection or defective contact in wiring harness between V3A (female) (8) – L26 (female) (1) 3) Disconnection or defective contact in wiring harness between V4A (female) (18) – L26 (female) (12) 4) Defective work equipment controller
Received data are not updated
–––
1) Defective joint connector JL22 or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) – L26 (female) (1) 3) Short circuit with chassis ground in wiring harness between V4A (female) (18) – L26 (female) (12) 4) Defective work equipment controller
Received data are not updated
–––
1) Defective joint connector JL22 or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) –L26 (female) (4) 3) Short circuit with power source in wiring harness between V4A (female) (18) – L26 (female) (12) 4) Defective work equipment controller
Received data are not updated
–––
1) Defective joint connector JL17, JL18, JL22, or JL23 2) Disconnection or defective contact in wiring harness between Received data V3A (female) (8) – L08 (female) (1) 3) Disconnection or defective contact in wiring harness between are not updated V3A (female) (18) – L08 (female) (3) 4) Defective main monitor
–––
1) Defective joint connector JL17, JL18, JL22, or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) – L08 (female) (1) 3) Short circuit with chassis ground in wiring harness between V3A (female) (18) – L08 (female) (3) 4) Defective main monitor
Received data are not updated
–––
1) Defective joint connector JL17, JL18, JL22, or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) – L08 (female) (1) 3) Short circuit with power source in wiring harness between V3A (female) (18) – L08 (female) (3) 4) Defective main monitor
Received data are not updated
WA1200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
Normal condition
Voltage (between V3A (8), (18) – chassis): 4–8V
Voltage (between V3A (8), (18) – chassis): 4–8V
Voltage (between V3A (8), (18) – chassis): 4–8V
Voltage (between V3A (8), (18) – chassis): 4–8V
WA1200-3
Condition of machine caused by abnormality
Alarm buzzer
Failure history Saved: fi Other: x
Phenomena under abnormal condition
Resetting method
Diagnosis code
–––
–––
fi
Communication with CGC and engine controller is impossible. When left is When (–) wire is shorted, not satisfied. failure does not occur (Communication is possible).
–––
–––
fi
Communication with CGC and When left is engine controller is impossible. not satisfied.
V-107
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-108
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-108
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-108
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-109
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-109
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-109
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-110
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-110
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-110
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-111
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-111
–––
–––
fi
Display of real-time monitor does not change.
When left is not satisfied.
V-111
V-107
20-813 (8) 2
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING -7
Nt -
3i
Abnormal
Failure
Izailur
Actior
system
mode
code
code
Buzzer output
-
34
Flash synchronizing signal (For main monitor)
-
Boom bonom pressure sensor
-
36
Boom head Dressure sensor
___
Short circuil with chassis ground
---
_--
1) Short circuit with chassis ground in wiring harness between Vl (female) (16) - L99 (female) (2) 2) Defective VHMS controller
E841
-__
1) Short circuit with power source in wiring harness between Vl (female) (16) - L99 (female) (2) 2) Defective VHMS controller
Disconnection
--_
--_
1) Disconnection or defective contact in wiring harness be&veer Vl (female) (14) - LO6 (female) (10) 2) Defective VHMS controller
--_
Short circuit with chassis ground
--_
--_
1) Short circuit with chassis ground in wiring harness between Vl (female) (14) - LO6 (female) (10) 2) Defective VHMS controller
___
Short circuit with power source
E843
_--
1) Short circuit with power source in wiring harness between Vl (female) (14) - LO6 (female) (10) 2) Defective VHMS controller
Disconnection
---
--_
1) Disconnection or defective contact in wiring harness between Vl (female) (13) - LO7 (female) (6) 2) Defective VHMS controller
-__
___
1)Short circuit with chassis ground in wiring harness between Vl (female) (13) - LO7 (female) (6) 2) Defective VHMS controller
_-_
E644
--_
1) Short circuit with power source in wiring harness between Vl (female) (13) - LO7 (female) (6) 2) Defective VHMS controller
Overcurrent
E861
_--
1)Defective boom bottom oressure sensor 2) Defective joint connector JF3 3) Disconnection or defective contact in wiring harness between Vl (female) (1) - F06 (female) (3) 4) Defective VHMS controller
Sensed voltage is below 0.5 V
Short circuit with chassis ground
__-
1) Defective boom bottom pressure sensor 2) Short circuit with chassis ground in wiring harness between Vl (female) (1) - F06 (female) (3) 3) Defective VHMS controller
Sensed voltage is below 0.5 V
Short circuit with power source
___
1) Short circuit with power source in wiring harness between Vl (female) (1) - F06 (female) (3) 2) Defective VHMS controller
Short circuit with chassis ground Short circuit with power source
Disconnection
E862
-__
I) Defective boom head oressure sensor 2) Defective joint connector JF3 3) Disconnection or defective contact in wiring harness between Vl (female) (10) - F14 (female) (3) 1) Defective VHMS controller
Short circuit with chassis ground
E862
--_
II Defective boom head pressure sensor 2) Short circuit with chassis ground in wiring harness between Vl (female) (10) - F14 (female) (3) 3) Defective VHMS controller
Short circuit with crower
-__
e-m
-
hzonnec-
37
Nork equipnent relief xessure sensor
-
Transmission main relief pressure sensor
20-814 0
E864
--_
Short circuit with chassis ground
IE864
-em
Short circuit with power source
---
_--
Disconnection
38
condition
--_
Disconnection
35
Abnormal
Disconnection
-
Check lamp (For main monitor)
of abnormality
1) Disconnection or defective contact in wiring harness between Vl (female) (16) - I99 (female) (2) 2) Defective VHMS controller
Short circuii with power
33
Contents
E866
Short circuit with chassis ground
E866
Short circuit with power source
--_
-__
m-m
I) Short circuit with power source in wiring harness between Vl (female) (10) - F14 (female) (3) !) Defective VHMS controller
_-_-Overcurrent
Overcurrent
Sensed voltage is below 0.5 V Sensed voltage
is
below 0.5 V
-__
I) Defective work equipment relief pressure sensor !I Defective joint connector JR14, JL2, JR16, or JR13 3) Disconnection or defective contact in wiring harness between Vl (female) (2) - HS2 (female) (2) 1) Disconnection or defective contact in wiring harness between V2A (female) (18) - HS2 (female) (3) j) Defective VHMS controller
nput voltage : 0.5 v
I) Defective work equipment relief pressure sensor !) Short circuit with chassis ground in wiring harness between Vl (female) (2) - HS2 (female) (2) $1Short circuit with chassis ground in wiring harness between WA (female) (18) - HS2 (female) (3) 1)Defective VHMS controller
nput voltage : 0.5 v
I) Short circuit with power source in wiring harness between WA (female) (18) - HS2 (female) (3) !I Defective VHMS controller
Sensing is mpossible
1) Defective transmission main relief pressure sensor 2) Defective joint connector JT2, JU, JT3, or JLll 3) Disconnection or defective contact in wiring harness between Vl (female) (2) - MT2 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (6) - MT2 (female) (3) 5) Defective VHMS controller
Input voltage c 0.5 v
1) Defective transmission main relief pressure sensor 2) Short circuit with chassis ground in wiring harness between Vt (female) (2) - MT2 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (6) - MT2 (female) (3) 4) Defective VHMS controller
Input voltage c 0.5 v
1)Short circuit with power source in wiring harness between WA (female) (6) - MT2 (female) (3) 2) Defective VHMS controller
__-
WA1 200-3
I
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALllY
TROUBLESHOOTING Condition of machine caused by abnormality
Normal condition
Buzzer is output when alarm is made, when load meter finishes measurement, etc. When output: Max. 1 V Normally: 20 - 30 V
$eb;zk$mp
Alarm buzzer
F~~~e~~~ Other:’ x __-
Buzzer does not sound.
--_
V-204
---
_--
_--
Buzzer does not sound.
---
V-204
-__
__-
Buzzer does not sound.
--_
_--
_--
---
_--
stops outputting.
When left is not satisfied_
v-113
Check lamp does not light up.
- - -
v-205
-_-
Check lamp keeps lighting up. itcFv;rscreen appears,
-__
V-205
_--
_--
kgzzerscreen
Check lamp keeps lighting up.
When left is
---
---
-_-
When alarm is made, caution lamp keeps lighting up or does not light up. Alarm is displayed on CGC, however.
---
---
-__
When alarm is made, caution lamp keeps lighting up or does not light up. Alarm is
---
-__
displayed onCGC.however. Whenalarmis made,caution lampkeeps lighting upor doesnotlightup. Alarmis displayed onCGC.however.
When left is not satisfied.
v-115
_--
_--
0
Load measured by load meter is always 0 ton.
When left is not satisfied.
V-l 16
---
-_-
0
Load measured by load meter is always 0 ton.
When left is not satisfied.
V-116
---
-__
__-
-a-
0
---
---
0
-__
-__
-__
_--
-_-
0
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa {O kg/cm?)
When left is not satisfied.
v-119
0
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa (0 kg/cm%
When left is not satisfied.
v-119
__-
Real-time monitor is displayed. Max. pressure is always sensed.
-__
v-21 1
stops outputting.
OFF:
20 : 30 V
.
;08N;K)zIFat interval of stops outputting.
doltage (between ;~j”:;:‘“:
.
.
doltage (between f174 ‘“: $1,: .
-
.
Joltage (between ;;2 $-$1)): . - .
---
---
Voltage (between ;;A (;13-;3)): . - .
WA I 200-3
Diagnosi code
---
is
signal
Resetting method
___
Wh& check lamp is OFF: 20 - 30 V
$ck;;i;i;g
Phenomena under abnormal condition
appears,
not satisfied.
v-114
- - -
V-206
- - -
V-206
V-207 Accuracy dispersion depends on operation of lever. (Back pressure cannot be corrected with boom head pressure.) Accuracydispersiondependson $%$~s%~bot
be corrected with boom head pressure.) Load measured by load meter is extremely low.
When left is not satisfied.
v-117
When left is not satisfied.
v-117
---
V-208
__-
__-
0
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa (0 kg/cm%
When left is not satisfied.
v-121
_-_
---
0
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa f0 kg/cm%
When left is not satisfied.
v-121
-_-
---
__-
Real-time monitor is displayed. Max. pressure is always sensed.
-__
v-212
20-8 15 0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
No.
Abnormal system
Failure mode
Disconnection Steering 39 relief pressure
20-816 (8) 2
Input voltage < 0.5 V
Input voltage < 0.5 V
Sensing is impossible
–––
Short circuit with power source
–––
–––
1) Short circuit with power source in wiring harness between V2A (female) (16) – HS3 (female) (3) 2) Defective VHMS controller
–––
1) Defective torque converter outlet pressure sensor 2) Defective joint connector JT2, JL2, JT3, or JL11 3) Disconnection or defective contact in wiring harness between Input voltage V1 (female) (2) – MT3 (female) (2) 4) Disconnection or defective contact in wiring harness between < 0.5 V V2A (female) (5) – MT3 (female) (3) 5) Defective VHMS controller
E868
Short circuit with chassis ground
E868
–––
1) Defective torque converter outlet pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (2) – MT3 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (5) – MT3 (female) (3) 4) Defective VHMS controller
Short circuit with power source
–––
–––
1) Short circuit with power source in wiring harness between V2A (female) (5) – MT3 (female) (3) 2) Defective VHMS controller
–––
1) Defective transmission modulating pressure sensor 2) Defective joint connector JT2, JL2, JT3, or JL11 3) Disconnection or defective contact in wiring harness between V1 (female) (2) – MT5 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (15) – MT5 (female) (3) 5) Defective VHMS controller
Input voltage < 0.5 V
Input voltage < 0.5 V
E871
Input voltage < 0.5 V
–––
Short circuit with chassis ground
E871
–––
1) Defective transmission modulating pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (2) –MT5 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (15) – MT5 (female) (3) 4) Defective VHMS controller
Short circuit with power source
–––
–––
1) Short circuit with power source in wiring harness between V2A (female) (15) – MT5 (female) (3) 2) Defective VHMS controller
Sensing is impossible
–––
1) Defective transmission lubricating oil pressure sensor 2) Defective joint connector JT3 or JR11 3) Disconnection or defective contact in wiring harness between V1 (female) (5) – MT1 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (14) – MT1 (female) (3) 5) Defective VHMS controller
Sensing is impossible
–––
1) Defective transmission lubricating oil pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (5) – MT1 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (14) – MT1 (female) (3) 4) Defective VHMS controller
Sensing is impossible
Input voltage < 4.8 V
Transmission 42 lubricating oil Short circuit with chassis pressure ground
44 PPC relief pressure
–––
1) Defective steering relief pressure sensor 2) Defective joint connector JR14, JL2, JR16, or JR13 3) Disconnection or defective contact in wiring harness between V1 (female) (2) – HS3 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (16) – HS3 (female) (3) 5) Defective VHMS controller
E867
Disconnection
Ambient 43 temperature
Abnormal condition
1) Defective steering relief pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (2) – HS3 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (16) – HS3 (female) (3) 4) Defective VHMS controller
Disconnection Transmission 41 modulating pressure
E867
Contents of abnormality
Short circuit with chassis ground
Disconnection Torque converter 40 outlet pressure
Failure Action code code
E872
E872
Short circuit with power source
E872
–––
1) Defective transmission lubricating oil pressure sensor 2) Defective joint connector JT3 or JR11 3) Short circuit with power source in wiring harness between V2A (female) (14) – MT1 (female) (3) 4) Defective VHMS controller
Disconnection
–––
–––
1) Defective ambient temperature sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (10) – PH1 (female) (1) 3) Defective VHMS controller
Input voltage > 4.7 V
Short circuit with chassis ground
E877
–––
1) Defective ambient temperature sensor 2) Short circuit with chassis ground or with power source in wiring harness between V2A (female) (10) – PH1 (female) (1) 3) Defective VHMS controller
Input voltage < 0.3 V
Short circuit with power source
E877
–––
1) Defective ambient temperature sensor 2) Short circuit with power source in wiring harness between V2A (female) (10) – PH1 (female) (1) 3) Defective VHMS controller
Input voltage > 4.7 V
–––
1) Defective PPC relief pressure sensor 2) Defective joint connector JR14, JL2, or JR7 3) Disconnection or defective contact in wiring harness Input voltage between V1 (female) (2) – HS4 (female) (2) 4) Disconnection or defective contact in wiring harness between < 0.5 V V2A (female) (1) – HS4 (female) (3) 5) Defective VHMS controller
Disconnection
E878
WA1200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
TROUBLESHOOTING
Normal condition
Condition of machine cause d by abnormal@ I
Alarm buzzer
I:ailurehistol Saved: C Other: x
Phenomena under abnormal condition
Xagnosis code
-_-
---
0
Real-time monitor is displayeo Min. pressure is always sensed. (0 MPa 10 kg/cm%
When left is not satisfied.
___
--_
0
Real-time monitor is displayed Min. pressure is always sensed. (0 MPa {O kg/cm31
When left is not satisfied.
___
---
___
Real-time monitor is displayed Max. pressure is always sensed.
_--
V-213
---
---
0
Real-time monitor is displayed Min. pressure is always sensed. (0 MPa {O kg/cm%
When letI is not satisfied.
V-123
-__
---
0
Real-time monitor is displayed Min. pressure is always sensed. (0 MPa f0 kg/cm%
When left is not satisfied.
V-123
_--
-__
___
Real-time monitor is displayed Max. pressure is always sensed.
--_
V-214
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa 10 kg/cm3)
When left is not satisfied.
V-124
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa IO kg/cm%
When left is not satisfied.
V-124
Real-time monitor is displayed. Max. pressure is always sensed.
___
v-215
When left is not satisfied.
v-125
Real-time monitor is displayed. Min. pressure is alwavs sensed. (0 MPa (0 kg/cm?)
When left is not satisfied.
V-125
Voltage (between ;-;A ‘263’; (12)): - .
Voltage (between V2A (5) - (3)): 0.7 - 5.3 v
Resetting method
Voltage (between ;‘A_‘;_53’ ; (12)):
_-_
___
__-
Real-time monitor is displayed. IS always t$rseyure
---
v-122
(0 MPa’{O kg/cm%
Voltage (between ;;A U43); (12)):
. - .
Resistance (between V2A (10) - (12)): Ambient temperature 20% Approx. 12 kQ 0°C: Approx. 4 kQ
Voltage (between ‘J2p_‘;‘3-Vf12”:
.
.
WA1 200-3
---
---
-__
0
Real-time monitor is displayed Min. pressure is always sensed. (0 MPa {O kg/cm%
When left is not satisfied.
V-125
---
_-_
0
PM Clinic display is abnormal (held at -30°C).
When left is not satisfied.
V-128
___
___
0
PM Clinic display is abnormal (held at 100°C).
When left is not satisfied.
V-128
___
_--
0
PM Clinic display is abnormal (held at -30°C).
When left is not satisfied.
V-128
0
PM Clinic is displayed. Min. oressure is alwavs sensed. (0 MPa IO kg/cm?)
When left is not satisfied.
v-129
---
20-817 0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING
No.
44
Abnormal
Failure
Failure
Action
system
mode
code
code
PPC relief pressure
Torque converter inlet pressure
SW power source (+24 VI
46
- - -
Short circuit with power source
---
---
1)Shor-t circuit with power source in wirin harness between V2A (female) (1) - HS4 (female 3 (3) 2) Defective VHMS controller
---
1) Defective torque converter inlet pressure sensor 2) Defective joint connector JT2, JU, JT3, or JLll 3) Disconnection or defective contact in wiring harness between Vl (female) (2) - MT4 (female) (2) 4) Disconnection or defective contact in wirin harness between V2B (female) (10) - MT4 (female) & 5) Defective VHMS controller
Input voltage c 0.5 v
Input voltage < 0.5 v
E884
E884
- - -
Short circuit with power source
---
---
1)Short circuit with power source in wirin harness between V2B (female) (10) - MT4 (fema Pe) (3) 2) Defective VHMS controller
Sensing is impossible
Disconnection
___
--_
1) Disconnection or defective contact in wiring harness of Vl (female) (8). (9) 2) Defective VHMS controller
Sensing is impossible
Short circuit withchassis ground
---
---
1) Short circuit with chassis ground in wiring harness of Vl (female) (8). (9) 2) Defective VHMS controller
Sensing is impossible
---
---
Disconnection
___
---
or defective contact in wiring harness of V2B (female) (8) 2) Defective VHMS controller
Sensing is impossible
Short circuit withchassis ground
---
---
1)Short circuit with chassis ground in wiring harness of V2B (female) (8) 2) Defective VHMS controller
Sensing is impossible
---
---
1)Short circuit with power source in wiring harness of V2B (female) (8) 2) Defective VHMS controller
Sensing is impossible
Disconnection
__-
--_
1) Disconnection or defective contact in wiring harness of V3A (female) (7) 2) Defective VHMS controller
Short circuit withchassis ground
---
---
1) Short circuit with chassis ground in wiring harness of V3A (female) (7) 2) Defective VHMS controller
---
---
1) Short circuit with power source in wiring harness of V3A (female) f7) 2) Defective VHMS controller
Sensing is impossible (Becauseof output of mcdulated clutch) Sensing is impcs-sible (Becauseof output of modulated clutch) Sensing is impossible (Becauseof output of modulatedclutch)
___
___
1)Defective cancel switch 2) Diinnection or defective contact in wiring harness of V3A (female) (14) 3) Defective VHMS controller
Sensing is impossible
- - -
- - -
1) Defective cancel switch 2) Short circuit with chassis ground in wiring harness of V3A (female) (14) 3) Defective VHMS controller
Sensing is impossible
Short circuit with power source
---
---
1)Short circuit with power source in wiring harness of V3A (female) (14) 2) Defective VHMS controller
Sensing is impossible
Disconnection
-_-
_-_
1) Defective subtotal switch 2) Disconnection or defective contact in wiring harness of V3A (female) (15) 31 Defective VHMS controller
Sensing is impossible
Short circuit withchassis ground
---
---
1) Defective subtotal switch 2) Short circuit with chassis ground in wiring harness of V3A (female) (15) 3) Defective VHMS controller
Sensing is impossible
Short circuit with power source
---
---
1) Short circuit with power source in wiring harness of V3A (female) (15) 2) Defective VHMS controller
Sensing is impossible
_ _ _
_ _ _
1) Defective boom proximity sensor 2) Disconnection or defective contact in wiring harness of V3A (female) (16) 3) Defective VHMS controller
Sensing is impossible
---
---
1) Defective boom proximity sensor 2) Short circuit with chassis ground in wiring harness of V3A (female) (16) 3) Defective VHMS controller
Sensing is impossible
---
---
1) Short circuit with power source in wiring harness of V3A (female) (16) 2) Defective VHMS controller
Sensing is impossible
_ __
_ __
1)Short
Short circuit source
Short circuit
with power source Disconnection 49
50
Cancel switch (Load meter)
Subtotal swsw;; (Load
Short circuit ;;$ceKWS
Disconnection
51
Boom proximity sensor
Short circuit withchassis ground Short circuit
with power source 52
ky;;;ading
20-8 18 0
_--
1) Defective torque converter inlet pressure sensor 2) Short circuit with chassis round in wirin harness between Vl (female) (2) - xl T4 (female) ( ) 3) Short circuit with chassis ground in wirin harness between V2B (female) (10) - MT4 (female ; (3) 4) Defective VHMS controller
with power
Engine speed (+)
Input voltage < 0.5 v
Short circuit with chassis ground
source
48
condition
E878
Short circuit
Small lamp ON voltage
Abnormal
Short circuit with chassis ground
with power
47
of abnormality
1) Defective PPC relief pressure sensor 2)Short circuit with chassis round in wirin harness between Vl (female) (2) - Y-lS4 (female) (2 3) Short circuit with chassis ground in wirin harness between V2A (female) (1) - HS4 (female) %3) 4) Defective VHMS controller
Disconnection
45
Contents
%Z$$$j$&‘$ mm pckr lcurca
circuit with power source in wiring harness of Vl (female) (8), (9) 2) Defective VHMS controller
1)Disconnection
Sensing
is
impossible
_--
WA1 200-3
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
TROUBLESHOOTING Normal condition
Condition of machine caused by abnormality
Alarm
F$‘Tebt&n’
buzzer
Others’ x
Diagnosi: code
When left is not satisfied.
v-129
__-
0
PM Clinic Min. pressure is always sensed. (0 MPa {O kg/cm%
_--
--_
___
PM Clinic Max. pressure is always sensed.
_--
---
0
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa {O kg/cm?)
When left is not satisfied.
v-130
_--
__-
0
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa {O kg/cm?)
When left is not satisfied.
v-130
---
_--
-_-
- - -
- - -
_--
--_
-_-
- - -
- - -
--_
---
-_-
Fuse may be broken.
---
-__
___
___
Failure does not occur.
--_
-_-
. - .
Voltage (between Vl (81, (9) - chassis): 20 - 30 v
Resetting method
_-Voltage (between ;‘p (;)3-$12)):
Voltage (between ‘JJB ‘;Oj v (12)): . - .
Phenomena under abnormal condition
Real-time monitor is displayed. Max. pressure is always sensed. (4.9 MPa {50 kg/cm? VHMS doesnet operate. (2 wiresare sat. Failureoccursonly whenbothwiresare disconnected.)
--_
v-219
Voltage (between V2B (8) - chassis): Small lamp ON:
ON: GND (When canceled) 3FF: OPEN Fuse is broken.
Switch is kept turned off. ON: GND (When subtotaled) OFF: OPEN
Switch is kept turned off.
___
___
Fuse is broken.
--_
-__
___
___
Trigger is not applied and load meter does not calculate load.
---
--
-__
_--
-__
Trigger is not applied and load meter does not calculate load.
___
__ _
__-
___
-_-
Trigger is not applied and load meter does not calculate load.
___
___
-__
_--
_-_
Data cannot be downloaded with service tool.
___
_-_
-
Load measurement !!?l!g:
OPEN
WA1 200-3
20-819 0
TROUBLESHOOTING
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR 1. The check lamp output is driven with VHMS. 2. As the signal to synchronize flashing of the caution lamp output of the main monitor, the ON/OFF output of VHMS is used. Permission of the alarm output is given by S-NET and is sent from VHMS to main monitor. 3. The check lamp and caution lamp are set independently (When two failures occur, both flash). Detecting condition 1 No.
Item
Display range
Detail of display range
Alarming condition Detecting condition 2 Before While engine engine starts is running
H: Normal L: Abnormal
Detecting condition 3 Failure detecting time (sec)
Resetting condition 1 Resetting condition
fi
–––
2
When left is not satisfied.
–––
fi
2
When left is not satisfied.
fi
10
When left is not satisfied.
Below specified level Below 1 segment of gauge (11%)
fi fi
–––
10
When left is not satisfied.
Below specified level Below 1 segment of gauge (11%)
–––
10
When left is not satisfied.
fi fi fi
fi fi fi fi
2
When left is not satisfied.
2
When left is not satisfied.
10
When left is not satisfied.
–––
fi
–––
When left is not satisfied.
Below 14.7 MPa {150 kg/cm } and after 60 sec after engine starts
–––
fi
5
When left is not satisfied.
Below 14.7 MPa {150 kg/cm2} and within 60 sec after engine starts
–––
fi
–––
When left is not satisfied.
(Cut-in/Cut-out 14 pressure)
Below 14.7 MPa {150 kg/cm2} and after 60 sec after engine starts
–––
fi
5
When left is not satisfied.
16 Battery fluid level (1) Below LOW level
OPEN (Fluid level is low) = 6 V cell is below 2 V
17 Battery fluid level (2) Below LOW level
OPEN (Fluid level is low) = 6 V cell is below 2 V
fi
fi
10
When left is not satisfied.
18 Battery fluid level (3) Below LOW level
OPEN (Fluid level is low) = 6 V cell is below 2 V When left is not satisfied.
1
Engine oil level
2
Engine oil pressure Below specified pressure
Refer to Engine Shop Manual
3
Engine coolant temperature
Above 105°C
Above 105°C
5
Fuel level
6 7
Torque converter oil temperature
8 9
Hydraulic oil temperature
Brake oil 10 pressure (F)
Below LOW level
Above 120°C
Above 120°C but 130°C alarm is not detected
Above 130°C
Above 130°C
Above 105°C
Above 105°C
Below 14.7 MPa {150 kg/cm2}
Below 14.7 MPa {150 kg/cm } and within 60 sec after engine starts 2
(Cut-in/Cut-out 11 pressure) Brake oil 13 pressure (F)
2
Below 14.7 MPa {150 kg/cm2}
19 Brake fluid level
Below specified level OPEN = 24 V (Fluid level is low)
fi
–––
10
20
Below specified level OPEN = 24 V (Fluid level is low)
–––
fi
10
When left is not satisfied.
21 Coolant level
Below LOW level
OPEN = 24 V (Coolant is insufficient)
fi
–––
2
When left is not satisfied.
22
Below LOW level
OPEN = 24 V (Coolant is insufficient)
–––
30
When left is not satisfied.
Transmission filter Above specified 23 differential pressure pressure
OPEN = 24 V (Clogging) and torque converter oil temperature is above 50°C
–––
fi fi
2
When left is not satisfied.
Clogging of air 24 cleaner (1)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When left is not satisfied.
of air 25 Clogging cleaner (2)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When left is not satisfied.
of air 26 Clogging cleaner (3)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When left is not satisfied.
of air 27 Clogging cleaner (4)
Above specified negative pressure
OPEN = 24 V (When clogged)
–––
fi
2
When left is not satisfied.
Voltage at alternator 28 terminal R
When charging is abnormal
Above 9.3 V (While engine is running) (Criterion while engine is running: Voltage of terminal R is above 9.3 V or engine speed > 600 rpm)
–––
fi
2
When left is not satisfied.
20-820 (8) 2
WA1200-3
TROUBLESHOOTING
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR
Alarm output Main monitor output
Display of message (CGC) Sensor Normal Real-time Saving of Error detecting display monitor, PM No. failure history component (Reference) Clinic (Reference) Saved: fi
Alarm display on CGC
Screen color
Cancel switch
Check lamp
Caution lamp
Buzzer
Abnormal
Yellow
Installed
Flashing
–––
–––
901
fi
CENSE
–––
fi
Abnormal
Red
Not installed
–––
Flashing
ON
902
fi
CENSE
–––
fi
Abnormal
Red
Installed
–––
Flashing
ON
904
fi
CENSE
Gauge
fi
Insufficient
Yellow
Installed
Flashing
–––
–––
905
x
VHMS
Gauge
–––
Insufficient
Yellow
Installed
–––
Flashing
–––
906
x
Gauge
–––
Abnormal
Yellow
Installed
–––
Flashing
–––
907
Gauge
–––
fi fi fi
–––
fi
–––
fi
–––
fi
–––
fi
–––
–––
–––
–––
fi
Abnormal
Red
Installed
–––
Flashing
ON
908
Abnormal
Red
Installed
–––
Flashing
–––
911
fi
Pressurizing
Yellow
Installed
–––
Flashing
–––
912
x
VHMS Gauge VHMS
Remarks
VHMS Abnormal
Red
Not installed
–––
Flashing
ON
913
fi
Pressurizing
Yellow
Installed
–––
Flashing
–––
912
x VHMS
Abnormal
Abnormal
Red
Yellow
Not installed
Installed
–––
Flashing
Flashing
–––
ON
–––
915
fi
916
fi
917
fi
918 Abnormal
Yellow
Installed
Flashing
–––
–––
925
Abnormal
Red
Not installed
–––
Flashing
ON
926
Abnormal
Yellow
Installed
Flashing
–––
–––
927
Abnormal
Red
Not installed
–––
Flashing
ON
928
Abnormal
Yellow
Installed
Flashing
–––
–––
931
fi fi fi fi fi fi
Abnormal
Yellow
Installed
Flashing
–––
–––
932
fi
Abnormal
Yellow
Installed
Flashing
–––
–––
933
fi
VHMS
VHSM VHSM VHMS
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
–––
VHMS Abnormal
Yellow
Installed
Flashing
–––
–––
934
fi
–––
–––
Abnormal
Yellow
Installed
Flashing
–––
–––
935
fi
–––
–––
Abnormal
Yellow
Installed
Flashing
–––
–––
937
fi
–––
–––
WA1200-3
VHMS
20-821 (8) 2
-TR(3UBLESHOOTlNG
ELECTRICAL CIRCUIT DIAGRAM
FOR VHMS SYSTEM
.ECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM
20-822 0
WA1 200-3
TROUBLESHOOTING
WA1 200-3
ELECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM
20-823 0
TROUBLESHOOTING
V-1, V-2, V-4
V-1 [E901] (Engine oil level below LOW level) is displayed Cause
Insufficient engine oil or defect related to CUMMINS engine controller (CENSE)
Remedy
Supply oil or see Service Manual of CUMMINS
V-2 [E902] (Engine oil pressure below specified pressure) is displayed Cause
Low engine oil pressure or defect related to CUMMINS engine controller (CENSE)
Remedy
Check or see Service Manual of CUMMINS
V-4 [E904] (Engine coolant temperature above specified temperature) is displayed fl This failure code is displayed when the engine coolant temperature is above 105°C (The caution lamp flashes and the buzzer sounds). Cause Engine coolant temperature above 105°C or defect related to CUMMINS engine controller (CENSE)
20-824 (8) 2
Remedy
Check or see Service Manual of CUMMINS
WA1200-3
V-5
TROUBLESHOOTING
V-5 EE9051 [Fuel level below specified level (before engine starts)] is displayed *
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing connector and inserting the T-adapter, or when monitor display, the CGC the on displayed longer no is code error the if position, original its to 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. This failure code is displayed before the engine starts.
Cause
4YE I ISvoltage between
Ir
R05 (female) 11)and J
resistance yEs between ROS - (female) (2) and chassisground 2 normal7 If VZA (female)(21is groundedtochassis, - Max. 1 R is resistancebatwaen R05 (female)(1) and - . Turn starting ;z;$ground switch OFF. * Disconnect R05. *Max. 1 R ‘,, *Turn starting switch OFF. . Disconnect V2A and R05. Is
Yl 1 Is
betresistance
ween I305 hale)
. See Table 1. - Disconnect R05.
NO
.
* DisconnectWA and R05. *Turn starting switch ON
NO
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (2) - R05 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between R05 (female) (2) chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between V2A (female) (2) R05 (female) (1)
Repair or replace
insufficient fuel or defective fuel level sensor
Suppiy fuel or replace fuel level sensor
Table 1 Fuel level
1
1 FULL (100%) 1 1
l/Z (50%)
1
I
11 (25%)
/
1 EMPTY (0%) 1
WA1 200-3
Resistance Approx. 10 R
1
Appror1 Approx. 48.5 Q
I
Aoorox. 85 R
1
20-825 0
TROUBLESHOOTING
V-5
V-5 Related electrical circuit diagram
VHM JR2
(DTI)
RAlO
(DTHD4)
TJW02526
20-826 0
WA1 200-3
V-6
TROUBLESHOOTING
V-6 [E906] [Fuel level below specified level (While engine is running)] 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 CGC 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. This failure code is displayed before the engine starts.
Cause
11 ” Ick&sground Is resistance between R05 -Max.lV NC - (female) (2) and - DisconnectWA chassis ground 2 and R05. - If VZA (female)is normal? * Turn starting switch ON. P YES grounded10chassis, * Max. 1 R ISresmance between _ Turn starting NO - RO5(female)(1) and chassisground switch OFF. 1 normal? * Disconnect R0.5. Is resistance bet. Max. 1 Q ween RO5 (male) NO - -Turn starting (1) and (2) as switch OFF. shown in Table l? * Disconnect VZA I I and R05. * See Table 1. Disconnect R05. yfrS
l
I
l
NO
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between VZA (female) (2) - R05 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between R05 (female) (2) chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between V&I (female) (2) R05 (female) (1)
Repair or replace
Insufficient fuel or defective fuel level sensor
Supply fuel or replace fuel level sensor
Table 1 Resistance
Fuel level 1 FULL (100%) 1
Approx. 10 R
l/2 (50%)
Approx. 32 R
1
l/4 (25%)
1 Approx. 49.5 R
EMPTY (0%) )
WA1 200-3
1
I
Approx. 85 R
20-827 0
TROUBLESHOOTING
V-6 Related
electrical
V-6
circuit
diagram
II
level Fuel sensor
TJW02526
20-828 0
WA1 200-3
V-7
TROUBLESHOOTING
V-7 [ES071 (Torque converter oil temperature
above 120°C) 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 CGC 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.
1 2 1Is resistancebetwen YES WA Ifemale)(3). T24 , r (female)11)and _ chassisground normal?
Is resistance between T24 Imale) _ (1) and (2) as shown in Table 17 - See Table 1. * Turn starting switch OFF. * Disconnect T24.
Defective VHMS controller
YES
II
NO - Min. 1 MR . Turn starting switch OFF. * Disconnect VZA and T24. NO
I
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (3) -T24 (female) (1)
Repair or replace
Torque converter oil temperature is above 120°C or defective torque converter oil temperature sensor
Repair or replace
Table 1
*j
Totsue converter oil temDerature sensor bon i tar)
v-7 Related electrical circuit diagram VHMS
LR7fDTI)
l!
WA1 200-3
_.
RA5 (DTI)
_,
TJW02527
20-829 0
V-8
TROUBLESHOOTING
V-8 [E908] (Torque converter A-
* *
above 130°C) is displayed
oil temperature
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the connector and inserting the T-adapter, or when removing monitor display, the CGC the on displayed longer no is code to its original position, if the error removed. problem has been check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. Remedy
Cause
YES -
1
_
* See Table 1. Turn starting switch OFF. * Disconnect T24. l
V-B Related
YES
chassis ground
lwmal?
Is
resistance between T24 knale) (1) and 12)as shown , in Table 17
2 Is rasisIancabetween T24 (3). 'kW(female) (female)(1) and
,
NO * Min. 1 MQ * Turn starting switch OFF. * Disconnact V2A and T24. NO
electrical
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (3) T24 (female) (1)
Repair or replace
Torque converter oil temperature is above 130°C or defective torque converter oil temperature sensor
Repair or replace
Tome carlverter ni L*,llr*l,ature YI II tmmmr sensor bon i tar)
circuit diagram
VHMS
LR7 (0
m
.*
RAlO [DTHD4)
TJW02527
20-830 0
WA1 200-3
TROUBLESHOOTING
v-9
oil temperature
V-9 [E911] (Hydraulic
above 105°C) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or connector and inserting the T-adapter, monitor display, the CGC the on displayed longer no is code error the if position, to its original 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
2
YES
Is resistance batwean V2A (female) (11). HSl ~famalel ._.
y,zs r
,
batwaan
HSl
(male)
(11 and (2) as shown I
I
Table 1. Turn starting switch OFF. * Disconnect HSl. - See
-Turn starting switch OFF. - Disconnect V2A and HSl.
I
l
Remedy
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (11) - HSl (female) (1)
Repair or replace
Hydraulic oil temperature is above 105% or defective hydraulic oil temperature sensor
Replace
Table 1 Temperature
Resistance
25°C
Approx. 37’ - 50 kI2
105°C
Approx. 3.0 - 3.6 kQ
V-9 Related
electrical
circuit diagram
VHMS
controller
V2A(07018)
JR16 (DTl)
0. 5’Y
Hydraulic LR2 (HD-85086)
oi
I sensor
TJW02528
WA1 200-3
20-831 0
v-10
TROUBLESHOOTING
[E912] (Low front or rear brake oil pressure) is displayed
V-IO *
* * * *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. This failure code is displayed when the brake cut-out oressure is below 14.71 MPa (150 kg/cm? (for 60 seconds after the engine starts). Perform the following troubleshooting when the cut-out presRemedy Cause sure is normal. Always connect any disconnected connectors before going on to the next step. Low front brake oil pressure or defective front brake oil pressure sensor
YES
I 1 If HR15 is
II
Low rear brake oil pressure or defective rear brake oil pressure sensor
Check or replace
Check or replace
L
J--
. Turn starting If HRlr ‘switch OFF. discon Disconnect HRlS. SC+=raiiure code NO dr-Start engine.
l
GotoA
-
di
l
* Turn starting switch OFF. . Disconnect HR16. h * Start engine.
_.
round normal?
* DisconnectVZA and HR16.
* Min. 1 MD - Turn starting switch OFF. Disconnect V2A and HR15.
VO
Contact of wiring harness between V2A (female) (8) - HR16 (female) (3) with chassis ground
Repair or replace
Contact of wiring harness between V2A (female) (7) - HR15 (female) (3) with chassis ground
Repair or replace
l
7 YES
Go to 8.
-
YF 6
*
Max.1 Q
HR16 ffamale) 13)and I if WA (female) 17) is
I
*Turn starring switch OFF. * DisconnectJR14
. __
From A
Max. 1 R -Turn starting switch OFF. Disconnect V2A and HR15.
and HR16.
l
NO
Disconnection or defective contact in wiring harness between JR14 (female) (6) - HR15 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between WA Ifemaie) (8) HR16 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between WA (female) (7) HR15 (female) (3)
Repair or replace
Defective VHMS controller
Replace
Contact of wiring harness between JR14 (female) (5) - HR16 (female) (2) with chassis ground
Repair or replace
Contact of wiring harness between JR14 (female) (6) - HR15 (female) (2) with chassis ground
Repair or replace
Disconnection or defective contact in wiring harness between JR14 (female) (5) - HR16 [female) (2)
Repair or replace
l
From S _
20-832 0
Is resistance betYES ween JR14 (female) - (5). HR16(female)(2) 9 and chassisground Is resistance batnormal? _ yfcS ween JR14 (female) * Min. 1 MQ NC - (6), HR15 (female) - -Turn starting switch OFF. a (2) and chassis ground IfJR14 - DisconnectJR14 - normal? and HR16. gmundedto chz Min. 1 MD is resistancebetween NO HR16 (female)(2) and - * Turn start@ chassisground switch OFF. normal? * Disconnect JR14 - Max. 1 R and HR15 -Turn starting NO switch OFF. . Disconnect JR14 and HR16. l
WA1 200-3
TROUBLESHOOTING
V-10 Related
electrical
v-10
circuit
diagram
VHMS
JR13 (DTIB)
brake Front oi I Pressure
Rear brake oil Pressure
RAlO(DTHD4)
TJW02529
WA1 ZOO-3
20-833 0
TROUBLESHOOTING
V-II *
* * * *
v-11
[E913] (Low front brake oil pressure) 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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. This failure code is displayed when the cut-in/cut-out pressure of the front brake is below 14.71 MPa (150 kg/cm21 (60 seconds after the engine starts). Perform the following troubleshooting when the front brake cut-in/cut-out pressure is normal. Always connect any disconnected connectors before going on to the next step.
Remedy
IYF! . .-
d Yl
replaced with rear
- Turn starting switch OFF. * Replace with (normal) rear brake oil pressure sensor. *Start engine.
* Max. 1 D . Turn starting switch OFF. - Disconnect V2A and HR15. IO
(61. HRl5 (female) (2) and chassis ground normal?
From A
* Min. 1 MQ Turn starting switch OFF. * Disconnect JR14 and HR15. l
20-834 0
- Min. 1 MR *Turn starting switch OFF. - Disconnect V2A and HR15. NO
NO
H
NC
-Max.10
*Turn startino switch
).~$m?ct ii14
and
NO
GotoA
-
Disconnection or defective contact in wiring harness between JR14 (female) (6) - HR15 (female) (2)
Repair or replace
Contact of wiring harness between V2A (female) (7) HRt5 (female) (31 with chassis ground
Repair or replace
contact in wiring harness between WA (female) (7) HR15 (female) (3)
Repair or replace
Low front brake oil pressure or defective front brake oil pressure sensor
Check or replace
Defective VHMS controller
Replace
Contact of wiring harness between JR14 (female) (6) - HR15 (female) (2) with chassis ground
Check or replace
WA1 ZOO-3
TROUBLESHOOTING
V-II
v-11
Related electrical circuit diagram
VHMS
controller
%,, Im-,A.,,,l
JL21fDTlBl
Front brake oi I Pressure
RA5 (LITI)
RAlU(DTHD4) qmp
TJW02530
WA1 200-3
20-835 0
v-12
TROUBLESHOOTING
V-12
[ES151 (Low rear brake oil pressure) 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 CGC monitor display, the problem has been removed.
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. This failure code is displayed when the cut-in/cut-out pressure of the rear brake is below 14.71 MPa (150 kg/cm21 (60 seconds after the engine starts). Perform the following troubleshooting when the rear brake cut-in/cut-out pressure is normal. Always connect any disconnected connectors before going on to the next step.
* *
cause
Gotok HR16 (female)(2) and
*Turn startingswitch
Yl Hi%6 (female1(31and 1
1If rear brake oil
* Disconnect WA and HR16. NO
- Max.
1Q -Turn starting switch OFF. Disconnect V2A and HR16.
Remedy
-
Disconnectionor defective contact in wiring harness between JR14 (female) (5) HR16 (female) 12)
Repair or replace
Contact of wiring harness between WA (female) (8) HR16 (female) (3) with chassis ground
Repair or replace
Disconnectionor defective contact in wiring harness between V2A (female) (8) HR16 (female) 13)
Repair or replace
Low rear brake oil pressure or defective rear brake oil pressure sensor
Check or replace
Defective VHMS controller
Replace
Contact of wiring harness between JR14 (female) (5) - HR16 (female) (2) with chassis ground
Check or replace
l
-Turn starting switch OFF. . Replace with (normal) front brake oil pressure sensor. . Start engine.
IO
5 YES Is resistance between JR14 (female) (5). HR16 (female) (2) and chassis ground normal?
From A M
. Min. 1 MD Turn starting switch OFF. - Disconnect JR14 and HR16. l
20-836 0
NO
WA1 200-3
TROUBLESHOOTING
V-12 Related
electrical
v-12
circuit diagram
VH
e ure
TJW02531
WA1 200-3
20-837 0
TROUBLESHOOTING
V-13
v-13
[916] (Disconnection or short circuit with chassis ground in battery fluid level sensor “1 “I 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 CGC monitor display, the problem has been removed. -)r Before carrying out troubleshooting, check that all the related connectors are properly inserted. f Always connect any disconnected connectors before going on to the next step. * Perform the following troubleshooting when the battery fluid level is normal.
F=Is resistance betYES
-
_ 2 ifV28 (female) (1) [s grounded to chassis. 1s resistance batwean _ RA7 (female) (1) and
YES _
1 Is voltage between RA7 (male) (1) and chassis ground normal? -5.5-6.5V . Disconnect RA7.
$aEa;?ground *Max.1 Q *Turn starting switch OFF. Disconnect V2B and RA7.
-
3
YES
Remedy
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between V2B (female) (1) - RA7 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between VZB (female) (1) RA7 (female) (1)
Repair or replace
Defective battery fluid level sensor ‘1’ or insufficient battery charge
Charge or replace
wean V2B (female)
(11, RA7 (female) (1) and chassisground normal?
-
NO Min. 1 MR *Turn starting switch OFF. * Disconnect V2B and RA7. l
NO
l
i.
V-13 Related electrical circuit diagram
VHMS
RA2 (DTP/DT
1)
TJW02532
20-838 0
WA1 200-3
v-14
TROUBLESHOOTING
V-14
[917] (Disconnection or short circuit with chassis ground in battery fluid level sensor “2”) 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 CGC 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. Perform the following troubleshooting when the battery fluid level is normal.
Ir *
* 3 YES Is resistancebetween VZB (female) (2). RA8 (female) (1) and chassisground normaI?
YES 2 If V26 (fern
-
Is voltage between RAB (male) (1) and chassis ground normal?
YES gs$:: EC;:;, _ RA6 (female) (1) and 1 chassisground normal?
- Max. 1 Q - - Turn starting switch OFF. Disconnect VZB - 5.5 - 6.5 V and RAB. - Disconnect RAB. NO
NO
*Min.lMR Turn starting switch OFF. - Disconnect V2B and RAB.
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between V2B (female) (2) - RAB (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between VZB (female) (2) RA6 (female) (1)
Repair or replace
Defective battery fluid level sensor ‘2’ or insufficient battery charge
Charge or replace
l
NO
l
I
I V-l 4 Related
electrical
circuit diagram
VHMS
Battery
TJW02532
WA1 200-3
20-839 0
v-15
TROUBLESHOOTING
V-15
*
* * *
[918] (Disconnection or short circuit with chassis ground battery fluid level sensor “3”) is displayed
in
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 CGC 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. Perform the following troubleshooting when the battery fluid level is normal.
ChJSe
3 _ MS ._reskance betYES wee” V2B (female) - 131.RA9 (female) (1) 2 and chassisground _ If V2B (female)(3) is normal? ES grourjdedtochassis, NO _ Is re%tance between _ . Min. f MD RA3 (female)11)and * Turn starting switch OFF. 1 chassisground normal? * Disconnect VZS and FiA9. Is voltage bet* Max. 1 R ween RA9 (male) - * Turn starting NO (1) and chassis switch OFF. ground normal? * Disconnect VZB .5.5-6.5V and RA9. ’ - Disconnect RA9. Is
NO
Remedy
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between VZB (female) (3) - RA9 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between V26 (female) (3) RA9 (female) (1)
Repair or replace
Defective battery fluid level sensor ‘3’ or insufficient battery charge
Charge or replace
V-15 Related electrical circuit diagram VHMS
TJW02532
20-840 0
WA1 200-3
TROUBLESHOOTING
V-16 *
* *
*
V-16
[E9251 [Brake fluid level below specified level (before engine starts)] 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 CGC 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. This failure
code is displayed
before the engine
starts.
CaUSe
YES I 1
I
If HRlO (female) (11 is grounded to chassis,does failure code disappear?
YES
I
Remedy
Low front brake fluid level or defective front brake fluid level sensor
Supply or replace brake fluid
Low rear brake fluid level or defective rear brake fluid level sensor
Supply or replace brake fluid
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between V3A (female) (5) HR6 (female) (1)
Repair or replace
2 * Turn starting switch OFF. - Ground HRlO (female) (1) to chassis. * Turn starting switch ON.
If HR6 (Lemale) (1) is _ groundedto dwsfailure No :~~~~s appear?
H
*Turn starting switch OFF.
ll”C - ___..__I urouno “no
(female) (1) to chassis. * Turn starting switch ON.
V-16 Related
electrical
NO between _ -Max.lQ . Turn aarting switch OFF. * DisconnectV3A and HR6. Disconnection or defective - Max. 1 Q contact in wiring harness between V3B (female) (5) * Turn starting NO HRlO (female) (1) switch OFF. * Disconnect V3B and HRlO. Ie
-.-.ce
Repair or replace
circuit diagram Front brake oil level
VHMS controller ake el
TJW02533
WA1 200-3
20-841 0
v-17
TROUBLESHOOTING
V-17
*
+I * *
[E926] [Brake fluid level below specified level (While engine is running)] 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 CGC 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. This failure code is displayed while the engine is running.
Cause
YES
code disappear? II *Turn starting switch OFF. * Ground HRlO (female) (1) to chassis. * Turn starting switch ON.
Remedy
Low front brake fluid level or defective front brake fluid level sensor
Supply or replace brake fluid
Low rear brake fluid level or defective rear brake fluid level sensor
Supply or replace brake fluid
2
4 YES Defective VHMS controller
Replace
code disappear? * Turn starting switch OFF. . Ground HR6 (female) (1) to chassis. *Turn starting switch ON.
h Jj &&$gmund * Max. 1 R * Turn starting switch OFF. * Disconnect V3B and HRlO.
1
Disconnection or defective contact in wiring harness between V3A (female) (5) HR6 (female) (1)
I
Repair or replace
switch OFF* DisconnectV3A and HR6.
NO
contact in wiring harness between V3B (female) 15) HRlO (female) (1)
Repair or replace
V-17 Related electrical circuit diagram Front brake oil level VHM ake el
,,,I TJW02533
20-842 0
WA1 200-3
TROUBLESHOOTING
V-18 *
* * *
V-18
[ES271 [Coolant displayed
level below LOW level (before engine starts] is
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 CGC 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, This failure code is displayed before the engine starts. Remedy
CaUSe
4 YE!
I., If GO6 (female)
(1)
$j%j$jz~
and 12) are shorted to each other, does failure code disa ear?
Turn starting switch OFF. * Short GO6 (female) (1) and
- IS resistance MS between JR2 Imale) and (1) and
*
iI
I
- 0)
between
-
* Max. 1 R Turn starting switch OFF. * Disconnect JR2 and JR7. l
-
Turn starting switch ON.
- Max.
1R . Turn starring switch OFF. * Disconnect V3A and G06.
JR7 (male)
(2) and (1) normal?
NO
IL
ground normal?
. Max. 1 R N( * Turn starting switch OFF. * Disconnect G06.
Coolant level below LOW level or defective coolant level sensor
Supply or replace coolarr
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between GO6 (female) (2) -chassis ground
Repair or replace
Defective JR2 or JR7
Replace
NO Disconnection or defective contact in wiring harness between V3A (female) (10) - GO6
Repair or replace
V-18 Related electrical circuit diagram VHMS
RAlO
(DTHD4) 000
1
--I
GO6CDT11
Coolant sensor
level
TJW02534
WA1 200-3
20-843 0
TROUBLESHOOTING
V-19
v-19
[E9281 [Coolant level below LOW level (While engine is running)] 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 CGC 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. . This failure code is displayed while the engine is running.
* *
Y ‘ES
4Ylz
1
1If GO6
(female)
I
(1)
I
N? * Turn starting switch
* Turn starting switch OFF. * Short GO6 (female) (1) and (2) to each other. mTurn starting switch ON.
. Disconnect G06.
NO
- Max.
1R s Turn starting switch OFF. Disconnect V3A and G06.
I NO
l
V-19 Related
electrical
Cause
Remedy
Coolant level below LOW level or defective coolant level sensor
Supply or replace coolar
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between GO6 (female) (2) -chassis ground
Repair or replace
Defective JR2 or JR7
Replace
Disconnection or defective contact in wiring harness between V3A (female) (10) - GO6 (female) (1)
Repair or replace
circuit diagram
VHMS
Coolant level TJW02534
20-844 0
WA1 ZOO-3
TROUBLESHOOTING
v-20 *
v-20
[E931] (Clogging of transmission
oil filter) 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 CGC monitor display, the problem has been removed.
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted. Sr Always connect any disconnected connectors before going on to the next step.
Cause
and (2) are shorted to each other, does
YES
- Turn starting
If ROZ(female) and (2) are shorted
switch OFF.
(female) (1) and (2) to each other.
disappear? * Turn starting switch OFF. . Disconnect ~02. -
Short R02 (female) (1) and (2) to each other.
Is resistance between JR7 (male) (3) and (1) normal?
From A _
Max. 1 R * Turn starting switch OFF. Disconnect JR7.
4YE Is resistance YES between R02 (female) (2) and ROl 3 PIf v3A (female)I11 I is (female) (1) normal? groundedto chassis, p _ is resistancebetween _ -Max.lQ NI ND RO2Uynale) (1) and . Turn starting chassrsground switch OFF. normal? Max. 1 R * Turn starting switch OFF. * Disconnect V3A and R02. 6
*Disconnect ROl
-
NO
YES
Is resistancebetYES ween ~101(female) (2) and chassis 5 ground normal? * Max. 1 R * Turn starting switch OFF. * Disconnect ROl.
l
NO
NO
and AOi
Remedy
Clogging of transmission oil filter or defective transmission oil filter sensor (ROl )
Check or replace
Clogging of transmission oil filter or defective transmission oil filter sensor (R02)
Check or replace
Gotok
-
Disconnection or defective contact in wiring harness between R02 (female) (2) ROl (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between V3A (female) Ill) - RO2 (female) (1)
Repair or replace
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between ROl (female) (I) - chassis ground
Repair or replace
Defective joint connector (JR71
Replace
l
WA1 200-3
20-845 0
TROUBLESHOOTING
V-20 Related
electrical
w-20
circuit diagram
VHMS
TJW02535
20-846 0
WA1 ZOO-3
TROUBLESHOOTING
V-21
v-21
[E9321 [Clogging
of air cleaner (I)] 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 CGC 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.
*
ChUSe
Remedy
Replace
If connector B06
Y ES
Defective dust indicator relay 1
does failure code * Turn starting switch OFF. * Disconnect B06. n * Turn starting switch ON. . Turn starting switch OFF. Replace with another relay. Turn starting switch ON.
l
l
From A _
- Is resistance between B06 (female) -Max.lQ NC N- (1). 1132 (female) (2) *Turn starting 0 and chassis ground switch OFF. normal? * DisconnectV3B and L132 p . Max. 1 R NO * Turn starting switch OFF. * Disconnect B06 and L132.
Is resistance between L132 (female) _ (3) and chassis ground normal? * Max. 1 $2 * Turn starting switch OFF. - Disconnect L132.
WA1 200-3
4 YE: -IIs resistance betMS ween V3B (female) _ 3 (1) and L132 (female) (61 normal?
NO
Gotok
Replace
-
Disconnection or defactivc contact in wiring harness behnreen V3B (female) (1) L132 (female) (6)
Repair or replace
Contact of wiring harness between 606 (female) (1). L132 (female) (2) with chassis ground
Repair or replace
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between L132 (female) (3) chassis ground
Repair or replace
20-847 0
v-21
TROUBLESHOOTING
V-21 Related electrical circuit diagram
VHMS C
Dust indicator I relay
Dust
indicator 2 relay Dust indicator 3 relay Dust indicator 4 relay
I
TJW02536
20-848 0
WA1 200-3
V-22
TROUBLESHOOTING
V-22
[E933] [Clogging of air cleaner (211 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 CGC monitor display, the problem has been removed.
f
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.
*
ChJSe
Remedy
Defective dust indicator 2
Replace
Defective dust indicator relay 2
Replace
1 If connector 807 is disconnected, does failure code I disappear? I -Turn starting switch OFF. . Disconnect 807. P . Turn starting switch ON.
Y ES 2 relay 2 is replaced with another relay,
-r
4 YE5
resistamcebetYES ween ~38 (femaw (2) and L133 3 (female) 16) normal?
Gotok
-
Is
Is resistancebetween 807 (female)
* Turn starting switch OFF. Replace with another relay. Turn starting switch ON.
l
NC
and chassisground switch OFF. normal? * DisconnectV3E and L136 - Max. 1 R -Turn starting NO switch OFF. Disconnect 807 and L133.
l
Disconnection or defective contact in wiring harness between V3B (female) (2) L133 (female) (6)
Repair or replace
Contact of wiring harness between 807 (female) (1) L133 (female) (2) with GND harness or chassis ground
Repair or replace
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between L133 (female) (3) chassis ground
Repair or replace
l
5 YES Is resistance between L166 (female) _ (3) and chassis ground normal?
From A _
Max. 1 R -Turn starting switch OFF. . Disconnect L133. l
*
NO
The related electrical circuit diagram is the same as that for V-21.
WA1 200-3
See V-21.
20-849 0
TROUBLESHOOTING
V-23 J,
J, *
V-23
[E934] [Clogging of air cleaner (3)] 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 CGC 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
‘ES
I
If connector B08 is disconnected, does failure code disappear?
*Turn starting switch OFF. - Disconnect 808. * Turn starting switch ON.
Defective dust indicator 3
Y FS
Defective dust indicator relay 3
relay 3 is replaced h
l
4 YE! Ir Is resistance betYES ween ~36 (female) _ 3 (3) and L134 - bat(female) (6) normal? Is resistance ween Bo8 (female) P _ -Max.lQ N( - (1). L134 (female) (2) *Turn starting h10 and chassisground switch OFF. normal? . Okconnect V3B and L136 * Max. 1 D -Turn starting NO switch OFF. . Disconnect BOB and L134.
From A [groundnormal? c
Max. 10 * Turn starting switch OFF. - Disconnect L134.
-
1i I
I
NO
GotoA.
-
Disconnection or defective contact in wiring harness between V3B (female) (3) L134 (female) (6)
Repair or replace
Contact of wiring harness between 808 (female) (1) L134 (female) (2) with GNC harness or chassis ground
Repair or replace
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between
qepair or
1134 (female) (3) chassis ground
The related electrical circuit diagram is the same as that for V-21.
20-850 0
Replace
I
*Turn starting switch OFF. Replace with another relay. * Turn statting switch ON.
*
Remedy
See V-21.
WA1 200-3
V-24
TROUBLESHOOTING
V-24
[E935] [Clogging
of air cleaner (411 is displayed
j,
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 positio& if the error code is no longer displayed on the CGC 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
is disconnected, does failure code - Turn starting
Defective dust indicator 4
Replace
Defective dust indicator relay 4
Replace
If dust indicator
GotoA. Is resistance disaopear?
switch ON.
- Turn starting mritch OFF. . Replace with another relay. . Turn starting switch ON.
- Is resistance
Is resistance betwen L135 (female)
Max. 1 R *Turn starting switch OFF. . Disconnect L135.
*
11
(3) and chassis ground normal? 0
bet-
V3B (female) _ and Ll35 (female1(6) normal?
yEs
wee”
3
(4)
NO
-
bet-
wsen 609 (female) .Msx.lR NC - 11).L135 (female) (2) *Turn starting NO and chassis ground switch OFF. normal? . DisconnectV3B and L135 * Max. 1 R * Turn starting NO switch OFF. - Disconnect BO9 and L135.
5 YES
1 From A -
Remedy
Disconnection or defective contact in wiring harness between V3B (female) (4) L135 (female) 16)
Repair or replace
Contact of wiring harness between B69 (female) (1) L135 (female) (2) with GND harness or chassis ground
Repair or replace
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between L135 (female) (3) chassis ground
Repair or replace
The related electrical circuit diagram is the same as that for V-21. See V-21.
WA1 ZOO-3
20-851 0
v-25
TROUBLESHOOTING
*
* * *
charge by alternator)
[E9371 (Abnormal
V-25
is displayed
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting 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 CGC monitor display, the problem has been removed. Perform the following troubleshooting when fuse 1410) is not broken. If fuse IO is broken, check the wiring harness between the fuse and L152 for short circuit with the chassis ground. 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
Gotok
Remedy
-
/ES
-Max.ln
. Turn starting switch OFF. - Disconnect L152 and ERl IO
alternator terminal R and chassis .28t2V * Start engine.
I
NO
NO YES
6 Is resistance YES bstweenV2A r; l-l (female) (4) and
- Max.
1V . Turn starting switch OFF. * Disconnect L152 and ERl.
V-25 Related
srenal
electrical
NO
II
._
NI
Disconnection or defective contact in wiring harness between L152 (female) 12) - ERl (female) 6)
Repair or replace
Disconnection or defective contact in wiring harness between FS2 (male) (9) am L152 (female) (1). (3)
Repair or replace
Defective alternator signal relay fL152)
Seplace
Defective alternator
qepair or rplace
Defective VH MS controller
qeplace
Disconnection or defective contact in ti!ing harness between V2A (female) (4) L152 (female) (6)
qepair or aplace
Short circuit with power source in wiring harness between L152 (female) (21- ERl (female) (5)
qepair or ‘eplace
circuit diagram
relay
TJW07.537
20-852 0
WA1 200-3
v-10-I
TROUBLESHOOTING
v-101 * * f *
[E8111 (Abnormality in history
in NSVV power source system) is displayed
Perform the following troubleshooting when fuse 1413) is not broken. If fuse I-113)isbroken, check the wiring harness between the fuse and VHMS for short circuit with the chassis ground. 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. Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design), its disconnection is not taken up as a cause.
Cause
1 YES Isvoltage between Vl (6) and chassis around normal? *20-30V * Turn starting switch ON.
V-101
Related
NO
electrical
VHMS
Remedy
Defective VHMS controller
Replace
Disconnection, defective contact, or short circuit with power source in wiring harness between Vl (female) (6) - F63 (5) -fuse - FS3 (6) - battery relay terminal 6 - battery (+)
Repair or replace
circuit diagram
controller Fuse (I)
Bat terv
Slow
blow
Battery
\ ROI
R02.B
f TJWO2538
WA1 200-3
20-853
TROUBLESHOOTING
V-102 * *
v-102
[E812] (Short circuit with chassis ground sensor power supply)
in 24-V circuit of
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.
Remedy
Defect of sensor, disconnection of which turns off failure code
YES 1 If MT 2,3.4, and 5 are disconnected one by one, does failure code
Defect of sensor, disconnection of which turns off failure code
YES
-
I Short circuit with chassis
-Turn starting
ground in wiring harness between JT~ (female) (2). (3). 14). (5) -MT 5 (female) (2). MT4 (female) (2). MT3 (female), (2)) MT2 (female) (2)
4 YES
turn starting switch OFF. When disconnecting each connector, turn starting switch ON.
If JT2 is 1disconnected, does failure code disappear?
codedisappear? * Turn starting switch ON. -When connecting each connector, turn starting switch OFF. When disconnecting
between pins of JT2
i - Turn
startina switch ON. -
Repair or replace
-
Go to A. NO
I *Turn starting .switch . ._ON.
,.
1 Eective
JT2, JR14, or
Replace
Repair or replace
-Turn starting switch ON.
1disconnected.
11
P
1normal7 - Min. 1 MR - Turn starting switch OFF. - Disconnect Vl and JL2.
20-854 0
IU N
Short circuit with chassis ground in wiring harness between JL2 (female) (4) JTZ (female) 11)or between JL2 (female) (5) - JR14 (female) (1)
Repair or replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) JU (female) (3)
Repair or replace
WA1 200-3
TROUBLESHOOTING
V-102
Related
electrical
v-102
circuit diagram
Transmission main relief Pressure sensor
VHMS
Con t ro I ler
Torque outlet Pressure
v, ~07020~
converter oil sensor
Torque converter inlet oil Pressure sensor Transmission modulated Pressure
oil sensor
J T2 (DT2)
Front brake oil Pressure sensor Rear brake oil Pressure sensor Work eauipment relief oil Dressure sensor Steering relief oil Pressure sensor
Pressure
sensor TJW02533
WA1
200-3
20-855 0
TROUBLESHOOTING
V-103 * *
v-103
[E813] (Short circuit with chassis ground in 12-V circuit of sensor power supply)
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.
Remedy
Cause
YES 1 If F15 is disconnected, _ does failure code disappear? *Turn starting switch ON. NO
2 Is resistance betweenV1 (female) (3) and
YES x -
chassis ground
normal?
- Min. l
l
V-103
Related
NO
1 MQ Turn tiarting switch OFF. Disconnect VI and F15.
electrical
circuit
Defective wheel rotation sensor
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (3) F15 (female) (1 J
Repairor replace
diagram
Wheel VHMS controller )OUtPUt
Vl (07020) (t24v)]307/
FL2 (HD-25086) 3
E
307
Fl 5 (DT2) 0.75fG
rotat
ion
sensor
1 307
TJW02540
20-856 0
WA1 200-3
v-104
TROUBLESHOOTING
[E814] (Short circuit with chassis ground in 5-V circuit of sensor power supply)
V-104 * f
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. Remedy
Y ES
YES
disappear?
I
* Turn starting switch ON. Is resisrance between (female)
-
Vl (5) and
If R05 is YES disconnected, does failure code disappear? * Turn starting 2 Ne switch ON.
normal? 1 MR Turn starting switch OFF. . Disconnect Vl and MTl.
- Min. *
NO
5 YES between Vl (femaie) (4) and
From A
~&ahaground
Min. 1 MR * Turn starting switch OFF. * Disconnect Vl and AES3 l
V-104
Related
electrical
-
chassis ground * Min. 1 MR - Turn starting switch OFF. * Disconnect R05 and RES3.
ND chassis ground
Replace
Defective fuel level sensor
Replace
-
Gotok between R05 (female) (1) and ll0rmal7
-
Defective transmission lubricating oil pressure sensor
11 NO
Nf
1
Short circuit with chassis ground in wiring harness between R05 (female) (1) - RES3 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between Vl (female) (5) MT1 (female) (2)
Repair or replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (4) RES3 (female) 1
Repair or replace
circuit diagram
VHMS controller
RT2 (HD-85086)
Transmission oil lubricating sensor Pressure
TJW0254 I
WA1 200-3
20-857 0
TROUBLESHOOTING
V-105
V-105 [E818] (Wrong connection of connector) is displayed in history fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.
Cause
1 YES Is voltage between V2A (9), (12), V3A (9), V3 B (12) and chassis ground as shown in Table 1?
NO
Remedy
Defective VHMS controller
Replace
Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness of improper voltage
Repair or replace
Table 1 V2A (9) – chassis ground V2A (12) – chassis ground V3A (9) – chassis ground V3B (12) – chassis ground
Voltage (V)
20 – 30 V
0–5V
0–5V
20 – 30 V
V-105 Related electrical circuit diagram
20-858 20-858 2 (8)
WA1200-3
TROUBLESHOOTING
V-107 * *
v-107
[E824] (Communication with CGC and engine controller impossible) is displayed in history
is
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
Defective CGC, engine 4YE! 5 controller, or VHMS I IS voltaae between controller
Ir
IU
m m.*, w’mdcz uem. bmw.3mJL, uamaw,z d 01 Uemde, K m * hllll JL1 L‘nmdd II, _._
E-II
ween JLl (male) (1) and (2) and (6) and between JLl (3) and
- Turn starting switch OFF. - Disconnect JLl .
V-107
Related
H
*Min.lMQ * Turn starting nnritch OFF. * Disconnect JLl. C2. Dl, and V4A.
NO no switch OFF. - Disconnect jL1, C2, Dl, and V4A.
I NO
electrical
1 NO
Short circuit with power source in wiring harness 1 having abnormal value Short circuit with chassis
,ground in wiring harness Ihaving abnormal value
Remedy
Replace
Repair or replace
Repair or replace
Disconnection or defective contact in wiring harness having abnormal value
Repair or replace
IDefective joint connector ,TJLl)
Replace
circuit diagram
VH
TJW02543
WA1 200-3
20459 0
TROUBLESHOOTING
V-108 * * *
V-108
fE8251 (Abnormality in S-NET communication between transmission controller) is displayed in history
VHMS -
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. If E826, E827, and E828 occur simultaneously, disconnection, defective contact, short circuit with chassis ground, or short circuit with power source has occurred in the VHMS controller or in the wiring harness between V3A (8) and JL22 (1). CallSo
Go to A.
-. [tWC;;ss~sgrOund 1 1 resistance -Min. 1 MS2 MS betweenV3A Nf . Turn starting (female) (8) and C3B c switch OFF. (female) (4) normal? _ - DisconnectV3A and as. * Max. 2 R - -Turnstarting NO (male) (I) and (8) switch OFF. Disconnect V3A and C3B. Is
I
Short circuitwith chassis ground in wiring harness between V3A (female) (8) - C3B (female) (4) Disconnection or defective contact in wiring harness between WA (female) (8) - C3B (female) (4)
Remedy
-
Repair or replace
Repair or replace
l
NO
(male) (1) and (2)
Defective joint connector (JL22)
Replace
Defective joint connector (JL17)
Replace
Disconnect JL22.
- Max.
1D * Turn starting switch OFF. -Disconnect JL17.
I NO
I Is resistance
II
Go to B.
-
Replace
FromA
i=
- Max.
1V * Disconnect V3A and C3B. *Turn starting switch ON.
From B -)
* Turn starting switch OFF. * Disconnect JL18.
1 1
NO
10 YE:
Is voltage between YES ~38(female) 112) and chassis 9 ground normal? 1s resrstancebeYES tween VW (female) * Max. 1 V NI - (18). C3B (female) . DisconnectV3A (12) and chassis 8 and US. ground normal? Is resistance *Turn starting switch ON * Min. 1 MR betweenV3A (female) (18) and Turn starting NO r.Z3;.Z;,male)112) switch OFF. Disconnect V3A = Max. 2 R and C3B . Turn starting NO switch OFF. * Disconnect V3A and C3B. l
l
20-860 0
NO
Defective joint connector (JL18)
Replace
Short circuit with power source in wiring harness between V3A (female) (8) - C3B (female) (4)
Repair or replace
Defective transmission controller
Replace
Short circuit with power source in wiring harness between V3A (female) (18) - C3B (female) (12)
Repair or replace
Short circuit with chassis ground in wiring harness between V3A (female) (18) - C3B (female) (12)
Repair or replace
Disconnection or defective contact in wiring harness between WA (female) (18) - C3B (female) (12)
Repair or replace
WA1 200-3
v-109
TROUBLESHOOTING
V-109
* * *
[E826] (Abnormality in S-NET communication between modulated clutch controller) is displayed in history
VHMS -
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. If E825, E827, and E828 occur simultaneously, disconnection, defective contact, short circuit with chassis ground, or short circuit with power source has occurred in the VHMS controller or in the wiring harness between V3A (8) and JL22 (I).
Cause
4YE! IC Is voltage between YES MO1 (female) It) 3 and chassis ground normal?
Is resistancebetween V3A (female) NC . (81,MO1(female) (1) - -Max.lV . DisconnectV3A and chassisground and Mol. normal? *Turn starting switch ON Min. 1 MD Turn starting NO switch OFF. * Disconnect V3A and Mol. l
l
between JU2 (male) (1) and (7)
Remedy
Gotok
Short circuit with power
source in wiring harness between V3A (female) (8) - MO1 (female) (11
Repair or replace
Short circuit with chassis ground in wiring harness between V3A (female) (8) - MO1 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between V3A (female) (8) MO1 (female) (1)
Repair or replace
Defective joint connector (JL22)
Replace
. Disconnect V3A * Turn starting switch OFF. * Disconnect JL22.
I NO
YE 5 Is resistance I between JU3 (male) (1) and (7) normal7 t
From A -I
- Max.
1R -Turn starting switch OFF. . Disconnect JL23.
7 YE: Go to B. Is resistancebetYES ween WA (female) - (18). M01 (female) 6 Short circuit with chassis (12) and chassis Is resistance ground in wiring harness ground normal? between V3A between V3A (female) * Min. 1 MR NC (female) (181and (18) - MO1 (female) (12) . Turn starting MO1(female) (12) switch OFF. normal? * DisconnectWA and MO1 contact in wiring harness sMax.2R betvveen V3A (female) (18) * Turn starting NO - MO1 (female) (12) switch OFF. * Disconnect V3A and Mol. Defective joint connector (JL23) 0
a MS Isvoltage
between MO1 (female) (12) _ and chassis ground normal?
From 0 -
- Max. 1 V Disconnect V3A and Mol. Turn starting switch ON. l
NO
-
Repair or replace
Repair or replace
Replace
Defective modulated clutch controller
Replace
Short circuit with power source in wiring harness between V3A (female) (18) - MO1 (female) (12)
Repair or replace
l
20-862 0
WA1 200-3
v-109
TROUBLESHOOTING
V-109
Related
electrical
circuit diagram
TWW02601
WA1 200-3
20-863 0
TROUBLESHOOTING
V-110
* * *
v-110
between [E8271 (Abnormality in S-NET communication work equipment controller) is displayed in history
VHMS -
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. defective contact, short circuit with disconnection, If E825, E826, and E828 occur simultaneously, in the VHMS controller or in the occurred has source power with circuit chassis ground, or short wiring harness between V3A (8) and JL22 (I).
Cause
4YE! 6
I
c
Gotok
Remedy
-
$SZ&~H I Is resistancebetI IL y~z ween V3A Ifemale) -Max.lV NC - (8). L26 (female) (1) - DisconnectV3A and chassisground 2 and LZ6. normal? . Turn starting switch ON Is resistance Min. 1 MD * YES betweenV3A NO - (female) (8) and LZ6 - * Turn starting switch OFF. (female) (1) normal? 1 * Disconnect V3A Is resistance *Max.2!.2 and L26. _ *Turn starting between JL22 NO (male) (1) and (2) switch OFF. normal? * Disconnect V3A
- Max.
1R . Turn starting switch OFF. . Disconnect JL22.
-I
NO
I Is resistance between JL23 (male) (1) and (2) normal?
I I I
- Max.
1R -Turn starting switch OFF. . Disconnect JL23.
_ Is resistance ; betweenV3A - (female) (18) and L26 (female) (12) “o”nal?
lMax.2R . Turn starting switch OFF. Disconnect V3A and L26.
Disconnaction or defective contact in wiring harness between V3A (female) (8) L26 (female) (1)
Repair or replace
Disconnaction or defective contact in wiring harness between V3A (female) (8) U6 (female) (1)
Repair or replace
Defective joint connector (JU2)
Replace
IO
Is voltage between _ L26 (female) (12) and chassis ground normal?
From S _
*Max.lV Disconnect V3A and L26. -Turn starting switch ON. l
7 YE! Is resurtancebetYES wee” V3A (female) - (181.L26 (female) 6 (121and chassis ,ground normal? . Min. 1 MQ N( *Turn starting switch OFF. * DisconnectV3A and LZ6 NO
Go to 0.
-
Short circuit with chassis ground in wiring harness between V3A (female) (18) - L26 (female) (12)
Repair or replace
Disconnection or defective contact in wiring harness between V3A (female) (181 - L26 (female) (12)
Repair or replace
Defective joint connector (JK3)
Replace
Defective work equipment controller
Replace
Short circuit with power source in wiring harness between V3A (female) (18) - L26 (female) (12)
Repair or replace
l
8 YES
20-864 0
Repair or replace
and L26.
Y
From A
Short circuit with chassis ground in wiring harness between V3A (female) (8 - l.26 (female) (1)
NO
WA1 200-3
v-110
TROUBLESHOOTING
V-110
Related
electrical
circuit diagram
II
II
II
TWW02601
WA1 200-3
20-865 0
v-111
TROUBLESHOOTING
V-l 11 [E828] (Abnormality in S-NET communication main monitor) is displayed in history * * *
between
VHMS -
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. If E825, E826, and E827 occur simultaneously, disconnection, defective contact, short circuit with chassis ground, or short circuit with power source has occurred in the VHMS controller or in the wiring
between
harness
V3A (8) and JL22 (1). CaUSS!
GotoA.
(female) (8) and LO8 (female) (11 normal? aMax.2R * Turn starting switch OFF. * Disconnect V3A and L08.
(male) (1) and (8) normal? between JL17 (male) (1) and (6) .Max.lR *Turn starting switch OFF. . Disconnect JL17.
*Max.lR . Turn starting switch OFF. . Disconnect JU2.
1
. DisconnectWA and L08.
NO
NO
7 YE YES 6
From A -c
From 6 -)
Is resistance _ * Max. 1 R YES_ between JL18 NC -Turn starting (male) (1) and (6) 5 normal? switch OFF. Is voltage between * Disconnect JU3. - Max. 1 D Lo8 (female) (1) * Turn starting NO and chassis switch OFF. ground normal? - Disconnect JL18. . Max. 1 V * Disconnect V3A NO and L08. * Turn starting switch ON. 10 YE!
Is resistance betweenV3A (female) (18) and LO8(female) (3) _normal? * Max. 2 R -Turn starting switch OFF. * Disconnect V3A and L68.
20-866 0
Is resistance between JL23 (male) (1) and (8) normal?
Is voltage between YES LO8 (female) (3) and chassis 9 ground normal? Is reswance bet- yes waen WA (female) *Max.lV N( - (181. LO8(female) (3) s DisconnectV3A ground chassis and 8 and L08. normal? * Turn starring switch ON . Min. 1 MR - . Turn starting NO _
switch OFF. * Disconnect V3A and LO8 NO
Remedy
-
Short circuit with chassis ground in wiring harness between V3A (female) (81 - LO8 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between V3A (female) (8) LO8 (female) (1)
Repair or replace
Defective joint connector (JL22)
Replace
Defective joint connector (JL17)
Replace
Go to 8.
-
Defective joint connector (JL23)
qeplace
Defective joint connector (JL18)
?eplace
Short circuit with power source in wiring harness between V3A (female) (8) - Lo8 (female) (1)
qepair or aplace
Defective main monitor
Replace
Short circuit with power source in wiring harness between V3A (female) (18) - Lo8 (female) (3)
Repair or replace
Short circuit with chassis ground in wiring harness betwean V3A (female) (18) - Lo8 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between V3A (female) (18) - Lo8 (female) (3)
Repair or replace
WA1 200-3
v-102
TROUBLESHOOTING
V-111 Related
electrical
circuit diagram
Transmission ontroller
TWW02601
WA1 200-3
20-867 0
v-113
TROUBLESHOOTING
V-l 13 [E8411 (Short circuit with power source in buzzer output system) is displayed in history * f
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
1 YES voltage between Vl (female) (16) and chassis ground normal? Is
NO
* Max. 1 V - Turn starting switch OFF. * Disconnect Vl and L9g. Turn starting switch ON.
inserted.
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between Vl (female) (16) - I39 (female) (2)
Repair or rePlace
l
V-113 Related electrical circuit diagram Emergency Parking brake cancel switch Main
monitor
L89
LO6 (040 16)
(M4)
0.5fL VHMS controller
Caution relay
Vl
buzzer
(07020)
FS2
(S12
Blue)
Fues (I)
Caution buzzer
TJW02518
WA1 200-3
20-869 0
v-114
TROUBLESHOOTING
V-114 * J,
[E843]
(Short circuit with power source in check lamp system) is displayed in history
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
Is voltage between Vl (female) (14)
* Max. 1 V -Turn starting switch OFF. . Disconnect VI and L06. * Turn starting switch ON.
V-l 14 Related
NO
electrical
VHMS Controller
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between Vl (female) (14) - LO6 (female) (10)
Repair or replace
circuit diagram
Main
monitor
TJW02545
20-870 0
WA1 200-3
TROUBLESHOOTING
V-115
v-115
[E844] (Short circuit with power source in flash synchronizing signal system) is displayed in history
*
Before carrying out troubleshooting,
Ir
Always
connect
any disconnected
check that all the related connectors are properly connectors before going on to the next step.
Cause
1 YES Is voltage between Vl (female) (13) and chassis ground normal? ; Max. 1 V * Turn starting switch OFF. * Disconnect Vl and L07. *Turn starting switch ON.
V-115
Related
NO
electrical
VHMScontroller
WA1 200-3
circuit
inserted.
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between Vl (female) (13) - LO7 (female) (6)
Repair or replace
diagram
Main
monitor
20-871 0
TROUBLESHOOTING
V-116 *
* *
V-116
[E861] (Disconnection or short circuit with chassis ground in boom bottom pressure sensor system) is displayed-in history
Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the wiring harness between the fuse, VHMS controller, and F06 (female) (2) for short circuit with the chassis ground. 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
*
4YES .I
Is resistance betYES ween ~06 (female) _ NO Max. 10 (31 and chassis * Turn starting switch 2 _ ground normal? OFF. If F06 (female) (3) is - Disconnect JF3. YES groqded to chassis, * Min. 1 MR _ IS resonancebetween _ Turn starting NO Vl (female1 (1) and switch OFF. 1 ck%?grc”“d n 1 * Disconnect Vl *Max.10 and F06. Turn starting of boom head NO pressure switch, is switch OFF. * Disconnect Vl and F06. . Turn starting switch ON. NO l
l
YES
From A
-
Max. 1 Q -Turn starting switch OFF. . Disconnect F06 and Vl.
204372 0
NO
Go to A.
Is resistance between JF3 (male) (1) and (4)
YES 3 r
l
Remedy
Defective joint connector (JF3) Short circuit with chassis ground in wiring harness between Vl (female) (1) FfE (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between Vl (female) (1) F06 (female) (3)
Repair or replace
Defective boom bottom pressure sensor
Defective VHMS controller Disconnection or defective contact in wiring harness between Fo6 (female) (2) - Vl (female) (81, (9)
Repair or replace
WA1 200-3
TkOUBLESHOOTlNG
V-116
Related
electrical
V-116
circuit diagram
VHMS
Boom bottom pressure sensor
TWW02602
WA1 200-3
20-873 0
v-117
TROUBLESHOOTING
V-117
*
* *
[E862] (Disconnection or short circuit with chassis ground in boom head pressure sensor system) is displayed in history
Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the wiring harness between the fuse, VHMS controller, and F14 (female) (2) for short circuit with the chassis ground. 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
4YES ez
8 _ &_ If F14 (female) (31 if yES groundedto chasrx _ I* resistancebetween _ Vl (female)
(10) and
chassisground
ground normal? * Min. 1 MD - Turn starting switch OFF. Disconnect Vl and F14. NO l
replaced with that of boom bottom pressure switch, is
*Turn starting switch OFF. Disconnect Vl and F14. l
*Turn starting switch ON.
NO
From A
-
Max. 1 Q * Turn starting switch OFF. * Disconnect F14 and Vl.
20-874 0
i---NO
Is resistance betweenJF3 (male) (1) and (5) normal? .Max.lR NO *Turn starring switch OFF. * Disconnect JF3. NO
Gotok
Remedy
-
Defective joint connector (JF3)
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (10) - F14 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between Vl (female) (10) - F14 (female) (3)
Repair or replace
Defective boom head pressure sensor
Replace
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between F14 (female) (2) - Vl (female) (81, (9)
Repair or replace
WA1 200-3
TROUBLESHOOTING
V-l 17 Related
electrical
v-102
circuit diagram
VHMS controller
TJW02548
WA1 200-3
20-875 0
TROUBLESHOOTING
V-118
* * *
V-118
[E863] (Disconnection or short circuit with chassis ground in rea.r brake oil pressure sensor system) is displayed in history
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. If E864, E865, E867, and E868 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14 (female) (1).
Cause
1 1 If rear brake oil 1 pressuresensor is
1
1
Defective rear brake oil pressure sensor
I
4YE Ilf HR16 (female) (2) is
Ir
. Turn starting switch OFF. * Replace pressure sensor normal -Turn switch
with one.
JR14 (male) (1) and (5). between JL2
- Max. * Turn
starting ON. - Max. 1 Q -Turn starting switch OFF. . Disconnect JR14, Jl2, or JR13.
1R starting switch OFF. * Disconnect HR16 and V2k
I Vl. NO
IO
7 YE!
I Is resistance bet-
YI
From
Aie/ lMax.lR . Turn starting switch OFF. . Disconnect HR16.
20-876 0
,~~~
* Turn starting switch OFF. * Disconnect V2A and HR16.
NO
1r
GotoA.
Remedy
Replace
-
contact in wiring harness between Vl (female) (2) HR16 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between Vi% (female) (8) HR16 (female) (31
Repair or replace
Joint connector having improper resistance (JR14, JL2, or JR131
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) HR16 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (8) - HR16 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between HR16 (female) (1) -chassis ground
Repair or replace
WA1 200-3
TROUBLESHOOTING
V-118
Related
electrical
V-118
circuit diagram
VH
JRl3tDTlB)
e
Battery
RAlO
(DTHD4)
8L
TJW02531
WA1 200-3
20-877 0
v-119
TROUBLESHOOTING
[E864] (Disconnection or short circuit with chassis ground in work equipment relief pressure sensor system) is displayed in history
V-119
inserted. +r Before carrying out troubleshooting, check that all the related connectors are properly step. next the to on going before * Always connect any disconnected connectors short If E863, E865; E867, and E878 occur simultaneously, disconnection, defective contact, or * JR14 and (2) (female) VI between harness wiring the in occurred has ground circuit with chassis (I). (female)
Cause
Defective work equipment relief pressure sensor
MS
I r
I
sensor is replaced with normal one,
is
system normal?
. Turn starting switch OFF. Replace pressure sensor normal wth one. (steering oil pressure sensor) * Turn starting switch ON.
l
If HSZ Ifemale I31 is grounded to chassis, is resistance between WA
YI
(181 and Ifemale)
2
chassis
round normal?
1If HS2 3
- Max. 1 R switch starting *Turn OFF. HS2 and * Oisconnect
NO
0
7 YE!
5
I * Turn starting switch OFF. Disconnect V2A and HS2.
l
*Max.lR * Turn starting switch OFF. D&connect HS2,
NI
Vl.
1 tS
FromA ~~~0{~~
Gotok
(2) is
switch OFF. * Disconnect HS2 and WA.
- Max. 1 R * Turn starting switch OFF. * Disconnect JR14, JL2, JRl6, or JR13.
1Is resistance
Ifemale)
grounded to chassis, is resistance between Vl bnale) (2) and chassis round normal?
YES
IO
NO
resistanca bet-
ir
Remedy
Replace
-
Disconnection or defective contact in wiring harness between Vl (female) (2) HS2 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness behveen V2A (female) (18) - HS2 (female) (3)
Repair or replace
Joint connector having improper resistance fJR14, JL2, JR16, or JR13)
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) HS2 (female) (2)
qepair or .eplace
Short circuit with chassis ground in wiring harness between V2A (female) (18) - HS2 (female) (2)
3epair or pplace
Disconnection or defective contact in wiring harness between HS2 (female) (1) chassis ground
qepair or aplace
l
20-878 0
WA1 200-3
TROUBLESHOOTING
V-l 19 Related
electrical
v-119
circuit diagram
VHMS
r
ipment ii e sensor
Bat terv
RAlO [DTHDI) 000 I
TJW02550
WA1 ZOO-3
20-879 0
TROUBLESHOOTING
V-120
v-120
[E865] (Disconnection or short circuit with chassis ground in front brake oil pressure sensor system) is displayed in history
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted. Jr Always connect any disconnected connectors before going on to the next step. Ir If E863, E864, E867, and E878 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14 (female) (1 I.
Cause
Defective front brake oil pressure sensor
4YES tf HR15 (female) CZ! is YES _
* Turn starting switch OFF. - Replace pressure sensor with normal one. (rear brake oil pressure sensor) . Turn starting switch ON.
n 2
~0
Is resistance between JR14 (male) (1) and (6). between JLZ (male) (3) and (51, or betwean JR13 (male) 1 and 6 normal?
‘I,,, -Max.1 R -Turn starting switch OFF. Disconnect JR14, JL2, or JR13.
3 If HR15 (female)(3) is groundedto chassis. is resistancebetween _ WA (female)(7) and f;~~7ground * Max. 1 R * Turn starting switch OFF. . Disconnect HR15 and V2A.
GotoA
Remedy
Replace
-
groupded to chassis, IS resistance between _
;f;;kNand normal? aMax.lC.2
NC
* Turn starting switch OFF. - DisconnectHRlS and Vl. NO
IO
Disconnection or defective contact in wiring harness between Vl (female) (2) HRl5 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between VZA (female) (7) HRl5 (female) (3)
Repair or replace
Joint connector having improper resistance (JR14, JL2, or JR131
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) HR15 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between VZA (female) (7) - HR15 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between HR15 (female) (1) -chassis ground
Repair or replace
l
7 YES 1IS resistance bat-
M
~
5
I Isresistance From A dig::;
I 1
* Max. 1 R Turn starting switch OFF. * Disconnect HR15.
- Turn starting switch OFF. * Disconnect V2A and HR15.
l
20-880 0
0
NO
1r
WA1 200-3
TROUBLESHOOTING
V-120
Related
electrical
v-120
circuit diagram
VHMS
r
JR13tDTIB1
Fran t brake oi I Pressure
TJW07.530
WA1 200-3
20-881 0
v-121
TROUBLESHOOTING
[E866] (Disconnection or short circuit with chassis ground in transmission main relief pressure sensor system) is displayed history
V-121
* * +
in
Before carrying out troubleshooting, check that ail the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between Vl (female) (2) and JT2 (female) (1).
Cause
Defective transmission main relief pressure sensor
sensor is replaced
Yl
* Turn starting switch OFF. . Replace pressure sensor with normal one. - Turn starting switch ON.
Imale) (1)and12).kwaen JLZImaW(31and (0.
* Max. 1 n Turn starting switch OFF. * Disconnect JTZ, JL2, JT3, or JLll.
4YEI If MT2 (female)(2) is MS groundedto chassis, _ 1sresistancebetween _ Vl (female)(2) and 3 chassisground If MT2 (female)(3) is normal? , groundedto chassis, NC is resistancebetween _ .Max.lQ *Turn starting switch OFF. , * DisconnectMT2 and Vl. * Max. 1 Q *Turn starting NO switch OFF. . Disconnect MT2 and WA.
l
0 7 YES Yl 6
1Is resistancebetYE
. Min. 1 MQ NO *Turn starting switch OFF. - DisconneciVl and
6 I Is resistance
From A
-f%$%~ .Max.lR * Turn starting switch OFF. Disconnect MT2.
iS[
1
1 . Min. 1 MR - Turn starting switch OFF. . Disconnect VZA and MTZ.
0
Go to A.
Remedy
Replace
-
Disconnection or defective contact in wiring harness between Vl (female) (2) MT2 (female) (2)
Repair or replace
Disconnsction or defective contact in wiring harness between V2A (female) (6) MT2 (female) (3)
Repair or replace
Joint connector having improper resistance (JTZ, JK, JT3, or JLll)
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) MT2 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between VZA (female) (6) - MT2 (female) (3)
Repair or replace
Disconnection or dsfsctive contact in wiring harness between MT2 (female) (1) chassis ground
Repair or replace
l
20-882 0
WA1 200-3
TROUBLESHOOTING
V-121
Related
VHMS .._
electrical
v-121
circuit diagram
Transmission main relief ensor
TJWO2552
WA1 200-3
20-883 0
V-122
TROUBLESHOOTING
[E8671 (Disconnection or short circuit with chassis ground in steering relief pressure sensor system) is displayed in history
V-122
* f *
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. If E863, E864, E865, and E878 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14 (female) (1).
Cause
ES
Defective steering relief pressure sensor
1
GotoA.
1
1 If steering relief
switch OFF. - Replace pressure sensor with normal one.
(1)ad (41.between (male) Bland(5). JU Imale) 121 JR16(male1 berwem JR13 and(41.or-
switch ON. Max. 1 R * Turn starting switch OFF. * Disconnect JR14, JU, JR16, or JR13. l
- Mar
1R *Turn starting switch OFF. * Disconnect HS3 and V2k
1
Vl.
NO
7 YES
Ai61 - Max. 1 R - Turn starting switch OFF. * Disconnect HS3.
20-884 0
normal
IO
I
. _. -MI2
ween VZA (female) (16). HS3 (female)
* Min. 1 MD * Turn startino switch OFF.. Disconnect V2A and HS3.
contact in wiring harness between Vl (female) (2) HS3 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between WA (female) (16) - HS3 (female) (3)
Repair or replace
Ir
Defective VHMS controller
Replace
IL
Short circuit with chassis ground in wiring harness between Vl (female) (2). HS3 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (16) - HS3 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between HS3 (female) (1) chassis ground
Repair or replace
(21, HS3 (female) (2) and chassisground
YE
-
Joint connector having improper resistance (JR14, JU, JR16, or JR13)
I IS resistancebet-
From
Remedy
-Turn starting switch
1
- DisconnectVI and HS3.
NO
NC
WA1 200-3
TROUBLESHOOTING
V-122
Related
electrical
v-122
circuit diagram
VHMS
Steering relief
oil sensor
TJW02553
WA1 200-3
20-885 0
v-123
TROUBLESHOOTING
V-123
* * *
[E8681 (Disconnection or short circuit with chassis ground in torque converter outlet oil pressure sensor system) is displayed in history
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. If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause
Defective torque converter outlet oil pressure sensor
YES
1 rlf tOmu
000v.3-ter
outlet oil pressure sensor is replaced
* Turn starting switch OFF. * Replace pressure sensor with normal one. - Turn starting switch ON.
and(4). betwen JKlmabJfllaed(41, ImaId
lMax.lR *Turn starting switch OFF. Disconnect JT2, Jl.2, JT3, or JLl 1.
4YE! If MT3 Wemale)(2) is chassis, to YES grounded _ ts resistancebetween _ Vl (female)(2) and 3 chassis,ground If MT3 (female)(3) is -gfUMf. ; gmundedto chassis, * Max. 1 n NC . ISresistancebetween _ *Turn starting switch WA (female)(5) and OFF. &&siiTground - DisconnectMT3 and Vl. . Max. 1R *Turn starting NO switch OFF. . Disconnect MT3 and V2k
IO
Gotok
Remedy
Replace
-
Disconnection or defective contact in wiring harness between Vl (female) (2) MT3 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between ‘&!A (female) (5) MT3 (female) (3)
Repair or replace
Joint connector having improper resistance (JT2, JU, JT3, or JLll)
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) MT3 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (5) - MT3 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between MT3 (female) (1) chassis ground
Repair or replace
l
YI 5 I Is resistance From A ~~~rr?.~~
*MaxlR * Turn starting switch OFF. - Disconnect MT3.
20-886 0
I
7 YE! Is resistance betyEs ween Vl (female) - (2). MT3 (female) (2) 6 and chassis ground Is resistancebetnormal? --Min. 1 MS2 wean WA (female) NC (5).MT3(female) (31 - * Turn starting switch and chassisground OFF. normal? * DisconnectVl and MT3. * Min. 1 MR NO * Turn starting switch OFF. * Disconnect WA and MT3.
WA1 200-3
v-123
TROUBLESHOOTING
V-123
Related
VHMS
electrical
circuit diagram
Tome outlet
converter oil ensor
TJW02554
WA1 200-3
20-887 0
V-124
TROUBLESHOOTING
V-124
f * *
[E8711 (Disconnection or short circuit with chassis ground in transmission modulation pressure sensor system) is displayed in history
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. defective contact, or short disconnection, if E864, E865, E867, and E878 occur simultaneously, VI (female) (2) and JT2 between circuit with chassis ground has occurred in the wiring harness
(female) (I 1.
Cause
Defective transmission modulation pressure sensor
YES
4YE If MT5 (female) (2) is to chassis, gryded IS resistance between Vl (female) (2) and
yEs _ 3
* Turn starting switch OFF. - Replace pressure sensor with normal one. Turn starting switch ON.
l
n i I
- Max. 1 Q starting switch N’ ‘$
FoEi&ground
Max. 1 R - Turn starting switch OFF. * Disconnect MT5 and WA. -
JL2 (male) 13)and(4). bshwnJT3lmakl~1lad U. orbetwen JLll ImaW
.Max.lR . Turn starting switch OFF. mDisconnect JT2, JL2, JT3, or JLll.
- Disconnact Vl.
MT5 and
NO
JO
7 YE Is resistance bet-
5 I Is resistance
From A
-jz;?tt -
Max. 1 R * Turn starting switch OFF. . Disconnect MT5.
20-888 0
I * Turn starting switch OFF. . Disconnect V2A and MT5
NO
Replace
-
_
~o~$ground
If MT5 (femalejob
; groundedto chassis, . ISresistancebetween v2A (female)(151and -
Remedy
fr
Disconnection or defective contact in wiring harness between Vl (female) (2) MT5 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between V2A (female) (15) - MT5 (female) (3)
Repair or replace
Joint connector having improper resistance (JT2, JL2, JT3, or JLll)
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) MT5 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (15) - MT5 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between MT5 (female) (1) chassis ground
Repair or replace
WA1 200-3
TROUBLESHOOTING
V-124 Related
electrical
v-124
circuit diagram
I sor
TJW02555
WA 1200-3
20-889 0
TROUBLESHOOTING
V-125
* *
v-125
[ES721 (Disconnection or short circuit with chassis ground in transmission lubricating oil pressure sensor system) is displayed in history
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
Defective transmission lubricating oil pressure sensor
4YE! 1 If MT1 (female) (2) is transmlsslon yEs younded to chassis, lubricatingoil _ u.resistancebetween_ pressure sensor is Vl (female1(5) and 3 replaced with chassisgmund normal one, is It MT1 &zmale)(3) is YES youndedtochassis, RQRMR 1:. em normal? _ 1sresisrancebenueen _ -Max.lQ NC * Turn starting *Turn starting switch VZA (female)(14) and switch OFF. 2 r;h%&s$ground OFF. - DisconnectMT1 and * Replace pressure Is resistance betVl. * Max. 1 R ween .JT5 (male) (1) sensor with and (5) and between Turn starting normal one. NO NIO JLll (male) (1) and switch OFF. * Turn starting r4) “orr”a’L . Disconnect MT1 switch ON. * Max. 1 R and VZA. * Turn starting NO switch OFF. l
Gotok
Remedy
Replace
-
Diaconnaction or defective contact in wiring harness between Vl (female) (5) MT1 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between V2A (female) (14) - MT1 (female) (3)
Repair or replace
Joint connector having improper resistance (JT3 orJRl1)
Replace
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (14) - MT1 (female) (3)
Repair or replace
Short circuit with chassis ground in wiring harness between Vl (female) (5) MT1 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (14) - MT1 (female) (3)
Repair or replace
* Disconnect JT3 and JR11 BYE:
YI 6 Is resistance yes
wen
V2A
bet-
(female)
- (14). MT1 (female) Is resistance
From A betwee” MT1 (female) (1) and chassisground normal? . Max. 1 R * Turn starting switch OFF. * Disconnect MTl.
20-890 0
(3) and chassis normal?
5
, ground -
.
- Min. 1 MD -Turn starting switch OFF. * Disconnect V2A and MTI. NO
* Turn starting switch OFF. + Disconnect Vl and MTl. uo
NO
Disconnection or defective contact in wiring harness betwean MT1 (female) (1) chassis ground
Reoair or
WA1 ZOO-3
TROUBLESHOOTING
V-125
Related
electrical
v-125
circuit diagram
Transmission lubricating oil pressure sensor
VHMS
1
rb7
WA 1ZOO-3
TJW02556
20-891 0
V-126
TROUBLESHOOTING
V-126
Ir -k
[E874] (Short circuit with chassis ground in torque converter temperature sensor system) is displayed in history
oil
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 Is reGstanc8between YES WA (female) (3). T24 - (female)(1) and 1 chassisground IlOmMl?
,_ Is resistance between T24 _ (male) (1) and 12) normal? - 40 kf2 at normal temperature (25°C) -Turn starting switch OFF. * Disconnect T24.
YES
NO *Min.lMR *Turn starting switch OFF. . Disconnect V2A and T24. NO
V-126 Related electrical circuit diagram VHMS
controller
20-892 0
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (3) - T24 (female) (1)
Repair or replace
Defective torque converter oil temperature sensor
Replace
Torque convert er oil temperatur e I_--.__ sensor unon I Ior) kUKl
WA1 200-3
TROUBLESHOOTING
V-127
V-127
[E8751 (Short circuit with chassis ground and with power source in hydraulic oil temperature in history
* *
sensor system) is displayed
check that all the related connectors are orooerly Before carrying out troubleshooting, ’ Always connect any disconnected connectors before going on to the next stei.
Cause
3 YES Ez 2 PIs rasisIaGce belwaan y~z -
chassisground
1 _
Is resistance between HSl (male) (1) and (2) normal?
- 3.5 - 4.0 M at normal temperature (25°C) * Turn starting switch OFF. * Disconnect HSl.
V-127 Related
VHMS roller
VZAifemale) IllI. (female) (1) and
HSl
Is voltage between V2A (female) (11) and chassis ground normal? -Max.lV
Remedy
Replace
Short circuit with power p
NO * Turn startingswitch OFF. - DisconnectWA and HSl. *Turn startingswitch ON.
_normal? * Min. 1 MR * Turn starting NO switch OFF. * Disconnect V2A and HSl. NO
electrical
Defective VHMS controller
inserted.
source in wiring harness between V2A (female) (7 1) - HSl (female) (1)
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (female)(l) (ll)-HSl
Repair or replace
Defective hydraulic oil temperature sensor
Seplace
circuit diagram
V2A(07018)
LR2 (HO-85086)
Hrdraul ic oi I sensor
8 2801
TJW02528
WA1 200-3
20-893 0
TROUBLESHOOTING
V-128 * J,
V-128
[E875] (Short circuit with chassis ground in ambient temperature sensor system) is displayed in history
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
Cause
4YE: Is voltage between VIA (female) (10) and chassis ground normal?
YES 3 r - Is resistanoe between ; VZAIfemale)(10).PHl -- Max. 1 v - (female1(1) and - -Turn starting switch
dwsis ground nonal?
Min. 1 MR - Turn starting switch OFF. Disconnect V2A and PHl.
*
* Max. 1 R * Turn starting switch OFF. * Disconnect V2A and PHI.
-
* Approx. 12 kf2 at normal temperature (25’C) *Turn starting switch OFF. - Disconnect PHl.
Related
OFF. - Disconnect
V2A and PHl
NO
IO
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (10) - PHl (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (10) - PHl (female) (1)
Repair or replace
Repair or replace
Defective ambient temperature sensor
NO
VHMS rol ler
Defective VHMS controller
Disconnection or defective contact in wiring harness between V2A (female) (10) - PHl (female) (1)
I
electrical
NC
Turn Rarting switch ON.
l
Is resistance between PH 1 (male) (1) and (2) normal?
V-128
<
_
Remedy
circuit diagram
VZA (070
I81
. temperature LR2 (~~-85086) 0.76fE
TJWO2557
20-894 0
WA1 200-3
v-129
TBQUBLESHOOTING
V-129
* * Ir
[E878] (Disconnection or short circuit with chassis ground in PPC relief pressure sensor system) is displayed in history
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. If E863, E864, E865, and E867 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14 (female) (1).
Cause
YES
Defective PPC relief pressure sensor
1 If PPC relief pressure sensor is replaced with normal one, is system normal? El * Turn starting switch OFF. Replace pressure sensor with normal one. -Turn starting switch ON.
YI 2
l
-Max.
1R * Turn starting switch OFF. * Disconnect JR14 JL2, or JR7.
From A
Is resistance between HS4 - (female) (1) and chassisground normal?
- Max. 1 Q . Turn starting switch OFF. . Disconnect HS4.
20-896 0
4 YE? If HS4 (female)(2) is MS groundedto chassrs, rsresotance between _ 3 - Vl (female)(2) and ;has$ground If HS4 (female)(3) is o a groundedto chassis, N( is r&stance betwean _ - Max. 1 Q -Turnstarting switch V2A (female)(11and chassisground OFF. normal? * Disconnect HS4 and Vl. * Max. 1 R * Turn Starting NO switch OFF. * Disconnect HS4 and V2A. IO
7 YE: Is resistance betyfzs ween Vl (female) - (2). HS4 (female) 12) _ 6 and chassis ground Is resistancebetnormal? YES ween VZALfemale) P * Min. 1 MR NC - (1). HS4Jfemale) (3) - *Turn starting switch and chassisground 5 OFF. ~ normal? . DisconnectVl and * Min. 1 MR I - -Turn NO
starting
Switch ncF _. . . *Discon lnect V2A and HS4. NO
Gotok
Disconnection or defective contact in wiring harness between Vl (female) (2) HS4 (female) (2) contact in wiring harness between V2A (female) (1) HS4 (female) 13)
Remedy
Replace
-
Repair or replace
Repair or replace
Joint connector having improper resistance (JR14, JU, or JR71
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) HS4 (female) (2)
Repair or replace
Short circuit with chassis ground in wiring harness between V2A (female) (1) - HS4 (female) (3)
Repair or replace
Disconnection or defective contact in wiring harness between HS4 (female) (1) chassis ground
Repair or replace
WA1 200-3
v-129
TROUBLESHOOTING
V-129
Related
electrical
circuit diagram
VHMS
JR14tDT2)
e
RA5 (DTt)
RAlO(DTHD4) 000
WA1 200-3
I
20-897 0
v-130
TROUBLESHOOTING
V-130
* * +
[E884] (Disconnection or short circuit with chassis ground in torque converter inlet oil pressure sensor system) is displayed in history
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. If E866, E868, and E871 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause
Defective torque converter inlet oil pressure sensor
YES
iS
.~.
1
If
normal?.
YES
gmu?ded to chassis, IS resmance between _ VZB (female) (10) and
_ - Turn starting switch OFF. 2 ;has$is,ground _ a - o - Replace pressure kresatancebetwenJT2 between (3). ard (1) (male) Max. 1 Q sensor with _ JK Imale) Ill and (3). normal one. NO bSweenJT3Imale)~l)and - -Turnstarting JLll (male) switch OFF. (3).orbetween - Turn starting (11and I21normal? - Disconnect MT4 switch ON. - Max. 1 R and V2B. Turn starting NO switch OFF. * Disconnect JT2, JL2, JT3, or JLll.
IS reststance between Vl (female) (2) and
chassis wo”“d .normal) - Max. 1 R N IO * Turn starting switch OFF. MT4 and *Disconnect
‘ VI. NO
S
7YE 1 Is resistance bet-
II
3 5
Max. 1 R - Turn starting switch OFF. - Disconnect MT4. l
20-898 0
I 1
FromAdgCt%;
- Turn starting switch OFF. - Disconnect V2B and MT4. IO
-
_
l
I Is resistance
Replace
ground&dtc chassis,
YES _
3 svstem
Gotok
Remedy
NO
Disconnection or defective contact in wiring harness between Vl (female) (2) MT4 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between V2B (female) (10) - MT4 (female) (3)
Repair or replace
Joint connector having improper resistance (JT2 JL2, JT3, or JLll)
Replace
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (2) MT4 (female) (2)
qepair or peplace
Short circuit with chassis ground in wiring harness between V2B (female) (10) - MT4 (female) (3)
qepair or .eplace
Disconnection or defective
,contact in wiring harness MT4 (female) (1) ,chassis ground 1between
Iepair or ,eplace
WA1 200-3
TROUBLESHOOTING
V-130
Related
electrical
v-130
circuit diagram
VHMS Tome inlet sensor
oi
t:onverter I Dressure
Cl
TJW02559
WA1 200-3
20-899 0
TROUBLESHOOTING
V-201 * k *
v-201
Disconnection or short circuit with power source in 24-V system of sensor power supply
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. Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design), its disconnection is not taken up as a cause.
CaUSe
2 YES
Defective VHMS controller
Is voltage between YES Vl (female) 12) and _ 1 r chassis around I normal?II lfcmalsl I21 and hrrl, 2, 3.4,5 Ifemale) (21, and between V1 Ifemale) (2) and HR15. 16 (female) (2). HS2.3.4, (female)
* Max.
1R * Turn starting switch OFF. * Disconnect Vl, MT1 - 5, HR15, 16, and HS2 - 4.
20-900 0
NO Min. 1 V *Turn starting switch OFF. * Disconnect Vl, MT1 - 5, HR15.16, . Turn sartina switch ON.
Short circuitwith power source in wiring harness between Vl (female) (2) and MTI, 2,3,4,5 (female) (2). and berween Vl (female) (2) and HR15.16 (female) (2). HS2,3,4, (female) (21
l
and HS2 - 4.
Disconnectionor defective contact in wiring harness between Vl (female) (2) and MTl. 2.3,4,5 (female) (2). and between Vl (femaie) (2) and HR15, 16 (female) (2), HS2,3,4, (female) (2)
Remedy
Replace
Repair or replace
Repair or replace
WA1 ZOO-3
TROUBLESHOOTING
V-201
Related
electrical
v-201
circuit diagram
Transmission main relief Pressure sensor Toraue outlet Pressure
converter oil sensor
Torque converter inlet oil Pressure sensor
FRZIHD-46082)
RT2 (HD-85086)
LR2(HD-85086) A 5OOC
Transmission modulated Pressure
oil sensor
JRl4tOT2) o'75f8
Front brake oil Pressure sensor Rear brake oil Pressure sensor Work equipment relief oil Pressure sensor Steering relief oil Pressure sensor
Pressure
sensor TJW02539
WA1
200-3
20-901 0
v-202
TROUBLESHOOTING
V-202 * f f
Disconnection or short circuit with power source in 12-V system of sensor power supply
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. Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design), its disconnection is not taken up as a cause.
I 2
IS resistance
between
F15 @male) (1) and &E;,ground
_
Short circuit with power source in wiring harness between Vl (female) 13) FlS (female) (1)
chassis ground normal? -
*
Max. 1 V
1
s
NO
Turn starting switch OFF. Disconnect Vl and F15. *Turn starting switch ON.
Repair or replace
l
Disconnection or defective contact in wiring harness between Vl (female) (3) - F15 (female) (1)
l
-Max.lQ NO *Turn starting switch OFF. * Disconnect Vl and F15
V-202 Related electrical
controller
FL2 (HD-25086)
VI (07020)
)O”fP”f
Repair or replace
circuit diagram
Wheel VHMS
Remedy
Defective VHMS controller
Is voltage between Vl (female) (3). F15 (female) Ill and -
YES 1 If Vl (female) (3) is gmundedtochassis.
YES
CaUSe
(f24V)j307(
3
B
307
F 15 (DT2)
rotation
sensor
1 307
TJW02540
20-902 0
WA1 200-3
TROUBLESHOOTING
V-203
V-203 Disconnection
or short circuit with power source in 5-V system of sensor power supply
* Before carrying out troubleshooting, check that all the related connectors are properly inserted. -k Always connect any disconnected connectors before going on to the next step. * Since the GND line harness of VHMS cannot be disconnected b its disconnection is not taken up as a cause.
4YEs rk voltage between
1 normal?
Max. 1 R * Turn starting switch OFF. - Disconnect R05 and RES3. *
RES3 (female) (1) and chassis ground Is resistance between Vl
l-l
I
.Max.lV . Turn starting NO switch OFF. Disconnect Vl and RES3. * Turn starting switch ON.
(female) (4) and REs3 (female) (1)
normal?
-
GotoA.
fA
Short circuit with power source in wiring harness between R05 (female) (1) RES3 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between R05 (female) 11) RES3 (female) (2)
Repair or replace
Short circuit with power source in wiring harness between Vl (female) (4) RES3 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between Vl (female) (4) FiES3 (female) (1)
Repair or replace
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between Vl (female) (5) MT1 (female) (2)
Repair or replace
Disconnection or defective contact in wiring harness between Vl (female) 6) - MT1 (female) (2)
Repair or replace
l
s Max. 1 Q * Turn starting switch OFF. * Disconnect Vl and RESJ.
NO
~ha&sground
1normal? * Max. 1 R * Turn starting switch OFF. * Disconnect Vl and MTl.
V-203 Related
electrical
11
- Max. 1V NC *Turn staning switch OFF. - DisconnectVl and MTl. -Turn Sartina switch ON.
NO
circuit diagram
VHMS controller
i
Transmi lubrica Dressur
ss ion tina oil e sensor
TJW02541
WA1 200-3
20-903 0
TROUBLESHOOTING
w-204
V-204 Disconnection output Ir *
or short circuit with chassis ground in buzzer
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.
* 2
Defective VHMS controller
YES
Is resistance betMS
1 If Vl (female)
grounded to is resiRance
-
(2) -
*
L99 @male) (2) and ckzssztground
l
l
Replace
~ Short circuit with chassis ground in wiring harness between Vl (female) (16) - L99 (female) (2)
a”d chassis ground normal?
(16) is _ chassis, between _
* Max. 1 R * Turn starting switch OFF. . Disconnect Vl and L99.
Wee” Vl (female) (16). LSS (female1
Min. 1 MC? NO Turn starting switch OFF. Disconnect Vl and L99.
Repair or replace
Disconnection or defective contact in wiring harness between Vl (female) (16) - L99 (female) (2)
NO
Repair or replace
V-204 Related electrical circuitdiagram Emergency parking brake cancel switch Main
monitor
LO6
(040
16)
L89 0.5fL
0.. t
i>
I8 I
I
I
1
VHMS controller
(M4)
3 124AC
Vl
(07020)
II
FS: - ! (S12
Blue)
Fues (11
ion er
A
20-904 0
TJW02516
WA1 200-3
v-205
TROUBLESHOOTING
V-205
*
Disconnection lamp system
or shot-t circuit with chassis ground in check
Before carrying out troubleshooting,
Jc Always
connect
any disconnected
check that all the related connectors are properly connectors before going on to the next step.
2 YES I Is resistance betII YES ween VI (female) - (14).LO6 (female) _ 1 (10) and chassis ‘If Vl (female)(14) is ground normal? ground&to chassis, NO is resistancebetween _ . Min. 1 MQ LO6(female) (10) and *Turn starting chassisground switch OFF. normal? * Disconnect Vl and L06. Max. 1 R . Turn starting NO switch OFF. * Disconnect Vl and LO& l
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (14) - LO6 (female) (10) Disconnection or defective contact in wiring harness between Vl (female) (14) - LO6 (female) (10)
I
inserted.
Replace
Repair or replace
Repair or replace
V-205 Related electrical circuit diagram
Main
monitor
TJW02545
WA1 ZOO-3
20-905 0
TROUBLESHOOTING
V-206
* *
V-206
Disconnection synchronizing
or short circuit with chassis ground in flash signal system
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
2
YES
1 ~~;za;;ssis grounded to chassis, is resistance between LO7 (female) (61 and
- Max.
1Q -Turn starting switch OFF. . Disconnect Vl and L07.
V-206
Related
ground
f
NO Min. 1 MQ *Turn startina switch OFF.* Disconnact Vl and L07. -
I
NO
electrical
VHMS controller
inserted.
Remedy
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between Vl (female) (13) - LO7 (female) (6)
Repair or replace
Disconnection or defective contact in wiring harness between Vl (female) (13) - LO7 (female) (6)
Repair or replace
circuit diagram
LO7 (04012)
Main
monitor
TJW02546
20-906 0
WA1 200-3
V-207
TROUBLESHOOTING
V-207 Short circuit with power source in boom bottom sensor system f *
pressure
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 VI (female) (1) and chassis ground normal? - Max. 1 V * Turn starting switch OFF. * Disconnect Vl and F06. * Turn starting switch ON.
NO
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between Vl (female) (1) F06 (female) (3)
Repair or replace
V-207 Related electrical circuit diagram
TJW0.2547
WA1 200-3
20-907 0
V-208
TROUBLESHOOTING
V-208 * j,
Short circuit with power source in boom head pressure sensor system
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
1 YES
Max. 1 V * Turn starting switch OFF. mDisconnect Vl and F14. * Turn starting switch ON.
V-208
Related
Short circuit with power source in wiring harness between Vl (female) (10) - F74 (female) (3)
NO
electrical
Remedy
Defective VHMS controller
Is voltage between Vl (female) (10) and chassis ground normal? l
inserted.
Repair or replace
circuit diagram
VHMS
TJW02548
20-908 0
WA1 200-3
v-209
TROUBLESHOOTING
V-209 Ir f
Short circuit with power source in rear brake oil pressure sensor system
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
I 1 YES Is
voltagebetween
V2A (male) (8). HR16 (female) (3) and chassis ground normal?
.Max.lV *Turn starting switch OFF. Disconnect V2A and HR16. *Turn starting switch ON.
-
NO
I
cause
inserted.
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (8) - HR16 (female) (3)
Repair or replace
l
V-209 Relatedelectrical
circuit diagram
JR13 (DTlB)
JR14 (DT2)
oil
e wessure
RA5 CDT11
Bat terv
RAt 0 (DTHD4) OL
TJW02531
WA1 200-3
20-909 0
v-210
TROUBLESHOOTING
V-210 Short circuit with power source in front brake oil pressure sensor system Sr *
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.
Defective VHMS controller
1 YES Is
voltagebeMeen
VZA (female) (7). HR15 (female) (3) and chassisground normal? l l
l
l
Max. 1 V Turn starting switch OFF. Disconnect WA and HR15. Turn starting switch ON.
Replace
~ Short circuit with power source in wiring harness ~between V2A (female) (7) - HR15 (female) (3)
NO
Repair or replace
V-210 Related electrical circuit diagram
JR13
(DTIB)
LR7 (DTI)
RAI 0 (DTHD4) 000
I
TJW02530
20-910 0
WA1 200-3
TROUBLESHOOTING
V-211 Ir +
v-21 1
Short circuit with power source in work equipment pressure sensor system
relief
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
Remedy
t-= 1
YES
ISvoltage between V2A (female) (18). HS2 (female) (3) and chassis ground IllJmlal? * Max. 1 V * Turn starting switch OFF. . Disconnect V2A and HS2. -Turn starting switch ON.
V-211
Related
NO
electrical
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (18) - HS2 (female) (3)
Repair or replace
circuit diagram
VHMS con
JR/6
(DTII
L
Work esuiment relief oil .e sensor
TJW02550
WA1 200-3
20-911 0
TROUBLESHOOTiNG
V-212 * +
v-212
Short circuit with power source in transmission sensor system
relief pressure
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 VHMS controller MT2 (female)(3) and chassisground nO~~l7 * Max. 1 V -Turn starting switch OFF.* Disconnect WA and MT2. *Turn starting switch ON.
V-212
Related
VHMS
Replace
I Short circuit with power source in wiring harness between WA (female) (6) - MT2 (female) (3)
NO
I
electrical
Repair or replace
I
circuit diagram Transmission nain relief cvessure sensor l-l
TJWO2552
20-912 0
WA1 200-3
TROUBLESHOOTING
V-213 * *
V-213
Short circuit with power source in steering relief pressure 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
1 YES Is voltage between VZA (female) (16). HS3 (female) (3) and chassis ground nOrf?l~l? * Max. 1 V -Turn starting switch OFF. * Disconnect V2A and HS3. - Turn starting switch ON.
V-123
Related VHMS con
ol ler
--I
Remedy
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (16) - HS3 (female) (3)
NO
electrical
Repair or replace
circuit diagram
VI (07020)
L
il sensor
TJW02553
WA1 ZOO-3
v-214
TROUBLESHOOTING
V-214 * It
Short circuit with power source in torque converter pressure sensor system
outlet oil
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
I Is voltase
between V2A (f&ale) (5). MT3 (female) (3) and chassis ground tl0iTllal7
Max. 1 V Turn starting switch OFF. . Disconnect WA and MT3. * Turn starting switch ON. -
1 YES I I -
NO
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (5) - MT3 (female) (3)
Repair or replace
l
V-214 Related electrical circuit diagram VHMS
20-914 0
lortoe converter outlet oil Dressure sen t.or
WA1 200-3
V-215
TROUBLESHOOTING
V-215 * *
Short circuit with power source in transmission pressure sensor system
modulation
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 V2A (female) (151, MT5 (female) (3) and chassis ground normal? * Max. 1 V * Turn starting switch OFF.. * Disconnect V2A and MT5. Turn starting switch ON.
NO
I
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (15) - MT5 (female) (3)
Repair or replace
I
l
V-215
Related VHMS &roller
electrical
circuit diagram
VI fO70201
Transmission modulated oil wassure sensor
TJWO2555
WA1 200-3
20-915 0
V-216
TROUBLESHOOTING
V-216 * *
Disconnection or short circuit with power source in torque converter oil temperature sensor
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.
Remedy
CallSe
3 YES Is voltage between YES T24 (female) (1) and chassis 2 ground normal? If V2A Wemale)(3) is _ MS groundedto chassis, NO _ ISresistancebetween _ - Max. 1 V T24 (female)(1) and . Turn starting switch OFF. 1 chassisground * Disconnect V2A and T24. y normal? Is resistance * Turn starting switch ON. -Max. IQ between T24 NO *Turn startina (male) (1) and (2) switch OFF.normal? I * Disconnect V2A - 40 kC2at normal and T24. temperature NO (25’C) * Turn starting switch OFF. Disconnect T24.
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2A (female) (3) - T24 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between V2A (female) (3) - T24 (female) (1)
Repair or replace
Defective torque converter oil temperature sensor
Replace
l
V-216
Related
electrical
circuit diagram
Torsue converter oil temperature or)
VHMS
III
JL.21 (DTIB’
-44 J4 aa aa 41
TJW02527
20-916 0
WA1 200-3
V-217
TROUBLESHOOTING
V-217 t f
Disconnection
in hydraulic oil temperature
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.
I
No * 3.5 - 4.0 kQ at normal temperature (25°C) *Turn narting switch OFF. * Disconnect HSl.
V-217
Related
- Disconnect V2A and HSI. NO
electrical
circuit
Cause
Remedy
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between V2A (female) (11) - HSl (female) 11)
Repair or replace
Defective hydraulic oil temperature sensor
Replace
I I
I
diagram
VHMS
TJW02528
WA1 ZOO-3
20-917 0
V-218
TROUBLESHOOTING
V-218 *
Disconnection
in ambient temperature
sensor system
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
*
Cause
2 If V2A (female) (lo! is Y,-s
grounded to chess% 15 resistance between PHl (female) (1) and &a3ass~Tground
_
1
y
resistance between PHl _ (male) (1) and (2) normal?
Is
Approx. 12 kS2at normal temperature (25’C) *Turn starting switch OFF. Disconnect PHl. l
YES
_
k NO
. Max. 1 R Turn starting switch OFF. . Disconnect V2A and PHl. NO l
l
I
inserted.
Remedy
Defective VHMS controller
Replace
Disconnection or defective contact in wiring harness between VZA (female) (10) - PHl (female) (1)
Repair or replace
Defective ambient temperature sensor
Replace
I
I
l
V-218 Related
electrical
circuit diagram
VHMS
JR13 (DTIB)
TJW02557
20-918 0
WA1 200-3
v-219
TROUBLESHOOTING
V-219 Short circuit with power source in PPC relief sensor system or *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
ReDlace
Repair or replace
switch OFF.- Disconnect V2A and HS4. - Turn starting switch ON.
V-219 Related electrical circuit diagram VHMS
JR7 (DTl)
e
LR7 (DTI) B
TJW02558
WA1 200-3
20-919 0
v-220
TROUBLESHOOTING
V-220 *
*
Short circuit with chassis ground in fuel level 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
2 If VZA (female) (2) is Es 1
r
ween R05 (male) _ (1) and (2) as shown in Table 11
Table
Defective VHMS controller
Replace
Short circuit with chassis ground in wiring harness between V2A (female) (2) - R05 (female) (1)
Repair or replace
_
~Ft%t~~““dI I
-I*r&sancebet-
* See Table 1. * Disconnect RO5
gcouqded to chasss. IS resistance belween R05 (female) (1) and
Remedy
NO .Min.lMQ *Turn starting switch OFF. - Disconnect V2A and RO5.
Defective fuel level sensor
NO
1 Resistance Between (1) - (2) Approx. 10 Q
FULL (100%) l/2 (50%)
Approx. 32 R
l/4 (25%)
Approx. 49.5 Q
1 EMPTY
(0%)
V-220
Related
Between (1) - chassis grouncI
1
Approx.
electrical
Min. 1 MP
85 R
circuit diagram
VHM
LR2 (HD-85086)
TlW02526
20-920 0
WA1 200-3
V-221
TROUBLESHOOTING
V-221
Short circuit with power source in battery fluid level sensor “1”
*
Before carrying
*
Always
connect
out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step.
Cause
1 YES Is voltage between V2B (female) (1). RA7 (female) 11) and chassisground normal? NO * Max. 1 V *Turn starting switch OFF. - Disconnect V2B and RA7. *Turn starting switch ON.
inserted.
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness betweenV2B (female)(1) - RA7 (female) (1)
Repair or replace
V-221 Related electrical circuit diagram
VHMS
controller
LR~(HD-85086)
RA3 (DT21
1
Bat terv
RAl (DTZ/DTl)
TJW02532
WA1 200-3
20-92 0
1
TROUBLESHOOTING
V-222
V-222 Short circuit with power source in battery fluid level sensor “2” * *
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 V26 (female) (2). RAE (female1(1) and chassis ground lXXfT#el? . Max. 1 V *Turn starting switch OFF. * Disconnect V2A and RA8. Turn starting switch ON.
NO
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V2B (female) (2) - RA8 (female) (11
Repair or replace
l
V-222 Related
electrical
circuit diagram
VHMS
RA2 (DT2/DTI)
RA7 (DTl)
Battery Jevel sensor
20-922
TJW02532
WA1 200-3
V-223
TROUBLESHOOTING
V-223 Short circuit with power source in battery fluid level sensor “3” * *
Before carrying Always connect
out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step.
Remedy
Cause
1 YES Is voltage between V28 (female) (3). RAS (female) (1) and chassis ground IlO~al? *Max.lV . Turn starting switch OFF. . Disconnect V2B and RA9. * Turn starting switch ON.
V-223
Related
NO
electrical
VHMS controller
inserted.
Defective VHMS controller
qeplace
Short circuit with power source in wiring harness between V2B (female) (3) - RA9 (female) (1)
qepair or ,eplace
circuit diagram
LR2 (HD-85086)
RA3 CDT21
RAl(DTZ/DTl)
TJW02532
WA1 ZOO-3
20-923 0
V-224
TROUBLESHOOTING
V-224 Short circuit with chassis ground or power source in brake fluid level sensor * *
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
ES
ween HRlO (male) (1) and chassis . Turn starting switch OFF. * Disconnect HRlO. . Measure resistance when front brake tank is empty.
4YE
ween HR6 (female)
1Isresktance bet-
. Turn starting switch OFF. * Disconnect HR6 h (female). * Measure resistance when rear brake tank is
1and chassis ?I? II * Min. 1 MQ * Turn starting switch OFF.- Disconnect V3B and HRIO.
_1Is voltage
From A -
-Turn starting switch OFF. * Disconnect V3B and HAlO. - Turn starting switch ON.
Related
Defective front brake level sensor
Replace
Defective rear brake level sensor
Replace
Gotok
-
vccl ween V3A (female) I I 1 ‘A IS). HR6 (female) (1) I-l
empty.
V-224
1r
Remedy
electrical
NO
*Turn
stanina switch OFF. * DisconnectV3A and
_6 YES
between 1 1
Short circuit with chassis ground in wiring harness between V3A (female) (5) - HR6 (female) (‘1)
Repair or replace
Short circuit with chassis ground in wiring harness between V3B (female) (5) -HRlO (female) (1)
Repair or replace
Defective VHMS controller
Replace
5hort circuit with power ;ource in wiring harness cetween V3A (female) (5) - HR6 (female) (1)
Repair or replace
Short circuit with power source in wiring harness setween V3B (female) (5) - HRlO (female) (1)
Repair or replace
circuit diagram Front brake oil level
VHMS controller ake el
-n%-
20-924 0
TJW02533
WA1 200-3
TROUBLESHOOTING
V-225 * +
V-225
Short circuit with power source in coolant level sensor
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
1 YES
Defective VHMS controller
IS voltage between V3B ~fermle) 110). GO6 (female) (1) and chassis ground
*Max. 1 V * Turn starting switch OFF. * Disconnect V36 and G06. * Turn starting switch ON.
V-225
Related
-
electrical
I Replace
Short circuit with power source in wiring harness between V3B (female) (10) - GO6 (female) (1)
NO
inserted.
Repair or replace
circuit diagram
VHMS
RAlO
(DTHD4)
Coolant
level
TJW02534
WA1 200-3
20-925 0
TROUBLESHOOTING
V-226
* *
V-226
Short circuit with chassis ground or power source in transmission oil filter clogging sensor
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.
ChJSt?
2 YES MS , r _ Is resistancebatween V3A (female) (111, R02 (female) (1) and chassis around normal? Min. 1 MR - Turn starting switch OFF. - Disconnect V3A and R02.
-
Is voltage between V3A (female) (11). R02 (female) (1) and chassisground normal? NO ’ Max* ’ ” *Turn starting switch OFF. . Disconnect V3A and R02. - Turn starting switch ON.
l
V-226
Related
NO
Remedy
Defective transmission oil filter or VHMS controller
Replace
Short circuit with power source in wiring harness
Repair or replace
between V3A (female) (11) - R02 (female) (1) Short circuit with chassis ground in wiring harness between v3A (female)
Repair or replace
(11) - R02 (female) (1)
electrical
circuit diagram
VHMS
Transmission
TJW02535
20-926 0
WA1 200-3
TROUBLESHOOTING
V-227
* *
v-227
Short circuit with power source in air cleaner clogging (1) relay system
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
1 YES
1V * Turn starting switch OFF. * Disconnect V3B and L132. -Turn starting switch ON.
V-227
Related
Short circuit with power source in wiring harness between V3B (female) (1) - L132 (female) (6)
NO
electrical
Remedy
Defective VHMS controller
Is voltage between _ V3B (female) (1) and L132 (female) (6) normal?
- Max.
inserted.
Fieoair or
circuit diagram
VHMS controller DUS t
ind icator
I r clay
Dus t ind icator 2 r clay
-vindicator
31
-vindicator
-IDust 141 TJW02536
WA1 200-3
20-927 0
TROUBLESHOOTING
V-228 * *
V-228.229
Short circuit with power source in air cleaner clogging 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
1 YES Is voltage between V3B (female) (2) and L133 (female) (61 normal? . Max. 1 V * Turn starting switch OFF. - Disconnect V36 and L133. -Turn starting switch ON.
*
NO
V-229
*
hplace
Short circuit with power source in wiring harness between V3B (female) (2) L133 (female) (6)
aepair or replace
See V-227.
Short circuit with power source in air cleaner clogging system
(3) relay
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 V3B (female) (3) and L134 (female) (6) normal? - Max. 1 V - Turn starting switch OFF. . Disconnect V3B and L134. * Turn starting switch ON.
*
Remedy
Defective VHMS controller
The related electrical circuit diagram is the same as that for V-227.
*
(2) relay
NO
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V3B (female) (3) - Ll34 (female) (6)
Repair or replace
The related electrical circuit diagram is the same as that for V-227.
20-928 0
Remedy
See V-227.
WA1 200-3
TROUBLESHOOTING
V-230
* *
v-230
Short circuit with power source in air cleaner clogging (4) relay 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
1 MS Is voltage between V3B (female) (4) and L135 (female) (6) normal? * Max. 1 V * Turn starting switch OFF. mDisconnect V36 and L135. * Turn starting switch ON.
*
NO
Remedy
Defective VHMS controller
Replace
Short circuit with power source in wiring harness between V3B (female) (4) - L135 (female) (6)
Repair or replace
The related electrical circuit diagram is the same as that for V-227. See V-227.
WA1 200-3
20-929 0
V-231
TROUBLESHOOTING
V-231 j, *
Abnormal
charge by alternator
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
t-=--v= Defective VHMS controller
1 YES
( 1 Is resistance bet1ween WA (female) I (4). L152 (female) 16) and chassis ground n0l-nlal?
1 I
Min. 1 MR -Turn starting switch OFF. Disconnect V2A. L152, and JE3.
NO
l
I
I
l
V-231
Related
electrical
inserted.
Short circuit with chassis ground in wiring harness between V2A (female) (4) - L152 (female) (6) - El4 (female) (2), El5 (female) I?\ ,L,
I I
Replace
Repairor replace
I
circuit diagram
VHM
Alternator signal relay Fuse (I)
FS2 (SlZBlue) -___ m--l TJWO7.537
20-930 0
WA1 ZOO-3
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H- 1 Machine does not move ........................................................................................................... H- 2
Machine lacks power or speed (every speed range). ...........................................................
H- 3
Excessive time lag when starting machine or shifting gear ................................................
20-I 002 .20-1003 20-l 004
H- 4 Torque converter oil temperature is high ...............................................................................
20-1005
H- 5 Steering does not turn ..............................................................................................................
20-l 006
H- 6 Turning, response of steering is poor ....................................................................................
20-I 007
H- 7
Joystick lever is heavy.. ............................................................................................................
20-1008
H- 8
Steering wheel shakes or jerks ................................................................................................
20-I 009
H- 9 Turning radius is different between left and right at maximum steering ......................... 20-1010 H-10 Wheel brakes do not work or braking effect is poor ............................................................
20-1010
H-II
Wheel brakes are not released or brakes drag ......................................................................
20-1011
H-12
Boom does not rise.. .................................................................................................................
20-1012
H-13
Boom moves slowly or does not have sufficient lifting power ..........................................
.20-1013
H-14 When raising boom, becomes slow at certain height ..........................................................
20-1014
H-15
Boom cylinder cannot hold down bucket ...............................................................................
20-1014
H-16
Boom has large amount of hydraulic drift .............................................................................
20-1014
H-17
Boom fluctuates while working ...............................................................................................
20-1015
H-18
Boom drops momentarily when lever is operated from HOLD to RAISE.. ........................ 20-1015
H-19
Bucket does not tilt ...................................................................................................................
H-20
Bucket is moves slowly or has insufficient tilt back power.. ...............................................
.20-1017
H-21
Bucket movement becomes slow during tilt back.. ..............................................................
.20-1018
H-22
Bucket cylinder cannot hold down bucket.. ............................................................................
20-1018
H-23
Bucket has large amount of hydraulic drift ............................................................................
20-1018
H-24
Bucket fluctuates while traveling under load (work equipment valve HOLD). .................. 20-1019
H-25
Bucket dumps momentarily when lever is operated from HOLD to TILT ..........................
20-1019
H-26
Boom and bucket levers do not move smoothly ..................................................................
20-l 020
WA1 200-3
20-1016
20-1001 0
H-l
TROUBLESHOOTING
H-l Machine does not move points Ask the operator the following . Did the machine suddenly stop moving?
.
Yes = Component seized or damaged Was there any abnormal noise when the machine stopped moving? Yes = Component broken.
Checks before troubleshooting . Is oil level in transmission
. .
case correct?
Is monitor display normal? Is drive shaft broken?
I
No.
6) 7
- 8 9 10 11
Note
Problems
Low at every speed range. Transmission Low at certain speed ranges. modulating pressure too low Indicator fluctuates violently. Pilot pressure defective Torpue converter relief valve pressur- --- ‘---Torpue converter regulator valve pressure IOO m
1: If the solenoid valve and hydraulic pres-
sure are normal, the “m” in the Causes column indicates that the valve spool
does not work. Note
Transmission
IololoTOl
The following symbols are used to indicate the action to be taken when a cause of failure is located. 0: Repair X: Replace C: Clean A: Adjust
clutch pressure is low, but the cause cannot be found in the above table, a possible cause is cracks in the valve or transmission.
2: If the transmission
20- 1002 0
WA1 200-3
iROUBLESHOOTlNG
H-2 Machine
H-2
lacks power or speed (every speed range)
Checks before troubleshooting . Is oil level transmission case correct?
. .
Is there any leakage of oil from joints of piping or valves? Is parking brake or wheel brake dragged?
Checking l
l
. l
. .
8
9 ,. 11
for abnormalities
Engine high idling speed Torque converter stall speed Machine travel speed Transmission clutch pressure (both high pressure and low pressure) Pressure at outlet port of torque converter pump Pilot reducing pressure
0
Relief pressure at torque converter too low (Items 5 and 7 normal) Torque converter regulator valve pressure (outlet port pressure) toolow Iron or alumimum case. Modulating
WA1 200-3
0
particles stuck to strainer of transmission
pressure drops when oil temperature
rises.
0 0
20- 1003 0
H-3
TROUBLESHOOTING
H-3 Excessive time lag when starting machine or shifting gear Checks before troubleshooting . Is oil level in transmission
case correct? Is there any leakage of oil from joints of piping or valves?
.
4
Transmission range
modulating pressure too low in every speed
0000
6
As in Items 4; indicator fluctuates violently
0
6
Torque converter oil temperature
0
20- 1004 0
is above operating range.
0
WA1 200-3
TROUBLESHOOTING
H-4
H-4 Torque converter
oil temperature
is high
Ask the operator the following points . Does torque converter oil temperature
I
I
I
I
I
I
/
go up during torque converter stall, and down when the torque converter is not installed? Yes = Normal (incorrect selection of gear speed) Checks before troubleshooting . Is oil level in transmission
.
Is transmission
case correct? filter clogged?
Checking for abnormalities Ir If the oil temperature is normal but the
oil temperature gauge is outside the operating range, the oil temperature gauge is defective.
WA1 200-3
1
Pump makes abnormal noise when oil temperature
2
High idling and low idling speeds are too low.
3
Hvdraulic oressure at inlet oort of torque converter too low
4
Transmission
modulating pressure too low
is low.
0 0
0
0 lolo/
1 1
I
zo-1005 0
H-5
TROUBLESHOOTING
H-5 Steering
does not turn
Ask the operator the following points Did the problem suddenly start? l
Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
Checks before troubleshooting l
. . .
Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the steering shaft broken? Has the safety bar been removed from the frame? is steering valve open?
2
Steering wheel turns only in one direction (left or right)
3
1Steering
4
1Work
wheel is heavy in both directions (left and right)
equipment
I
moves
5
Work equipment
does not move
6
Abnormal
7
Abnormal noise comes from around PPC pump or hydraulic tank
noise comes from around PTO
I
Inl
00 00 0
I When steering relief pressure is measured
,9
Oil pressure is low or there is no pressure in both directions (left and right) Oil pressure is low or there is no pressure in one direction (left or right)
When steering pilot valve output pressure is measured, oil pressure is found to be low or there is no oil pressure When PPC valve (Orbit-roll) basic pressure iS measured
Ir
0000
lololol
Oil pressure is low
lo101
There is no oil oressure
lolol
1
I
There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.
20- 1006 0
WA1 200-3
H-6
TROUBLESHOOTING
H-6 Turning,
response of steering is poor
Ask the operator the following points . 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 previously any symptom, such as difficulty in steering? Yes = Wear of related equipments, defective seal
.
l
Checks before troubleshooting . Is the oil level in the hydraulic tank cor-
rect? Is the type of oil correct?
No. Problems
I
5
Turning, response of steering is poor in both directions (left and right)
,
.
( Work equipment moves
. . equipment _ .worn
6
7
also speed IS slow
Abnormal noise comes from around PTO
8
Abnormal noise comes from around steering pump or hydraulictank
9
Abnormal noise comes from around switch pump or hydraulictank
I
--I 10
11
*
.. ..
When steering relief pressure is measured
Oil pressure is low or there is no pressure in both directions (left and right)
I I I IO/O 10 10 I()( 0 /
10101 l0l0l0J --- I I I 0
oww
0 0
0 00
o(-j(-Jooonlnl
Oil pressure is low or there is no pressure in one direction (left or right)
I InI I0 I I
12
When steering pilot valve output pressure is measured, oil pressure is found to be low
0
13
When PPC valve (Orbit-roll) basic pressure is measured, oil pressure is found to be low
0
0
There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.
WA1 200-3
20- 1007 0
TROUBLESHOOTING
H-7 Joystick
H-7
lever is heavy
Checking for abnormalities . Is the steering difficult to turn? Yes = Go to H-6 . Measure the operating effort and turning speed, and check the STANDARD VALUE TABLE to see if they are abnormal. Ask the operator the following points 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
l
l
Checks before troubleshooting . Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the tire inflation pressure correct? l
Remedy/+/ /x/x
No. Problems Steering is heavy when turned in both directions (left and right)
2
Steering is heavy when turned in one direction (left or right)
S
Steering is heavy even when joint between steering shaft and Orbit-roil is disconnected
I
When s=adng relief pressure is measured
1 1 1
6
20- 1008 0
x
1
Oil pressure is low in both directions (left and right) Oil nressure is low in one direction (left or riaht)
000
I 0
101
0
When steering pilot valve output pressure is found to be low
WA1 200-3
H-8
TROUBLESHOOTING
H-8 Steering
wheel shakes or jerks
Checking for abnormalities . Is the steering difficult to turn? .
Yes = Go to H-6 Is there any abnormal noise from around the steering equipment?
Checks before troubleshooting . Is the steering wheel play correct? .
.
in the connecIs there any abnormality tion between the steering shaft and the steering pilot valve? Is the tire inflation pressure correct?
No. Problems 1
Steering wheel shakes or jerks in both directions (left and right)
2
Steering wheel shakes or jerks in one directions (left or right)
S
During operations or when traveling (when steering is neutral), steering wheel shakes or jerks in both directions (left and right)
4
During operations or when traveling (when steering is neutral), steering wheel shakes or jerks in one direction Cleftor right)
6
Steering wheel jerks or there is excessive shock when steering is operated to end of its stroke
6
Work equipment also jerks
7 8
g
10
11
WA1 200-3
When steering relief pressure is measured
When steering pilot valve output pressure is measured
Oil pressure is unstable in both directions (left and right)
lO[OlOj~
0 000
Oil pressure is unstable in one direction (left or right) Oil pressure is unstable in both directions (left and right)
0
Oil pressure is unstable in one direction (left or right)
When PPC valve (steering pilot valve) basic pressure is measured, oil pressure is found to be unstable
20-l 009 0
H-9, H-10
TROUBLESHOOTING
H-9 Turning radius is different between steering Causes and Remedy Defective adjustment stopper (4 l
H-10
left and right at maximum
of joystick lever
Wheel brakes do not work or braking effect is poor
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 points. 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 equipments, defective seal l
l
Checks before troubleshooting . 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? . Is the tire inflation pressure and tread pattern correct? l
l
20-1010 0
WA1 200-3
H-l 1
TROUBLESHOOTING
H-11 Wheel brakes are not released or brakes drag Ask the operator the following points. . 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 l
.
Does the brake pedal come back fully? Is the parking brake still applied (ON)?
No 1 2 0
When remaining pressure is released from brake accumulator circuit with left brake pedal only, brake is released
3 I
4
When remaining pressure is released from brake accumulator circuit with right brake pedal only, brake is released
5
When air bleed plug in wheel poeion is loosened, oil flows out and brake is released
6
When air bleed plug is loosened, a large amount of oil flows out
7
0 0 0
()
When brake disc wear is measured and brake pedal is released,
0
piston returns 8
When brake disc wear is measured and brake pedal is released, piston does not return
00
-
WA1 200-3
20-l 011 0
TROUBLESHOOTING
H-12
H-12
Boom does not rise
Ask the operator the following points . Did the problem suddenly fail to rise? l
l
+ Seizure or damage to various units. Was unusual noise produced? (Where did it emanate from?) Were there previous signs of the boom slowing down? + Wear of parts of flattening of spring.
Checks before troubleshooting . Is oil level in hydraulic tank correct?
.
Is travel of lift arm control lever and spool correct?
unable to rise. Or, the bucket operates but the boom is
20-1012 0
WA1 200-3
TROUBLESHOOTING
H-13
H-13
Boom moves slowly or does not have sufficient lifting power
Checks before troubleshooting . Is the travel of the boom control lever
l
l
and also the spool of the work equipment control valve correct? Seizure of work equipment linkage bushing. (Does emits abnormal noise) If the boom speed lowers when it is loaded, it must be overloaded. Check the load meter in this case.
Fault check
There is a strong relationship between faults involving lifting force and lifting speed. Such faults appear initially in the from of insufficient lifting speed. Measure the lifting speed of the lift arm when loaded and refer to the standard value table to determine whether or not there is a fault.
Ming speed is low. 2
3
Bucket tilt back force and speed are normal but boom lifting speed is slow.
0
Some as Item 1 except that boom lifting speed becomes particularly low when oil temperature
Hydraulic pump emits abnormal noise.
6
When the engine is at full, steering action is light and excessively fast.
6
When the engine is at full, steering action is heavy and slow.
7
Cylinder has a large amount of hydraulic drift.
6
The relief pressure of relief valve of work equipment control valve.
WA1 ZOO-3
0
rises.
4
00
00
0 0 00 0
000
20-1013 0
TROUBLESHOOTING
H-14
H-14, H-15, H-16
When raising boom, becomes slow at certain height
Checks before troubleshooting 0. External deformation of boom cylinder. Cause Swollen or internally damaged boom cylinder tube. * Regarding other faults occurring during boom rise, refer to item “H-13 Boom moves slowly or does not have sufficient lifting power”. l
H-15
Boom cylinder cannot hold down bucket
Refer to item “H-13 Boom moves slowly or does not have sufficient lifting power”. Checks before troubleshooting . Is travel of boom spool of work equipment control valve correct? Cause . Defective boom cylinder rod side suction valve seat of work equipment control valve . Oil leakage from boom cylinder piston seal
H-16
Boom has large amount of hydraulic drift
Ask the operator the following points Did the hydraulic drift suddenly become large? + Dirt lodged in valve or damaged parts. . Did the hydraulic drift gradually become large? + Worn parts. l
Checks before troubleshooting Is the boom spool in the hold position? + Seized ring bushing, defective spool detent. l
Troubleshooting and cause When measuring hydraulic drift, internal leakage of boom cylinder makes oil leakage noise. -_j Damaged cylinder packing. . When measuring hydraulic drift, boom cylinder does not make oil leakage noise. -_j Defective oil sealing of boom spool. + Defective check valve between pipings. l
20-1014 0
WA1 200-3
H-17, H-18
TROUBLESHOOTING
H-17
Boom fluctuates
while working
During excavation or ground leveling when the boom control lever is in the “HOLD” position, the bucket and boom move up and down in accordance with the terrain. Troubleshooting and cause Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the boom cylinder. 1. If the amount of hydraulic drift is greater than the standard value, refer to item “H-16 Boom has large amount of hydraulic drift”. 2. If the machine body can not be lifted up by the boom cylinder, refer to item “H-15 Boom cylinder cannot hold down bucket”. 3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the boom cylinder after the boom is moved several times to cause the boom cylinder to move through its entire stroke -+ the trouble is due to the generation of a vacuum in the cylinder. * If a vacuum is generated frequently + defective suction valve on boom cylinder rod side.
H-18
Boom drops momentarily RAISE
when lever is operated
from HOLD to
The boom drops momentarily under its own weight when the boom control lever is gradually shifted from the “HOLD” position to the “RAISE” position while the engine is at low idling. When the control lever is put completely into the “RAISE” position, the boom moves normally. Cause Defective seating of work equipment control valve or boom spool check valve. l
WA1 200-3
20-l 015
0
H-19
TROUBLESHOOTING
H-19
Bucket does not tilt back
Ask the operator l
l
l
the following
points
Did the bucket suddenly cease to move? + Seized or damaged equipment. Was any abnormal noise emitted (where did it emanate from?) Was there previous signs of the bucket slowing down? + Worn parts or flattening of spring.
Checks before troubleshooting . Is the travel of the bucket control lever
and spool correct?
20-1016 0
WA1 200-3
TROUBLESHOOTING
H-20
H-20
Bucket moves slowly or has insufficient
tilt back power
Checks before troubleshooting . Is the travel of the bucket control lever
l
and the work equipment control valve spool correct? Seizure of bushing in bucket linkage? (Does emits abnormal noise?)
Fault checks l
.
1
2
3 4
Check deficient tilt back force by performing actual work. Measure the operating speed of the bucket and check it against the standard value table to determine whether or not it is normal.
Boom lifting force and lifting speed are abnormal and also bucket tilt force and tilt speed are abnormal.
0000
Boom lifting force and lifting speed are normal but bucket tilt
0
force and tilt speed are abnormal. Phenomena
of item 1 become particularly bad when the oil
temperature
increases.
The hydraulic pump emits an abnormal noise.
0
ooc
0 00
action is light and excessively fast when the engine
WA1 200-3
20-1017
0
H-21, H-22, H-23
TROUBLESHOOTING
H-21
Bucket movement
becomes slow during tilt back
Checks before troubleshooting External deformation of bucket cylinder. l
Cause l l
Swollen or internally damaged bucket cylinder tube. As to other faults which occur when operating bucket, refer to item “H-20 Bucket moves slowly or has insufficient tilt back power”.
H-22
Bucket cylinder cannot hold down bucket
Refer to item “H-20 Bucket moves slowly
or has insufficient tilt back power”.
Checks before troubleshooting . Is the travel of bucket spool of work equipment control valve correct? Cause l
l
Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work equipment valve. Oil leakage from seal of bucket cylinder piston.
H-23
Bucket has large amount
Ask the operator l
l
the following
of hydraulic drift
points
Did the hydraulic drift suddenly become large? + Dirt lodged in valve or damaged parts. Did the hydraulic drift gradually become large? + Worn parts.
Checks before troubleshooting . Is the bucket spool in the hold position? + Seized ring bushing, faulty spool detent. Fault check . Use the standard value table to check whether or not the hydraulic drift of the bucket is actually large. Cause l l
l
Oil leakage in bucket cylinder Defective seating of safety valve (with suction valve) at bottom side. Defective oil sealing of bucket spool. Defective check valve between pipings.
20-1018 0
WA1 ZOO-3
TROUBLESHOOTING
H-24
Bucket fluctuates (work equipment
H-24. H-25
while traveling valve “HOLD”)
under load
Checks before troubleshooting Excessive play in pin and bushing of work equipment produced?)
l
linkage.
(Was an abnormal noise
Cause Defective piston seal of bucket cylinder. . Defective safety valve (with suction valve) for the head side of bucket cylinder. If the above symptoms occur together, refer to the troubleshooting items corresponding to each fault. _ . l
H-25
Bucket dumps momentarily to TILT
when lever is operated
from HOLD
The bucket dumps momentarily under its own weight when the bucket control lever is gradually shifted from the “HOLD” position to the “TILT” position while the engine is at low idling. When the control lever is put completely into the “TILT” position, the bucket moves normally. Cause . Defective seating of bucket spool check valve of work equipment valve.
WA1 200-3
20-1019 0
TROUBLESHOOTING
H-26
H-26
Boom and bucket levers do not move smoothly
Fault check Using the standard value table, check whether or not the operating effort of the lever is large.
20-1020 0
WA1 200-3
分解・組立 DISASSEMBLY AND ASSEMBLY 標準締め付けトルク表 …………………………………………………… 30-002 STANDARD TIGHTENING TORQUE
トルクフロー Ass’y ……………………………………………………… 30-069 TORQFLOW Ass’y
ガード＆フード Ass’y …………………………………………………… 30-110 GUARD & HOOD Ass’y
作業時の注意事項 ………………………………………………………… 30-003 PRECAUTIONS WHEN CARRYING OUT OPERATION
コンバータ Ass’y ………………………………………………………… 30-071 CONVERTER Ass’y
フロア／プラットフォームサポート，A/Cカバー Ass’y ……………… 30-112 FLOOR/PLATFORM SUPPORT, A/C COVER Ass’y
塗布剤リスト ……………………………………………………………… 30-005 COATING MATERIALS
トランスミッション Ass’y ……………………………………………… 30-077 TRANSMISSION Ass’y
コンソール／ダッシュ Ass’y …………………………………………… 30-113 CONSOLE/DASH Ass’y
特殊工具一覧表 …………………………………………………………… 30-006 SPECIAL TOOL LIST
バルブ Ass’y ……………………………………………………………… 30-080 VALVE Ass’y
作動油タンク Ass’y ……………………………………………………… 30-115 HYDRAULIC TANK Ass’y
特殊工具略図 ……………………………………………………………… 30-007 SKETCHES OF SPECIAL TOOLS
トルコン，トランスミッションライン Ass’y ………………………… 30-081 T/C, T/M LINE Ass’y
ステアリング油圧配管 Ass’y …………………………………………… 30-116 STEERING HYDRAULIC LINE Ass’y
DTコネクタピンの取り外し，取り付け ………………………………… 30-050 REMOVAL AND INSTALLATION OF DT CONNECTOR PIN
プロペラシャフト Ass’y ………………………………………………… 30-086 PROPELLER SHAFT Ass’y
ローダリンケージ Ass’y ………………………………………………… 30-117 LOADER LINKAGE Ass’y
HDコネクタピンの取り外し，取り付け ………………………………… 30-051 REMOVAL AND INSTALLATION OF HD CONNECTOR PIN
センタサポート Ass’yの分解・組立 ………………………………… 30-086-1 DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT Ass’y
キックアウトポジショナ Ass’y ………………………………………… 30-120 KICKOUT POSITIONER Ass’y
ハーネスの補修要領 ……………………………………………………… 30-051 REPAIR PROCEDURE OF HARNESS
フロントアクスル Ass’y ………………………………………………… 30-087 FRONT AXLE Ass’y
ロップッスキャノピ Ass’y ……………………………………………… 30-121 ROPS CANOPY Ass’y
エンジンマウント Ass’y ………………………………………………… 30-052 ENGINE MOUNT Ass’y
リヤーアクスル Ass’y …………………………………………………… 30-089 REAR AXLE Ass’y
エマージェンシステアリング Ass’y …………………………………… 30-122 EMERGENCY STEERING Ass’y
クーリングシステム Ass’y ……………………………………………… 30-055 COOLING SYSTEM Ass’y
デフキャリア Ass’y ……………………………………………………… 30-091 DIFFERENTIAL CARRIER Ass’y
ステアリングシリンダ Ass’y …………………………………………… 30-124 STEERING CYLINDER
フューエルタンク Ass’y ………………………………………………… 30-058 FUEL TANK Ass’y
ファイナル＆ブレーキ Ass’y …………………………………………… 30-096 FINAL & BRAKE Ass’y
リフトシリンダ Ass’y …………………………………………………… 30-126 LIFT CYLINDER Ass’y
エアコン Ass’y …………………………………………………………… 30-062 AIR CONDITIONER
J/S & アームレスト Ass’y ……………………………………………… 30-100 J/S & ARM-REST Ass’y
ダンプシリンダ Ass’y …………………………………………………… 30-128 DUMP CYLINDER Ass’y
エアコンパイピング Ass’y ……………………………………………… 30-064 AIR CONDITIONER PIPING Ass’y
ブレーキシステム Ass’y ………………………………………………… 30-103 BRAKE SYSTEM Ass’y
MESABIオイルクーラ Ass’y ……………………………………………… 30-131 MESABI OIL COOLER Ass’y
ダンパ Ass’y ……………………………………………………………… 30-066 DAMPER Ass’y
ローダコントロール Ass’y ……………………………………………… 30-105 LOADER CONTROL Ass’y
コントロールバルブ Ass’y ……………………………………………… 30-068 CONTROL VALVE Ass’y
フレーム Ass’y …………………………………………………………… 30-106 FRAME Ass’y
WA1200-3
30-001 (9)
DISASSEMBLY AND ASSEMBLY
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
3. TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS fl Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Nominal No.
Thread diameter of bolt
02 03, 04 05, 06 10, 12 14
Width across flats
14 20 24 33 42
Tightening torque (Nm{kgm})
Width across flat mm
Thread diameter mm
Varies depending on type of connector.
Target
Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010
{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}
44 103 157 422 883
{4.5} {10.5} {16.0} {43.0} {90.0}
4. TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS fl Unless there are special instructions, tighten the O-ring boss plugs to the torque below. kgm
Nominal No.
1.2 2.8 6 10 15.5
– – – – –
285 400 565 765 980
23.5 33 46.5 62.5 80
– 29.5 – 41 – 58 – 78 – 100
1,440 1,910 2,450 3,040 3,630
118 155 200 250 295
– – – – –
08 10 12 14 16 18 20 24 30 33 36 42 52
mm
mm
6 8 10 12 14
10 13 17 19 22
11.8 27 59 98 153
– – – – –
14.7 34 74 123 190
16 18 20 22 24
24 27 30 32 36
235 320 455 610 785
– – – – –
27 30 33 36 39
41 46 50 55 60
1,150 1,520 1,960 2,450 2,890
– – – – –
Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12
10 13 14 27
Nm
1.5 3.5 7.5 12.5 19.5
147 195 250 310 370
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
5.9 13.7 34.3 74.5
– – – –
kgm 9.8 23.5 46.1 90.2
0.6 1.4 3.5 7.6
– – – –
1.0 2.4 4.7 9.2
2. TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS fl In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque
Target
Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5
{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}
7.35 11.27 17.64 22.54 29.4 39.2 49.0 68.6 107.8 124.4 151.9 210.7 323.4
{0.75} {1.15} {1.8} {2.3} {3.0} {4.0} {5.0} {7.0} {11.0} {13.0} {15.5} {21.5} {33.0}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) fl Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. fl Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm})
Nm
Tightening torque (Nm{kgm})
Width across flat mm
Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size - Threads per (mm) inch, Thread series
Root diameter (mm) (Reference)
Range
Target
34 – 54 {3.5 – 5.5}
44 {4.5}
–
34 – 63 {3.5 – 6.5}
44 {4.5}
14
–
–
22
54 – 93 {5.5 – 9.5}
74 {7.5}
–
11 – 16UN 16
17.5
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
–
–
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
13 – 16UN 16
20.6
1 – 14UNS
25.4
3 – 12UN 16
30.2
02
19
03
9 16
– 18UN
14.3
Thread diameter
Width across flat
mm
mm
Nm
kgm
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
–
–
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
–
–
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
–
–
30-002 (9)
1
WA1200-3
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. 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. Do not pull the wires. • 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 uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. fl Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using face seal type Nominal number
Plug (nut end)
02 03 04 05 06
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628
Nut (elbow end) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628
Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04 05
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734
WA1200-3
• • • • • • •
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. fl When using the machine for the first time after repair or long storage, follow the same procedure.
Taper 1/8
4. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water 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 have been removed, always bleed the air from the system after reassembling the parts. fl For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
ød
06 08 10 12 14 16 18 20 22 24 27
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
øD
3) If the part is not under hydraulic pressure, the following corks can be used. Part Number
•
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 pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 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 eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Method of disassembling, connecting push-pull type coupler fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the following page when disassembling and connecting the coupler.
2) Split flange type hoses and tubes
Nominal number
2. • • • • •
L DEW00401
30-003 (9)
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Before
carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
Type 2
Type 1
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
• Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Even
if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
2)
Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) fl The adapter can be pushed in about 3.5 mm. fl Do not hold rubber cap portion (4).
3)
After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2)
4)
Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) fl Since some hydraulic oil flows out, prepare an oil receiving container.
Disassembly
Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) fl Do not hold rubber cap portion (4). After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) fl When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
Connection
2)
30-004 (9)
WA1200-3
DISASSEMBLY AND ASSEMBLY
COATING MATERIALS
COATING MATERIALS fl The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. fl For coating materials not listed below, use the equivalent of products shown in this list. Komatsu code LT-1A
LT-1B
LT-2
LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735
Aron-alpha 201 Loctite 648-50 LG-1
LG-5
Gasket sealant
LG-6
LG-7 Three bond 1211 Three bond 1207B
WA1200-3
Part No.
Q’ty
Container
Main applications, features
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. Used for plas20 g Polyethylene 790-129-9050 tics (except polyethylene, polyprophylene, container (2 pcs.) tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. • Features: Resistance to heat and chemicals Polyethylene 09940-00030 50 g • Used for anti-loosening and sealant purcontainer pose for bolts and plugs. Adhesive: • Used as adhesive or sealant for metal, 790-129-9060 1 kg glass and plastic. (Set of adhesive Hardening Can and hardening agent: agent) 500 g Polyethylene • Used as sealant for machined holes. 790-129-9040 250 g container • Used as heat-resisting sealant for repairing 790-126-9120 75 g Tube engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 790-129-9140 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive Polyethylene • Quick cure type (max. strength after 30 minutes) 790-129-9130 2 g container • Used mainly for adhesion of rubbers, plastics and metals. Polyethylene • Resistance to heat, chemicals 79A-129-9110 50 cc • Used at joint portions subject to high container temperatures. • Used as adhesive or sealant for gaskets 790-129-9010 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 790-129-9080 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. 790-129-9020 200 g Tube • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type 790-129-9070 1 kg Tube • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for repairing 790-129-9090 100 g Tube engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 419-15-18131 100 g Tube sealing material • Used as sealing material for transfer case 790-129-9030
150 g
Tube
Category Molybdenum disulphide lubricant
Komatsu code
Part No.
Q’ty
Container
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
Various
Various
G2-LI
G2-CA
Molybdenum disulphide Grease grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER Primer SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PENGUINE SEAL 580 Adhesive SUPER ”S“ or ”W“ Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE Caulking SEAL No. 2505 material SEKISUI SILICONE SEALANT
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
Various
Various
400 g ✕ 10 Bellows type 400 g ✕ 20 Bellows type 16 kg Can
400 g 16 kg
400 g 16 kg
• Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling 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 heavy load portion
• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects on Bellows type microorganisms, animals, and plants. Can
20 ml
Glass container
20 ml
Glass container
417-926-3910
Main applications, features
320 ml
Polyethylene container
20Y-54-39850
310 ml
Polyethylene container
417-926-3920
320 ml
Polyethylene container
20Y-54-55130
333 ml
Polyethylene container
• Used as primer for cab side (Using limit: 4 months)
Adhesive for cab glass
Category
• Used as primer for glass side (Using limit: 4 months) • ”S“ is used for high-temperature season (April - October) and ”W“ for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)
30-005 (9)
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST fl Tools with part number 79T- - cannot be supplied (they are items to be locally manufactured). fl Necessity: ■: Cannot be substituted, should always be installed (used). ●: Extremely useful if available, can be substituted with commercially available part. fl New/remodel: N: Tools with new part numbers, newly developed for this model. fl R: Tools with upgraded part numbers, remodeled from items already available for other models. fl Blank: Tools already available for other models, used without any modification. fl Tools marked fi in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Component
Symbol
fl Tools having Nos. SMT-fififi-fifififi are shown for manufacture in the field and are not set as special tools (their prices are not set). Accordingly, they cannot be supplied.
Component
Necessity
Q’ty
■
1
N
• SMT-890-1710 • Sleeve
■
1
N
• SMT-890-1720 • Spacer
■
1
N
2
SMT-890-1810
Push tool
■
1
N
3
SMT-890-1820
Push tool
■
1
N
SMT-890-1200
Ass’y–Draw
■
1
N
• SMT-890-1210 • Socket
■
1
N
• SMT-890-1220 • Guide
■
1
N
2
SMT-890-1230
■
1
N
3
• SMT-890-1240 Test/J
■
1
N
• SMT-890-1250 Test/J
■
1
N
4
SMT-890-1310
Wrench
■
1
N
1
SMT-890-1410
Socket
■
1
N
SMT-890-1500
Ass’y–Draw
■
1
N
• SMT-890-1510 • Socket
■
1
N
• SMT-890-1520 • Guide
■
1
N
3
SMT-890-1530
Socket
■
1
N
4
SMT-890-1540
Socket
■
1
N
5
SMT-890-1550
Socket
■
1
N
6
SMT-890-1560
Socket
■
1
N
7
790-302-1280
Socket (Width across flats: 55 mm)
■
1
Symbol
Part No. SMT-890-1700
Disassembly, assembly of damper cover assembly
1 B
1 Disassembly, assembly of torque converter assembly
C
2 Disassembly, assembly of transmisD sion assembly
Part Name Push tool
Socket
New/ re– Sketch model
fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi
Nature of work, remarks 1
Part No.
Part Name
Necessity
Q’ty
New/ re– Sketch model
790-314-1000
Puller
■
1
790-101-4000
Puller
■
1
790-101-1102
Pump
■
1
SMT-890-2100
Push tool
■
1
N
• SMT-890-2110 • Guide
■
1
N
• SMT-890-2120 • Guide
■
1
N
• SMT-890-2150 • Guide
■
1
N
• SMT-890-2160 • Guide
■
1
N
• SMT-890-2170 • Plate
■
1
N
• SMT-890-2180 • Bolt
■
1
N
• 01643-33690
• Washer
■
2
• 01580-03629
• Nut
■
2
• SMT-890-2130 • Guide
■
1
N
• SMT-890-2140 • Guide
■
1
N
• SMT-890-2210 • Guide
■
1
N
• SMT-890-2220 • Guide
■
1
N
• 791-775-1140
• Bolt
■
1
N
• 01643-33080
• Washer
■
2
• 01580-03024
• Nut
■
2
790-101-4000
Puller
■
1
790-101-1102
Pump
■
1
SMT-890-2300
Push tool
■
1
N
• SMT-890-2310 • Sleeve
■
1
N
• SMT-890-2320 • Sleeve
■
1
N
• SMT-890-2330 • Plate
■
1
N
• SMT-890-2210 • Guide
■
1
N
• SMT-890-2220 • Guide
■
1
N
• 791-775-1140
• Bolt
■
1
N
• 01643-33080
• Washer
■
2
• 01580-03024
• Nut
■
2
SMT-890-2410
Push tool
■
1
N
SMT-890-2420
Push tool
■
1
N
SMT-890-2430
Push tool
■
1
N
SMT-890-2440
Push tool
■
1
N
(9)
Press fitting of bearing
Press fitting of bearing
Press fitting of dust seal
Press fitting of retainer and oil seal
Disassembly, assembly of center hinge
K
fi fi fi fi fi
Press fitting of bearing AdjuSMTent pre-load on input gear bearing Removal, installation of modulated clutch piston nut Press fitting of transmission front housing bearing
Press fitting of transfer output shaft oil seal
2
Press fitting of transfer output shaft dust seal Press fitting of transfer output shaft coupling cover Press fitting of transfer output shaft bearing
fi fi fi fi fi fi fi
Press fitting of bushing
fi fi fi fi
Press fitting of dust seal
Support of transfer output shaft Removal, installation of transfer coupling bolt
3
30-006
fi fi fi fi fi fi fi
Nature of work, remarks
WA1200-3
DISASSEMBLY AND ASSEMBLY
Component
Symbol
1
Removal, installation, disassembly, assembly of work equipment assembly
V
2
Part No.
SPECIAL TOOL LIST
Part Name
Necessity
Q’ty
793-890-2500
Push tool
■
1
N
• 793-890-2510
• Shaft
■
1
N
• 793-890-2520
• Nut
■
1
N
• 793-890-2530
• Sleeve
■
1
N
• 793-890-2540
• Sleeve
■
1
N
• 793-890-2550
• Plate
■
1
N
• 793-890-2560
• Plate
■
1
N
• 793-890-2570
• Spring
■
4
N
• 793-890-2580
• Guide
■
1
N
• 793-890-2590
• Ring
■
1
N
• 793-890-2610
• Bolt
■
6
N
• 01580-02016
• Nut
■
6
• 01236-40512
• Screw
■
6
• 04530-12030
• Eyebolt
■
2
• 04530-11222
• Eyebolt
■
2
793-890-2700
Push tool
■
1
N
• 793-890-2710
• Sleeve
■
1
N
• 793-890-2720
• Sleeve
■
1
N
• 793-890-2730
• Shaft
■
1
N
• 793-890-2740
• Nut
■
1
N
• 793-890-2750
• Guide
■
1
N
• 793-890-2760
• Ring
■
1
N
• 793-890-2770
• Bolt
■
4
N
• 01580-02016
• Nut
■
4
• 04530-11222
• Eyebolt
■
2
792-340-1120
Nut wrench
■
1
796-550-1310
Wrench
■
1
792-525-3000
Micrometer
■
1
790-425-1670
Adapter
■
1
790-425-1660
Wrench
■
1
SMT-890-3100
Tool assembly
■
1
SMT-890-3110
• Cylinder
SMT-890-3120
• Piston
SMT-890-3130
• Shaft
SMT-890-3140
• Plate
1
2 Disassembly, assembly of axle · final drive · brake assembly
Nature of work, remarks
Press fitting of boom bushing
Press fitting of ring bushing
Removal, installation of sleeve nut
Adjustment of side bearing preload
W
3
WA1200-3
New/ re– Sketch model
Adjustment of hub bearing preload
30-006-1 (9)
!J3B*sm
!#33lca~~
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
OF SPECIAL TOOLS
.w *~t~k~~~~~~~~l~t~~~~~~~(~-~~~~~~~~~~. NOTE:
Komatsu
cannot
accept any responsibility
for special tools manufactured
according
to these sketches.
$~a-~y~~i~~~Bl St AJ-U70-007 #3 k&T&, lii8CMli co.5tm R0.64.2mIo:tl Thisspaceris eauivalent to one in jigdrawingNo. AJ-U70-007 #3 of KomatsuEC . Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2 unlessotherwise specified. #AmI 1 V mWll?fA R’l? 1
; HEAT TREATMENT 1 CASE DEPTH MATERIAL
pI,;mj-
MASS (kg1
.
ss4cJo PART NAME
PAMT CM SJFACE mAT.arz
SPACER
1 SCALE
NONE
ThissPaceris euuivalent to one in jigdrawingNo. AJ470-007#2 of KomatsuMEC . Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2 unlessotherwise specified. V I
tiIOl!
/
CASE DEPTH MATEATAL HEAT TREATMENT HRC26-32 s45c #A#WL /Idenim andtmerinn PAMT (R PART NAME MASS (kg)
12
SLEEVE
sJ?=da TREIT.lm
WA1200 (31 HEAT TREATMENT CASE DEPTH I . I . p(AT& MASS (kg) PART NAME
PUSH
TOOL
1
APPLICATION Q’TY MATERIAL
RDJTOFI
SJmcE TE4r.coK
SCALE
NONE
WA1 200-3
30-007 0
53i$T*$!Rz
!+35kJX!sr$H
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
:d) *~t=~~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.
1
B2/B3
1
NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
1 ”
A
” $38
” A
Detailof "A"
” $3
$jJ
Detailof "A"
r-;-5-----y-+_
111 1.4,ik,
‘=Q
\‘::\,_
t-4
I
I
III
I
L”
I
. .
_----
ti
----._---
____
‘#lBA
I
LF-~j-------
Thismater is equivalent to one in jig drawingNo. AJ-U70-008-A of KomatsuMEC . Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 -R0.8unless otherwise specified.
ThissDaceris eauivalent to one in jig drawingNo. AJ-D70-008-B of KomatsuMEC . Chamferoutsidecornersto CO.5and round insidecornersto R0.6 - R0.8unless otherwise smified. WA 1200(31 APPLICATION
.
HEAT
I
TREATMENT
1
CASE
OEPTH
[kg)
8.5
PART
,
PUSH
NAME
TOOL
PAINT WI SUFFACE TFEATXOM
/
SCALE
NONE
30-008 0
WA1200 (31
1
APPLICATION
MATERIAL
ss400
I
PmTrti MASS
1 Q’TY HEAT
I
TREATMENT
CASE
DEPTH
MATER
B’TY IAL
ss400
Fmii MASS
[kg)
4.8
PART
PUSH
NAME
TOOL
PAINT OR SWACETREAT.CXJE
SCALE
142,o,A
NONE
WA1 200-3
4-33sE!s#iH
53l?e*uL
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
(
NOTE:
-‘- -:‘p q.$
co
a*
0
\
oocc;
/
1,
.----------
k/
:
It:
I q I r-7-Y
,f
I _-------I ’
i
-
‘,
I l
1
I
I
I.
I
a-------
WA1200131 1 1
I
I
I I I ( ---f r i -7 i I
: I
$~l;t’Z~I&%Q!~o”oi
40-85155-OOA
#l3i~t16.
I
[. ;
HEAT TREATMENT
APPLICATION 1 Q’TY MATERIAL
CASE DEPTH
KflTICti!
I
WA1 200-3
to these sketches.
i
‘.
i-
according
.
--L
86. 67
\
for special tools manufactured
0-J
V
I
cannot accept any responsibility
;f
8
--
I
Komatsu
Thissocketis equivalent to one in ii9drawing No. 40-85155-OOA AwazuPlant.
PART NAME
MASS Ik g)
8.8 SCALE
NONE
I
ASS'Y-DRAW
PAMT (R
SURFACE TREAT.coDE I
33l#*%l2t
mIE!81$m SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
1 Cl (2/3)
NOTE:
1
Komatsu cannot accept any responsibility
for special tools manufactured
1.47
It) ‘7
according
to these sketches.
0.15
v
d
P
77 WAi200131 1 175
APPLICATIONQ’TY
.. HEAT
I
TREATMENT
1
&423295311301 MASS (kg1
Thissocketis eauivalent to one in jigdrawingNo. 40-85t55-001 AwazuPlant.
5.7
I
1
CASE
DEPTH
HRC5863 PART
NAME
SOCKET
MATERIAL
SCM415H PAINTOR SURFACE lREAT.cooE
SCALE
NONE
30-010 0
WA1 200-3
53##-wi
!l333kIB%H
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
-&I *~t~kb~~~~~~~~Wt~~l~~~~~~-~~~ff~~~~~~.
I
Cl (3/3)
NOTE:Komatsu
I
cannot accept any responsibility for special tools manufactured according to these sketches.
_ 8 -9
_
170
I 6
66
* _,4 ~
7v
z (r0
G 0 as
1 00
W
o2
/
---
__&__-_-___
n1wJ J5,driIled hole
44 g
.
g
Thissocketis ecmivalent to one in iio drawingNo. 40-85155-002 AwazuPlant.
YC
.I.
PLATE PART
NAME
I
s43c / i ii : MATER I AL jUY/nr y@
3.1 REMARKS
GUIDE
SUEFACE TREU.CODE
SCALE
NONE WA1 200-3
11
5H#*mi
!fs33cm~~
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
-w *iTlcd:
I
t3~~~~-fi~~ll~~-~~~-C~~f;flt-Wlo)~ff~~~~~1.
NOTE: Komatsu cannot
c2
accept any responsibility for special tools manufactured
according to these sketches.
------__-_ ------
\
I
Thissocketis eauivalent to one in jig drawingNo. 40-85161-001 AwazuPlant.
30-012 0
WA1 200-3
m#*%m DISASSEMBLY
!#3mZao AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
w 1 C3(1/2)
*lzlt-.k
NOTE:
1
~~~~~~~~LWl~~~~~~~~~-~~~~~~~~~~.
Komatsu cannot accept any responsibility
40-85227-001
T$;I~ wjjP$#i4m&#
ThisSocket is ealiivalent
01 SYM.
1
PART
STKM13A 1 1 10.5” c SS4O”P ’ ’ ’ n f 543 HEAT
TREATMENT
rIIJNi u
fi
4
A
ss jij
.
- SAE~~;lr"h-En?fdd
42C-.13-15120
DETAIL
OF
SAE
I NVOLUTE
(NONE)
SPL I NE
SH,AT
c
! Thermal%/!t!of ‘__. . . MASS (kg1
I
.
SCALE
1
CASE
-PA-RT
PART
NO.
?!S,MT,89.0:
IAPPLICATIONI
Q’TY
m 1
NAME
T!~I/~J
11
DEPTH
/ HRC20-30
material,
-p-t-/
1.56
NONE WA1 200-3
Awazu Plant.
NAME
I
TJ
to these sketches.
BtI~&P;hbc
to one in jig drawing No. 40-85227~001
PIPE BOSS GEAR
!3
according
I
I
I
for special tools manufactured
PAINT Cfl SWFACE,,IREAT.COE
I
I
124,O.d 30-013
0
%#*%I3 DISASSEMBLY
CINCH SKETCHES OF SPECIAL TOOLS
AND ASSEMBLY
2s:) *~t~~~~~~~~~~l~t~~~~~~~~~-~~~~~~~~~~. NOTE:
Komatsu
cannot
accept any responsibility
for special tools manufactured according to these sketches.
Thissocketis euuivalent to one in jigdrawing No. 40-85228-001 AwazuPlant.
inioiutespline 60X22X2. 5
I 1
I-
Pressureangle
s43c
_iHAt
I
E3lA
!iiOo”1 “10.19;
20”
I
00
4‘/;r;‘Jr
Ex774‘/ti3Yk
PART NAME
J
1 1 '$.
MATERIAL UV!3$ffs~
REMARKS
f Thermal refining of material SWACE
Detail
of
involute
spline
TiEAT.CODE
shaft
125.o.L 30-O 14 0
WA1 200-3
53l!#*+Jlz
DIZZY
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
h
d -
--
c
-------_--_
k
z
,= y
A
/\ /'
z
_-co.5
i
A co.5
-22-l -
218
‘\
d
(240)
++ \ &
),
00
A-A
03 WM.
PIPF PART
NAME
$TKMM I s43c
i 1
1MATERIAL ewi3
4.8 +127xt8 2.2t22 qAsp
REMARKS
I
SCALE
NONE WA1 200-3
!&%*a2
~71~~H
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
l__!L-l
NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
------
--------
-----
--&________
I
100
This socket is equivalent to one in jig drawing No. 40-85159-001 Awazu Plant.
WdPOO131 1
04 02 SYM.
BAR PI ATF PiPE PART NAME
2 10.051. 1 I 1.5 I. ~TKMI~Ai l6.1 i$lOOXt6 I s53c 1 i-2.2 I.
/SS4OOP I s53c
j MATER[AL[UY~~f;~j
REMARKS
HEAT
I
]
CASE
7 b-L#i.hh
AIlTmi I
j I
TREATMENT
I Flame hardening PART NAME MASS (kg1 9.9
SOCKET
DEPTH
APPLICATION O’TY MATERIAL
s53c PAINTL-R SURFACE TAEAT.WOE
SCALE
NONE 30-016 0
WAl200-3
33fR*$m
6v.%IE%H
DISASSEMBLY AND ASSEMBLY
1 D2(1/3)
SKETCHES OF SPECIAL TOOLS
NOTE:
-1
120 204
$o"old I$!l&WBirsbti40-85154-OOA
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
* WAlXtO131
1
ME&H,
Thissocketis eauivalent to one in jigdrawingNo. 40-85154-OOA AwazuPlant.
HEAT I . I FumB! MASS (kg)
13.2
CASE
TREATMENT
PART
NAME
ASS'Y-DRAW
DEPTH
1
APPLICATION Q’TY MATERIAL
PAINT(R
SUR?Q TREAT.COOE
SCALE
NONE WA1 200-3
30-017 0
53-fe*%i&
t%3?kIWer$H
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
%&I *~t~~d~~~~~~~~Wt~~~~7~~~~-~~~~~~~~~~.
1 D2 (2/3)
NOTE:
1
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
Harden, turn with lathe, then finish with sandpaper
I
Surface must be sharp and free
-25.
5_ 44. I-
120
5kO. I__ I-
WAi200 131 1 1
w HEAT
,;,:232953 *g/i
W~I~~WB~B~
40-85154-001
This socket is euuivalent
30-018 0
#%P~3I
to one in jigdrawingNo. 40-85154-001 AwazuPlant.
MASS(kg)
8.3
TREATMENT
CASE
1130
DEPTH
HF?C58-63 PART
NAME
SOCKET
APPLICATION B'TY MATERIAL
SCM415H PAIN3 OF! SURFACE TREAT.CUOE
SCALE
NONE WA1 200-3
$34WX@El
53s*at
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
m 1 D2(3/3)
*Iat-k
NOTE:
1
154
16. 5
for special tools manufactured
according to these sketches.
r’ 66
27. 5
bQ~:~~M~~~FG-~,t~~~~~b-Wlo)~~~~~~~~.
Komatsu cannot accept any responsibility
m
E
C-
S%
4:’ OD
7v
_---
-----
I
145
r u
I
__J
02 01 SYM.
BAR PLATE
.s43c s43c
HEAT
RTM[ m' I
Thissocketis euuivalent to one in jig drawing NO. 40-85154-002 AwazuPlant.
REMARKS
MATERI AL ffJY/Wyczp
PART NAME
I
10,5. 1 4.4 .
1
TREATMENT
ztiy$igzk I after f inishiw
MASS (kg)
4.9
CASE
DEPTH
HRC30-36 PART
NAME
GUIDE
WAlX)O I31
1
APPLICATION MATERIAL
Q’JY
4
PAINT (El SUFFACE TREAT.COoE
SCALE
NONE WA1 200-3
30-019 0
fpt#*%m
!i33#IW%H SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
-82 *iat-h NOTE:
~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
t Y
v
40
I
I
83
93. 5 *
i
I
196.
5
N
131 ) 1 f WA1200 r
HEAT
;
TREATMENT
1
CASE
Thissocketis euuivalent to one in jig drawingNo. 51-85154-003 AwazuPlant.
7.6
/APPLICATION I ~‘17
s53c
afterf inishim MdSS (kg)
DEPTH
PART
NAME
SOCKET
FAINT OR
SWFACf TREAT.COOE
SCALE
NONE 30-020 0
WA1 200-3
m#*4!m
!f33ZkIWls$B
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
‘rl) *Faclt-k ~~~~~~~~LWt~9l~~~~~~-~~~~~~~~~~. NOTE:
Komatsu cannot accept any responsibility
$o”,IL! WI#%WBrnSI 40-85153-001
for special
tools
manufactured
according
to these
sketches.
I!ama.
Thissocketis eouivalent to one in jig drawingNo. 40-85153-001 AwazuPlant.
q@@ ,li\
~#ll~ltf~
V
May be finished with latheafterheattreatment HEAT
t
03 1
WM.
i
GUIDF OCKFT PART
NAME
I s53c II 12.2. I s53c II 16.9. 1MATER I AL ]UlY/¶j@$~
TREATMENT
CASE
%&~XF? L K&N; Hardening and tefiwering ! after finishing MASS (kg) PART REMARKS
9.1
DEPTH
.___
HRC36w42 SEE NAME
SOCKET
,_.
WAlZCU 131 I 1 APPLICATION O’TY MATERIAL
DWG
PAINT OR WIFACE lFEAT.cooE
SCALE
NONE WA1 200-3
30-02 0
1
!4+3s#IE?sl$rn
53-#+*#i42
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
,&) *~lt-~13~~:~~~~~~tt-7~~~~~~t-Wle>-ff~~~~~~. NOTE:
-__
,d /,A
_
I
&;.L
I,
I
1’
i,\. --._ f----i ‘\
!
-3
t---
q.k===J= j a-j
1
/
;
i
/
j
i
/
8
I
Komatsu cannot accept any responsibility
5 drilled
hole
U70-OP/TF-85156-2
/
I
---_--
I;\‘ /I I
_---
---__
t
t
I I
I
v
III
/
\
$I@
/
/
/ii /
to these sketches.
\ c
-=----,“I ii5-T“
according
I
c__-__-__-__-__-ji_” ~_______________~
1’
for special tools manufactured
/
/
Stamp
40
20
/
z:_:
/
L
__-__-__-__ I .
I!I !I
I
I__-__-__-__-__-_i ii
”
-
i_______________J
May
be
wi th
finished
lathe
after
heat
tr eatment
1 WAiZOO(3) 1 I
*n”aM\
This
40-85
%:+Ig%WHm&f
socket
is
equivalent
156-00 to
one
1 @ii,“7’66, in
jis
drawing
No.40-85156-001
Awazu
Plant. NUNt
30-022 0
t
SKR?"" 8 9 0 - 1 5 5 0 n WA1 200-3
$39?kIE?BI$B
33%*s!m
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
is..) *~t~~$~~~~~~~~Wt~~L~7~~~~-~~~ff~~~~L~. NOTE: Komatsu cannot accept any responsibility
D6
for special
tools
manufactured
according
to these
sketches.
6-13. 5Zfy 6-13.5. drilled hole
INI
I
I
I
/
I/,
j / I
-_-
I
I
1
I
I
I A Hole
H7*.01*
40- ,85157-00 This socket is ewivalent
to onein ii47 drawing No.
40-85157-001 AwazuPlant.
v HEAT
01353-32335i 02 SYM.
j
BOLT BAR BAR
/
PART NAME
/
$%i
Standardoart
ss4ooi3 s53c s53c MATER I AL
6 1
!. , 2 ! 0.‘02!. 1 Qm. ! 1 I koi. if1y/91j ‘r’csy ,
II ! I REMARKS
j
TREATMENT
1 WA1200 I31 (
02 I 01 ; 7z&itARiz L poRrrar, Harden1 ng andtenweri rig : after finishing PART MASS (kg)
8.4
CASE
DEPTH
HRC36-42 NAME
SOCKET
APPLICATION
1
-I
Q’TY
MATERIAL
SEE DWG PRINTari SURFACE TREAT.CODE
SCALE
NONE WA1 200-3
30-023 0
!i3E%Js%H
53-~*sRZ
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
:A) Milt-~ NOTE:
ul1~~:~~~~~t-~~~-cr~~~~-‘31~39rff~~~~~~.
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
,rj-_-
JLL-1
_ $228.6
31 I -clYu
t;’
2150
yyIck;I:p
Upperh irwe
07-k‘/:j
Lowerhinge
I
SCALE
NONE 30-024 0
WA1 200-3
53s*wi DISASSEMBLY
$333aw3~ AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
1 Kl(Wi’) 1
NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
*,“,I% %Yc/ZS%%WHrn I@3 AJ-lJ70-004 #Z $?lS&:ap&a. ~~Xit$%$Plt CO.5 3-?%!YtRO. 6-l.
Zlz-c~nra,L
I:
Thismater is euuivalerrt to one in jig drawingNo. AJ-U70-004 #2 of KomatsuMEC Chamferoutsidecornersto CO.5and round insidecornersto R0.6 -Rf.2unless
Thismater is euuivalent to one in iio drawingNo. AJ-U70-004 #I of KomatsuMC . Chamferoutsidecornersto CO.5and round insidecornersto R0.6 -RI.2unless
0
.
-_. .. _
FllRiItq I
MASS (kg)
23.4 SCALE
NONE WA1 200-3
BA#lut
Hardening
PART
I
NAME
GUIDE PART
NO.
I I
PAINTal SURFACE ilEAT.CUIE
I
I I$M,T, tj9,0, 2 1,2Q ,A ;
TREATMENT
1 CASE DEPTH
I-
KlRTrow~ &A#;RJ
HRC26+32
and tempering
I HEAT
Hardening
MASS (kg)
16 SCALE
NONE
V
_
-MA&ii HRC26-32 and tempering s45c PAINT OR PART Ntd4E !iUFAIX lEAT.COE GUIDE I I I I
PART
NO.
-2 $M,T, - Ej 9,0, 30-025 0
+$3zKls~~
!iMf+*BE DISASSEMBLY
SKETCHES OF SPECIAL TOOLS
AND ASSEMBLY
*w *~t~~~~~~~~~~IWt~~t~~~~~~-~~~~~~~~~~. NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
This spacer is equivalent to one in jig drawing No. AJ-U70-004 #4 of Komatsu MEC _
I \/ Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified.
I .
This spacer is equivalent to one in jig drawing No. AJ-U70-004 #3 of Komatsu MEC .
.
; HEAT
Klmf
TREATMENT
1 CASE DEPTH 1 mum
1Q’TY
II-IEAT
TREATMENT
-CASE DEPTH
WAiZOO I31 1 R~PUCA~~’ Q’T~
I
wRi1a; IkAwzL H/q--J+32MATERIAi ~~~26-32 MATERIAL I Hardening I Hardening and tempering and tempering S45C' s45c 1 L PAINT OR PAINT OR PART NAME MASS (kg) ; PART NAME MASS (kg) SlFHCE TEAT. COPE SIK-AGE rnbT.COoE 6 i GUIDE . GUIDE 16 .
SCALE
NONE 30-026 0
#t;ARWl/
;
I ISM,T
PART
NO,
-, Ej 9,0, - 2
SCALE
-;
NONE
1
PART
NO.
$M,T,E)9,0,21,3Q
tA WA1200-3
!f33?kIEfiH
53l!l8*24Em
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
-El *~t~~~~~~~~~~l~t~~~~~~~l~-~~~~~~~~~~. NOTE:
Komatsu cannot accept any responsibility for special tools manufactured
accordingto these sketches.
MIN MIN
WA1200 (31 HEAT
I . I PuITrm’
CASE DEPTH
1.2
PART
NAME
APPLICATION Q’TY MATERIAL
PLATE
FAINT 08
v
1
ss400
MASS (kg)
WA1 200-3
TREATMENT
SURAIX lFFAT.CWE
4
!
HEAT
TREATMENT
CASE DEPTH
. I P@llI@lf
I
MASS (kg)
17.5
SCALE
SCALE
NONE
NONE
HRC30*36 PART
NAME
GUIDE
PAINTOR SUIFACZ TlEAT.CCOE
30-027 0
53f$3*llai
$-333cEEBa
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
*&I *Eat-k ~~~~~fi~~~~t~~~~~~~~~-~~~~~~~~~~. NOTE: Komatsu
cannot
accept any responsibility
Q9 02
for special tools manufactured
01
according
to these sketches.
MIN MIN
-----+
0-W ++
---_-
R z -82 A
P
I --
5
C _
t-
_c1
+
80 v<4
PLACES
18.54
1
GUIDE
SURFACE TFlEAT.CC#lE
SCALE
NONE 30-028 0
WA1 200-3
!f3BcLE@B
M#*%l~
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
‘iz) *Elt-h
1 K1(6/7)
1
NOTE:
~~~~~~~~~Wt~~t~~~~~~-~~~~~~~~~~.
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
MIN
36X3
\ WAi2ooI31 1 HEAT TREATMENT
I
Fal;lolj E$Ai%c;R L
Hardening and tempering PART
M&S (kg)
I WA1 200-3
6 SCALE
NONE
1 CASE
DEPTH
HB248~285 NAME
GUIDE II
I’
PART NO.
I~;S,MT:Q9,0:222,O,fi
1APPLICATION O'TY MATERIAL
s45c PllINl OR SWdCE ~~.CODE I
/\
SCALE
NONE 30-029 0
53B*4m
!#33%a@H
DISASSEMBLY AND ASSEMBLY
1 K1(7/7)
SKETCHES OF SPECIAL TOOLS
1
NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
PLACES
V
01I
HEAT #iAm
RlFmq
,
O? SYM.
30-030 0
BAR PART
NAME
SS4OOB s45c MATERIAL
2 1
M&S
0.07 . 11
B’lYIsEI q@y
GEMARKS
CASE
DEPTH
L
Hardening and tempering I
lkgl
11.14;
.
TREATMENT
PAINT OR SWACE TREAT.CME
PART NAME
GUIDE
\’
SCALE
NONE WA1 200-3
5MR*sm
#S#IJSE4
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
m
*~t~~~~~rh~~~l~t~~~~~~~~~-~~~ff~~~~~~.
NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
I
I_---
---y-----
II ::
“--
1
ii
I _-_-u-__ t--
l__-Ll-_____
J
: HA1200 (31 APPLICATION
HEAT
I I
.
TREATMENT
CASE
DEPTH
1 Q’TY
MATERIAL
PmTl MASS
(kg) .
SCALE
NONE WA1 200-3
PART
PUSH
NAME
TOOL
PAINT WI lHEAT.COOE
WFACI
230.0.A 30-03 1 0
1 Q(N)
1
NOTE:
Komatsu
cannot
accept any responsibility
for special tools manufactured
according
to these sketches.
This spacer is equivalent to one in jig drawing No. AJ-U70-011 #l of Komatsu MEC .
This spacer is equivalent to one in jig drawing No. AJ-U70-011 #12 of Komatsu MEC .
f&ruw~ co.5 U#li R0.64.2 mwl:t-~ Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified.
\-
V
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified.
IHEAT P&q
I
TREATMENT #iAM% L
Hardening
PART
7.2 SCALE
NONE
HRC26-32
and tempering
MASS (kg)
30-032 0
CASE DEPTH RIGTIM-
NAME
SLEEVE PApT
1 SM,T,, ;
NO.
-2 8 9,0,
Q’TY
MA;E;FL
. ; HEAT I ~~~
/ CASE DEPTH 1 m[n~r(,g 1Q’TY
p[RTIoN~ #khf&RL I
Hardening
HRC26-32
and tempering
aMA;;;FL
I
PAINT IJA
SUFACE TREAT.COOE , .
TREATMENT
PART
MASS (kg) \
13.3’ SCALE
NONE
SLEEVE
I
PAINT OR S&FACE TREAT.=
NAME
PART
I
.
NO.
- 2'3,1Q ,A I ZjM,T; E)9,0, I 1’
WA1 200-3
!#3sIE!lsis~
53l%*ai
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
NOTE:
Finish
Komatsu cannot accept any responsibility
corners
smoothly
with
for special tools manufactured
according
grinder
t I
I HEAT
This
spacer
is equivalent
to one in jig drawing No. AJ-U70-011 #3
of Komatsu MEC
1 CASE
TREATMENT
Kf?iIoN~ .
DEPTH
I
1 MATERIAL
ss400
MASS (kg)
PART
NAME ’
PLATE
22
WA1200-3
to these sketches.
SCALE
;
NONE
I I
PART
FAINT IJR SURFACE TEAT.CCXE
. NO.
SjM,T, L 8 9,0,- ;i 30-033 0
434xcNm
53l?B*%l~
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
.&I *~t~~~~~~~~~~~~c~~~~~~~~~-~~~ff~~~~~~. NOTE: Komatsu cannot accept any responsibility
'his spacer is equivalent to one in jig Irawing No. AJ-U70-006-C of Komatsu MEC
This spacer is equivalent to one in jig drawing No. AJ-U70-006-B of Komatsu MEC
.
S/ii
f YBX~~#JZ
t3
AJ-U70-006-D
&,TbL
W .
according
to these sketches.
_
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
This spacer is equivalent to one in jig drawing No. AJ-U70-006-D of Komatsu MEC
for special tools manufactured
f ~3J%k%&b
I$ AJ-U70-006-A
I%Taii;t
This spacer is equivalent to one in jig drawing No. AJ-U70-006-A of Komatsu MEC
.
” A ” +j-jFJ$@ Detai I of “A” !5U!w
CO.5 lk#ia R0.6w0.8
Detai I of “A”
i;mm:te
#ji$,!~~#.i CO.5 tm
RO.bO.8
mlIm~t.
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8
30-034 0
WA1200-3
433?DxBH
5m*mc
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
m 1 Vl (l/8)
1
*ixllt:‘k
NOTE:
~~~~~~~~~Wt~~/l~~~l~-~~~~~~~~~~.
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
---2
\
\
1 tlA1200 (31 1 .
, I
HEAT
TREATMENT
CASE DEPTH
mum! PART
MASS (kg) I
PUSH
NAME
TOOL
1
APPLICATION1 Q’TY MATERIAL PAINT OR
SIBFACE TREAT.CCllE I
SCALE
NONE WA1 200-3
30-035 0
53lYF*%It DISASSEMBLY
!l3%kIIE@H AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
:d) *lzlr-1 NOTE:
d3~~~~~~~L~tt_3~~T~~I~.-~~Wff~~~~~1.
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
-1
‘8V m40
Threaddepth:40
IHEAT TREATMENT ;pw11~~1 ImtWL
I
I
$$I! ~73$~~$%lli l!i
AJ-U70-001 #I&i?i3~
This spacer
is equivalentto one in jig drawing No. AJ-U70-001 #l of Komatsu MEC
&i#Wi
CO.,5 tidli R0.64.2
I;-tbm~:t~
Chamfero&side corners to CO.5 and round inside corners to RO.6 - Rj.2 unless otherwise swcif ied.
:
1 Hardening and MASS (kg)
98
tempering
PART
CASE ,
DEPTH
HRC26-32 NAME
SHAFT
mang!j
Q’TY
MA;;;FL PAINTOR mAT.COOE
SWAE
SCALE
NONE 30-036 0
WA1 200-3
alt#*%m
Oxfam
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
m
*~jl-~:13~~~;ht;~~~~t-31,~~~~t~.-wl~a~~~~~~~.
NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured according to these sketches.
Actually positioned on part No. 793-890-2510
v
#2 ill3~rrnai This spacer is equivalent to one in jig drawing No. AJ-U70-001 #2
of Komatsu MEC
.
.
I
idEAT
wRTrar;
Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2 unlessotherwise smcified.
I
!
CASE XJEPTH
&A&EL
HRC26*32
Hardening and tempering
PART
NAME
NUT SCALE
NONE WA1200-3
TREATMENT
PART
NO.
MATERIAL
s45c PAINT OR SlFAcE TFEAT. COE .
1 z9,3,Ej9,0,25,2Q
,A 30-037 0
53R*wL
!l+iSKLEsl$B
DISASSEMBLY AND ASSEMBLY
1
VI
(4/8)
SKETCHES OF SPECIAL TOOLS
1
NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
ItAJ-U70-001 #4~~ir;b3t This spacer is equivalent to one in jig drawing No. AJ-U70-001 #4
of Komatsu MEC
. This spacer is equivalent to one in jig drawing No. AJ-U70-001 #3
Chamfer outside corners to CO.5 and round inside
AMIWIM
corners to R0.6 - R1.2 unless
. mI@(
I I HEAT. TREATMENT %ma L I Hardening and tempering
MASS (kg)
9
30-038 0
PART,
CASE DEPTH
HRC26*32 NAME
SLEEVE
0 ’ TY
MATERIAL
s45c PAINTOR WFKETREAT. COOE
of Komatsu MEC
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless
I I HEAT
I MiI@(
I
1 CASE
TREATMENT
1
Harder?$%kempering
PART
MASS (kg)
17.5
SCAiE
SCALE
NONE
NONE
I
Q’TY
MPLIWIJN
DEPTH
HRC26?32 NAME
SLEEVE PART
MATERIAL
s45c PAINT OR
SWFACE
TEAT.CUE
. NO.
WA1 200-3
53-#f*wi DISASSEMBLY
+-3+%.IE@R
AND ASSEMBLY
SKETCHES
OF SPECIAL
TOOLS
.&I *~t~k$~~~~~~~I~~~~1~~~~~~-~~~~~~~~~~. NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
$ g@$lo This spacer
is equiva I ent to one in j ig drawing No. AJ-U70-001
#6
of Komatsu MEC
R0.64.2 trfIa~t.
Chamfer outside corners to CO.5 and round inside corners to RO. 6 - Rl. 2 un I ess
lHEAT PQRiroW! MASS (kg)
2.6
WA1 200-3
TREATMENT . PART
CASE DEPTH
WA1200 131 1 APfINXIoN
O’TY
MATERIAL
ss4go NAME ’
PLATE
PAINT OR SIRWE TEAT.COCE
to these sketches.
Thread depth : 10 Make 6 holes at equal intervals
639
I
This spacer
EM?li co.5 w
according
1Fii8hftdii
is equivalent
to one in j ig drawing
No. AJ-U70-001
co.5 tm R0.6~1.2mlIfJ~L
Chamfer outside corners to CO.5 and round inside corners to RO. 6 - Rl. 2 unless
I I HEATBAi;FATMENT
FURiiQJ! Hardening MASS (kg)
7.8
SCALE
SCALE
NONE
NONE
v
CASE DEPTH
#5
of Komatsu MEC .
r
biAl200 131 1 APPLIUm
MATERIAL
S45G
HRC26*32
and tempering
PART
NAME
PLATE
O’TY
PAINT
OR
SWACE TREAT-COLE
30-039 0
53B*$IE
m?u~~~
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
%B.i) mls-bc ~~~~~fi~~I~c~7ts~~~m-~~~ff~~~~~~. NOTE:
Komatsu cannot accept any responsibility
IdbarOER
Specifications
41
(EquaI I Y spaced)
[ 9%
Outside
1 ojB@
Wire diameter
1 I&X*
diameter
Cm) Cum)
Freeheight W
for special tools manufactured
to these sketches.
of spring
1
32
1
3
1
/
2
1 1
46
I
/.x5-
A-A
8&U
?f~x;ctf$ H#i!$~1bUla $!;8$
A32-03
~~,",~~a.
This spring is equivalent to compressivecoil spring,product No. A32-03, manufacturedby SANESU Co.,Ltd.
$88~TNM#J~ hl# AJ-801-024 tr3 I%tbh This spacer is equivalent to one in jig drawing No. AJ-801-024 #3
of Komatsu MEC WAl200(31
v
APPLICATION
(wAi200131 _ , HEAT wirm~
TREATMENT wmz
1 Hardening MASS (kg1
39.9 SCALE
NONE
30-040 0
according
CASE
L
OEPTH
~~~30-36
~~UTIM
MATERIAL
and tempering
PART
s45c
NAME
GUIDE
PAM
1 I
0.n
HEAT
TREATMENT
CASE
DEPTH
MATERIAL
SEE
FaiLor PART
MASS (kg)
IBI
NAME
SPRING
SIFUI TR5AT.W SCALE
’
PART
4 Q’TY
DWG
PUNT [R TIBT.wDE
SRdCE
NO.
NONE WA1200-3
53lB-ala
!f?3?#IE!sr$B
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
:w *Ht-k NOTE:
~~~~~fi~~~~t~~~~~~~l~-~~~~~~~~~~.
Komatsu cannot
accept
any responsibility for special tools manufactured according to these sketches.
WAVOOi31 1
t
M’lICllTIM Q’ TY ,HEAT A-A
$8 This
bi3SfAitWl~ spacer
is equivalent
,mim~ MASStkg) Iii to one
AJ-801-024 #4131~&3, in jig
drawing
No.
AJ-801-024 #4 of Komatsu
MEC
_
CASE DEPTH MATERIAL . ss400 PAINT OR NAME SW&E
RING
7.8
PART
SCALE
NONE WA1 200-3
TREATMENT . PART
j
TREAT .COOE .
NO.
‘7y9,3,89,0,25,90
,A 30-04 1 0
53?#*$Im
%3%7IE@O
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
22) *~c~k~~~~h~~~LW~~~1~~~~~~-~~~ff~~~~~~. NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured according to these sketches.
Q/5
This
spacer
is equivalent
to one in j ig drawing
MAi
No. AJ-801-024 #7 of Komatsu MEC .
6
APRI@TION 0 ’ TY I HEAT F&U%! MASS (kg)
1.1 SCALE
TREATMENT . PART
CASE DEPTH . NAME
BOLT. PART
MATERIAL
SS40OB PAINT OR SWXE TFWT.W
NO.
NONE 30-042 0
WA1 200-3
5m*wi
!f34zkIE@H
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
.&Ii)*l.ac-k NOTE:
~~~~~~~~I~l~~/l~~~~~-~~~~~~~~~~.
Komatsu cannot accept any responsibility
for special tools manufactured according to these sketches.
WA1200 131 I
HEAT
lxlli,i MASS (kg)
TREATMENT
CASE DEPTH’
PART
PUSH
NAME
TOOL
1
AfJFtICATI~ Q’TY MATERIAL
PUNTIIF! SWACE
TWJ.CWE
SCALE
NONE WA1 200-3
30-043 0
%f#*wi
$-3-3i#IE!sl$H
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
m *~t~~~~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~. NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
RO.5QT / RO.5 max.
Chamfer corners to C0.5, unless otherwise specified.
MATERIAL
s45c PAINT OA SIRFdCE TREAT.UXE This spacer is
ivalent to one in jig
-.-..
30-044 0
. .._ -_
drawing No. AJ-801-002#501 of Komatsu MEC
.
L
I
SCALE
I
NONE WA1200-3
33lB*sm
$-333=W~~
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
1 V2(3n) 1
NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Chamfer corners to C0.5, unless otherwise specified.
I i! This spacer is equivalent to one in jig drawing No. AJ-801-002 #502
of Komatsu MEC .
&EAT
TFIEATMENTI CASE DEPTH 1 MATERIAL
WRiIoN! W&R MhCC~l/rl~I 7.8 SCALE
s45c
]HRC26-32
t PART
PdINT
NAME
SLEEVE PART
SWACE I
IIA
TEAT
-CUE
.
NO.
NONE WA1200-3
30-045 0
!$3-EkIE!sl$B
33lR*sIlz
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
*ia *iziJt-kl b~~~~~~~~~t~~~S~~~~~-~~~~~~~~~~. NOTE: Komatsu cannot accept any responsibility
hT?l\tsPhdld CO.5 Chamfer
This spacer is equivalent to one in jig drawing No. AJ-801-002 #401
30-046 0
tmi%Pld R0.6-1.2
for special tools manufactured according to these sketches.
k~~oIo:t,
outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
of Komatsu MEC
.
SCALE
NONE WA1200-3
33-$T*sm
!#+!s?kiI~~rn
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
m I
v2(5/7)
I
*~t~kb~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
NOTE:
Komatsu
cannot
accept
any
for special tools manufactured according to these sketches.
responsibility
t-lb tually
positioned
on part
I
This spacer is equivalent to one in jig drawing No. AJ-801-002 #7
&4188ll
of Komatsu MEG
.
co.5 SkdiR0.6*1.2 tmn:tt
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified.
v
I
.
lHEAT
Riq f Hardening
$$iu;r~318$Z%iB6 It AJ-801-002#402 RiirQh
&ABE t and tempering
HRC24*30
of material
I
I
MASS (kg)
1
I o-9
I
PART
This spacer is equivalent to one in jig drawing No. AJ-801-002 #402
CASE DEPTH
TREATMENT
NAME
BOLT
of Komatsu MEC
.
.MATERIAL
s45.c PAINT OR SWFAE TiEAT.COE .
1
2.5
1
NlJT
-
I silkci
Tml.cm
SCALE
NONE WA1200-3
30-047 0
m
*Bll-dr $~~~~~~~~~t~~l~~~nl~-~~~~~~~~~~. for special tools manufactured
NOTE: Komatsu cannot accept any responsibility
-
I
I
v
A-A
13;WWL AJ-801-002 l!ii 1lr3WSMlii Spit This equivalent to one co.5MludR0.64.2RROIKtl tiwffi#lii corners to outside Chamfer spacer
is
in jig drawing No. AJ-801-002 a3
of Komatsu MEC
CO.5 and round inside corners to R0.6 - R1.2 unless
30-048 0
TREATMENT !$iA#Wt &KN! PART MASS (kg) lHEAT
.
1
DEPTt(
HRC30+36 .NAME
GUIDE
20 SCALE
CASE
;
PART
according
to these sketches.
I
MATERlAL
s45c PAINTOR SWACE TfE~T.COlE
NO.
-NONE WA1 200-3
m#*%l*
#$4?ax!88$B
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
-83 ~~t-~c3~~:~;pl_fi~~~~t-~,1~~~~~zS-~Je)~it~~~~~~. NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
4 - ZZ+'J
--
A-A
SiItrr38fiMMi110 AJ-801-002#4 lll%M This spacer is equivalent to one in jig drawing No. AJ-801-002 #4
~dM#t
CO. 5 MN
of Komatsu MEC
R0.6d.2 M114):ts
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified.
. ‘IHEAT .
V
APWUfIa( Q’ TY
TREATMENT
CASE DEPTH
MATERIAL
.
ss400
.
~RiHM!
MASS (kg)
13 SCALE
NONE WA1200-3
WA 12Oi[31 1
I
\
PART
NAME
RING PART
PAINTOR SWACE TEAT. CmlE .
NO.
I7,9,3,@9,0, 7,6Q tA 30-049 0
!f33?kIErs$H
53s*$!E
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
-&I *~t~~~~~~~~~~~~r~~t~~~~l~-~~~ff~~~~~~. NOTE:
*&a, This
Komatsu
EAI%;$E~f@6’nf tool
A J -0
assembly
is
Length
cLq=\ \ -__-__-__---
\
1 @p\__ ‘(,
1 J ,s
IC~P bolt
06 iCa~ bolt 05 IHexagon
30-049-l 0
0 8
\
bolt
1 JIS I JIS 1 J IS
I , ) _
length
74mm
1 - IMlOxl.5, L=65 I 4 I - 1~16x2. L=~O 1 3 1 - jM3Ox3. L=l65 1 2
J-fiiilb
is
01
Processed
SYM.
responsibility
one
in
io
24mm.
for special
tools
manufactured
according
to these
sketches.
1
JIS
I
~1s
%lMB#
tiEt’J29
jig
drawing
1
-
Mooka
Plant.
cwwo4994
rT!;tRl-30
MATERIAL R'TVSET ;;;;
NAME
No.AJ-00193P
1 1 1 - If?01 6, 39ifEa24mm 1 2 1 - IMlOxl.5, L=65 I 4 I - 1~16x2, ~=50
1 J IS
t.
I~dd3ld
PART
any
@%,“,T’dj~,
to
06 I~-Y-P~JC~
[Nominal size :6. Thread
bolt
accept
0 1 9 3 P
equivalent
of
07
--
08 IEye bolt 07
__I;:
\
cannot
WA1200 (31
REMARKS
1
APPLICATION Q'TY
I
I
HEAT TREATMENT
CASE
DEPTH
MATERIAL
WA1 200-3
w#*sm DISASSEMBLY
!l-sscLE&H SKETCHES OF SPECIAL TOOLS
AND ASSEMBLY
2%) *~t~~~~~~~fi~~LWI~~L~~~~~~-~~~ff~~~~~~. NOTE:
Komatsu
cannot
accept any responsibility
for special tools manufactured
5-11 drilled
according
to these sketches.
hole
($fiEx!iic) (DISP DWG) 4-M16x2330
3-101’1
79’115
20. 5
3-10 drilled hole seat hole I5
*n"nlX, +iRI%;iW@m;f This WA1 200-3
cylinder
is
AJ-00193P-02
equivalent
to
one
MASS (kg)
8%&7.660 in
jig
drawing
PART NAME
CYLINDER
52. 0 No.AJ-00193P-02 Mooka Plant.
PAINT OR SURFACE TREAT. CODE
SCALE
NONE
t
szi";""
8 !4 0 -?I
1 1 0
n 30-049-2 0
~1~~~
53#f*%B
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
*&) *~t~kd~~~h~~~LWt~~t~~~~~~-~~~~~~~~~~. NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
3-52f’J
I
240
I
1
This
Piston
is
equivalent
to
one
in
jig
drawing
No.AJ-00193P-01
Mooka
Plant.
SCALE
NONE
30-049-3 0
f
S;";"" 8 9 0 - 3 1 2 0 A WA1 200-3
53-?%*4!m
+33?kIE%El
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
-83 *~t~~~~~~~~~~r~t~~t~~~~l~-~~~~~~~~~~. NOTE:
This Mooka
shaft Plant.
is
esuivalent
to
one
in
.iis
drawing
No.AJ-00193P-04
This Mooka
Komatsu cannot accept any responsibility
Plate Plant.
is
equivalent
to
one
in
jig
for special tools manufactured
drawing
according
to these sketches.
No.AJ-00193P-03 cwwo4997
WAI200 (3)
2
WA1200(31
APPLICATION Q'TY HEAT TREATMENT
CASE
PORTION PART NAME
SHAFT SCALE
WA1 200-3
MATERIAL
ss400
MASS (kg)
NONE
DEPTH
+
PAINT OR SURFACE TREAT. COOE
SIR;""'8 9 0 - 3 1 3 0 n
I
APPLICATION Q'TY HEAT TREATMENT
CASE DEPTH
PORTION
MATERIAL
ss400
MASS (kg)
PART NAME
PLATE SCALE
NONE
f
PAINT OR SURFACE TREAT. CODE
Spei";"" 8 9 0 - 3 14 0 n 30-049-4 0
53l%*wz DT CONNECTOR
DISASSEMBLY AND ASSEMBLY
REMOVAL 1.
OF DT CONNECTOR
PIN
Using needle-nose pliers, tweezers, or pulling tool from DT connector, pull out wedge (I). (Photo shows male side)
INSTALLATION OF DT CONNECTOR PIN 1.
Xl
Hold wire (4) at 30 mm on rear side of crimped of contact.
part
:
i 2.
3.
Separating contact fixing claw (2) in connector from contact with flat-head screwdriver, tweezers, or pulling tool Xl, pull out wire to reset fixing claw.
2.
Holding (4).
3.
30-050 0
shield rubber
(grommet)
(3), pull out wire
PIN
Insert wire (4) on grommet side of connector. Ir Insert contact at end of wire (4) straight in grommet hole until it clicks. * Insert the wire until you catch a click (a sound made when the contact passes the fixing claw) and feel the contact collide with the end wall. Ir Pull the wire a little in the pull-out direction to confirm that the contact at the end of the wire is not removed.
After inserting
__
,
all wires, install wedge (1).
WA1 200-3
53FB*~& DISASSEMBLY AND ASSEMBLY
REMOVAL 1.
OF HD CONNECTOR
HD CONNECTOR
PIN
REPAIR
Select tool matched to wire size of pin to be removed from “Special Tools List”, and install it to wire.
PROCEDURE
Wire
2.
3.
I
Insert tool Xl in clearance between wire and connector seal driver (1) until it is stopped by contact. t Use a tool a little larger than the wire. * Take care not to break the wire and connector pin. Pull out wire
(2) together
see the
SAE
Length of cover to beremoved (mm) 3.96 - 5.54
0.5
2 - 24AWG
0.5 - 0.85
16 - POAWG
6.35 - 7.92
1.25 - 2.0
14 - IGAWG
6.35 - 7.92
2.0 - 3.0
12 - 14AWG
5.64 - 7.21
8.0
8 - IOAWG
10.9 - 12.5
15.0
Remove
with tool Xl.
size
1
/
6AWG
1
pin (1) of crimping
2 @Vi04861
I
10.9 - 12.5
tool X2.
Raise and turn knob (2) to select a size matched to wire size. (AWG sizes in above table are indicated on tool X2.) Loosen
locknut
(3) and turn adjustment
screw
(4).
INSTALLATION OF HD CONNECTOR PIN 1.
Hold wire (2) at 30 mm on rear side of crimped of contact.
2.
Insert wire on grommet side of connector. * Insert contact straight in grommet hole until it clicks. * Insert the wire until you catch a click (a sound made when the contact passes the fixing claw) and feel the contact collide with the end wall. t Pull the wire a little in the pull-out direction to confirm that the contact at the end of the wire is not removed.
WA1 200-3
Insert contact (5) in crimping tool X2. * Turn adjustment screw (4) so that the top of contact (5) will be flush with upper end a of the tool hole, then tighten locknut (3).
part
(6) in contact
OF HARNESS
OF HARNESS
Remove cover of wire. * For the length of cover to be removed, following table.
JIS
PIN, REPAIR PROCEDURE
6.
Insert wire
(5).
7.
Grip handles to crimp contact. * Grip the handles to the stroke open automatically.
end,
and they
ri-;;‘iT?i bAss’y ENGINE MOUNT Ass’y
aE#*mi DISASSEMBLY AND ASSEMBLY
,’
nzz+Y t 12)
LT-ZA@bKt
/'
WA1 200-3
r>-;i’iT’9i bAss’y ENGINE MOUNT Ass’y
mR*sm DISASSEMBLY
AND ASSEMBLY
Ii-);‘iTrfi ENGINE
t+Ass’y(2/3) MOUNT
16.2-6.
Ass’y (2/3)
9kom llGHTEN,Nt
il%Lh7
TORD”f
45-49.5Nm (4. 6-5. Okom)
fi -
TlGniEWlltTORPUE IffIJI 24-28Nm (2. 5-2. 6kom)
C 'I7 :j
(33.1-37.
Okomi
I
_-.-__-__-_.-__-__---I
--. \
l-
CWW04867
WA1 200-3
30-053 0
33fl3+*%3
IIj-;i‘;Y’+ i bAss’y ENGINE MOUNT Ass’v
DISASSEMBLY AND ASSEMBLY
Ii-;;‘>?‘3 ENGINE 1.
i
bAss’y(3/3)
MOUNT
Ass’y(3/3)
#%?Q)&LGGVX#Wlrf-t? (1)%x.
b
i-JL3wctzha.
KES 04. 123. 1 4 >I\“3 b L>f
(2)*-X:3427”
D 07281, D 07289
(3)Fr;taC
KES 04. 123. 3
Unspecified tightening torque shall be as follows. (1) Bolts: Conform to KES 04. 123. 1 Impact wrench (2) Hose clamps: Conform to KES D 07281, D 07289 (3) PT thread: Conform to KES 04. 123. 3 Change direction of hose clamp 180” each for double clamp portion. Engine oil Total volume: 290 .r? Exchange volume: 260 e Oil grade: E015-40CD Meet API CE or CF grade
PATTERN MUFFLER
OUTLET cwwo4931
For muffler stack installation follow steps below. a. Prepare pattern as shown and fit the pattern to the muffler outlet pipe. Mark lines along the pattern outside 4 places with unelasable pen. b. Assemble muffler stack with matching its flange to the mark. If adjustment at hole on muffler stack is not enough, max. 5 mm shifting is permitted.
30-054 0
WA1 200-3
/I-‘j;~--i;;:P&Ass’y COOLING SYSTEM Ass’y
53lF#*%lz DISASSEMBLY AND ASSEMBLY
3-Y
i9
COOLING
‘-i ;ifLsAss’y(l/3) SYSTEM
Ass’y (l/3)
’
-__-k:=::
?
-----__-__
WA1 200-3
3-‘J ig>X?&Ass’y COOLING SYSTEM Ass’y
33%*siil~ DISASSEMBLY AND ASSEMBLY
3-11
i?-iX5-&Ass’y(2/3)
COOLING SYSTEM Ass’y (213)
-_ -
3
;Nm
Skem)
X--
CWWO4869
30-056
WA1 200-3
3 - ‘J i$%-i;(&Ass’y COOLING SYSTEM Ass’y
53##-%li~ DISASSEMBLY AND ASSEMBLY
3‘ - ‘/ i 9-i Xf&Ass’y(3/3) COOLING SYSTEM Ass’y (3/3) ~-ii__
,______------
____-----
u
=ii=i=
------
,i_~~~+Ig$LI~~ -__-_____-
___ __
________------j-----
,fL&$
” &A
(I :z)
-_-
(FROM
Ctwo4868~ 77%.
HTC?P'1-SIN RADIATOR
(2)
/ v
(FROM
~~~04868)
(FROM
~~~048681
'_'
CWWO4870
WA1 200-3
30-057 0
3Mf-ii!s
7z~-IIL9>3Ass’y
DISASSEMBLY AND ASSEMBLY
7 ZL--JI~
FUEL TANK Ass’y
i?Ass’y(1/4)
FUEL TANK Ass’y(l/4)
A 1
-__-_____-_____-______-----z:
-3\
----__
I” 4
(
---_
@____ ’ lb-4ib ’
-_
‘m’
‘%\ --_
-
!
+_x (TO CWWO4874)
‘--_-_/i
,,,,F’
A-
=-+!
CWW04871
30-058 0
WA1 200-3
7 LL-IIL~ i3Ass’y FUEL TANK Ass’y
33fR*siEl DISASSEMBLY AND ASSEMBLY
7.1--MO~Ass’y(2/4) FUEL TANK Ass’y (2/4)
Z(G2-Ll)XttKt.
:%?-I.,, II “ATICED AREA
J-J GG
[If:61
11:s)
I-I IFROM
(1 :5) CWWO4871)
/ i ‘-1 “1
cwwo4872
WA1 200-3
30-059 0
M+*$m
7~-IW~~9Ass’y FUEL TANK Ass’y
DISASSEMBLY AND ASSEMBLY
7 ~--~l&i3Ass’y(3/4) FUEL TANK Ass’y (3/4)
(25-31.
5kem)
H-H
30-060 0
II :2.
5)
WA1 200-3
53~*slZ
7x-IlbSi3Ass’y FUEL TANK Ass’v
DISASSEMBLY AND ASSEMBLY
7 x--h9
i?Ass’y(4/4)
FUEL TANK Ass’y (4/4) '~77-Pi~17owx4
'1?3>t'i'/l REARCOYBINITIOH LAYP
(FROM
FULL
3681.9L
CWWO4871) c-c t1:2. 5) (FROM ~~~04873)
D-D (1:2) (FROM ~~~04873)
E-E (1:2. 51 (FROM ~~~04873)
F-F
B-B (1:2. 5) (FROM CWWO4872)
(1:2. 51
PTl/2
P (1:2. 5) (FROM CWWO4872)
&_________ __-__-__;________ ________-)) -_____&-------i------n__ / CWWO4874
WA1 200-3
30-061 0
53@-3m DISASSEMBLY
717’1
IP=I iAss’y AIR CONDITIONER Ass’y
AND ASSEMBLY
iAss’y(V2)
AIR CONDITIONER
Ass’y(l/2)
TltHTEYinG
fi#Ek9
TOPDUE
3.43~4.4lNm (0. 35-O. 45kam)
B-B (FROM
CWWO4876)
F-F
/PH
J-J
(TO
D-D (FROM
30-062 0
:2.5)
CWWO4876)
WA1 200-3
171 iAss’y AIR CONDITIONER Ass’y
53%*$&t DISASSEMBLY
17=1
AND ASSEMBLY
iAss’y(2/2)
AIR CONDITIONER
Ass’y (212)
r
~~&_-+L-~~~!l~ I
I
A
B (TO CWWO4875)
c
c i
___-i-“________________
i--B
i
T
A
mi
CWW04876
WA1 200-3
30-063 0
5383*wE
IP=I ;f \“+ e>gAss’y AIR CONDITIONER PIPING Ass’y
DISASSEMBLY AND ASSEMBLY
17=I
if\“4
ts”i9Ass’y(l/2)
AIR CONDITIONER
PIPING Ass’y(V2)
ii/
,_-----*
______L_L________L ____-__Ld_-______
“y
30-064 0
--<__ ._>
r-7
‘: i
“, ii__ -_-
4 .
“1
_ ---____
- -____
“Yy._ _-__-__-________
_‘_‘____-__-__T_
WA1 200-3
AIR CONDITIONER
DISASSEMBLY AND ASSEMBLY
17=I
il\“q
I?> 9Ass’y PIPING Ass’y
l?‘i9Ass’y(2/2)
AIR CONDITIONER 1.
>/\“I’
17’3
fpB83*$43~
PIPING
2.
Ass’y(2/2)
Precautions for filling air conditioner with refrigerant
(1) Keep the ambient temperature above 3°C (since the system does not work if the ambient temperature
Attention to connection of piping
is below 3°C).
(1) Coat ND-OIL8 (Compressor oil for non-freon) on O-ring. Be sure not to use oil of sniso base and liquid lubricants of CRC (mineral oil).
(2) Use Freon gas (R134a) as refrigerant.
(2) Remove the plugs of the air conditioner parts (devices and hoses) just before connecting those parts
(3) Before filling the air conditioner with refrigerant, be sure to evacuate the air conditioner by repetitive evacuation method. (The degree of vacuum must be above 750 mmHg.1
(to prevent dust and water from entering those parts). (4) The standard quantity of refrigerant to be supplied is 1.3 - 1.5 kg.
(3) Connect each hose securely by using two spanners. (Hold the device side with one spanner and tighten only the flare nut of the hose with another spanner.)
(5) Take care not to supply liquid Freon to the refrigerant system by holding the refrigerant can upside down or handling it wrongly.
(4) Do not connect the ports of receiver conversely. (5) Tightening torques of the following 1) Bolt: Conform to KES 2) Taper thread: Conform to KES 3) Nut: Conform to KES 4) Pipe connecting parts
parts must be as shown, unless other specified. 04. 123. 1 Impact wrench 04. 123. 3 DO1597
0 Nut type
D l/2
D 518
(6) Do not operate the compressor before filling the air conditioner with refrigerant.
G 24
0 27
3.
(I)
12 - 15 {I18 1471
CONDI out CONDZ out ret to unit in
a
M22 x 1.5
20 - 25 I196 - 2451
CONDl in CONDZ in
b
M24 x 1.5
30 - 35 (294 - 343)
Unit out
Ml6 x 1.5
Inspection after assembly Check that proper quantity of refrigerant was supplied to the air conditioner. Judge and adjust the quantity of refrigerant by the following method. Operating pressure of compressor
Number of bubbles passing through receiver sight glass
0.1 MPa Il.0 kg/cm*}
Bubbles pass sometimes or do not pass at all.
Proper
0.06 - 0.1 MPa IO.6 - 1.0 kg/cm*)
Bubbles pass continuously.
Insufficient
0.06 MPa to.6 kg/cm*}
Bubbles pass continuously.
I
Discharge refrigerant through pressure valve to proper level. Connect charging hose to compressor and supply refrigerant to proper level.
(2) Check the air conditioner starting normally. 4.
Precautions for discharging gas
(1) Before discharging gas, perform the oil return work (work to return compressor oil in the piping to the compressor). . Oil return procedure:
Block joint
Remedy
Set the fan switch to the MAX position and run the engine at low idling and operate the air conditioner for 5 minutes.
(2) Be sure to discharge the gas through the high-pressure valve.
~~ 5.
Precautions for repair work
(1) If a defective part is installed and the refrigerant needs to be discharged to repair that part, perform
.
6)
the oil return work, then discharge the refrigerant gradually through the valve rubbers installed to the high-pressure and low-pressure valves of the compressor. (It is very dangerous to disconnect the piping without reducing the pressure in the cooling system. Never do that.)
After tighten up, if the gas shall leak, clean and apply ND-OIL8 to the flares. And tighten as mentioned above.
Tube joint to click as assembly.
(2) When repairing the air conditioner, be sure to put on protective goggles. eyes, you may lose your eyesight.)
(If refrigerant enters your
(3) Do not repair the air conditioner in a dusty or damp place. (4) Once refrigerant is discharged and supplied again for a repair work, check the compressor (Specified quantity of oil: 130’~* cc, ND-OIL81 6.
Never
leave the machine
outdoors
without
installing
oil.
the cab.
When it is obliged to do so, take measures to protect the air conditioner (indoor unit) from rainwater.
WA1 200-3
30-065 0
"iif fAss’y DAM PER Ass' y
53+#*2m DISASSEMBLY AND ASSEMBLY
9kfAss’y(l/2) DAMPER Ass’ y (l/2) TlC”TENlNG
TOROUE
ti#bJid 245-309Nm
16x2 \/
TlG”TENlHG TORPUE
P#bh9
5.9--ll.8Nm (0. 6-l. 2Ksm)
TIGHTENING Pbkhl
TORPUE
98-123Nm (10~12.5Ks.m)
cwwo487a
30-066 0
WA1 200-3
ZI ; b J3--IL/ \“JldAss’y CONTROL VALVE Ass’y
53E#*sR~ DISASSEMBLY
3 =/ I- II
AND ASSEMBLY
--/LI\‘/I,
j'Ass'y
CONTROL VALVE Ass’y ,,GHTEHl”G
f#bh3
TDlO”E
294-314Nm {30-32komI
E-E TlGHTEnIYG
OQik5’
TOlO”
Zll-240Nm (?.I.+24.5komI
Ok81
30-068 0
53%*%lZ DISASSEMBLY AND ASSEMBLY
b/L?
7 q -Ass’y(l/2)
TORQFLOW
Ass’y(1
Y (TO
WA1 200-3
CWWO
b IL3 7 El -Ass’y TORQFLOW Ass’v
mf#*mz
b IL3 7 II -Ass’y TORQFLOW Ass’y
DISASSEMBLY AND ASSEMBLY
F /td’ 7 q -Ass’y(2/2) TORQFLOW Ass’y (2/2)
P (1 :2.
5)
Y
(FROM cwwo4879)
30-070 0
CWWO4880
WA1 200-3
DISASSEMBLY AND ASSEMBLY
GENERAL
DISASSEMBLY,
ASSEMBLY
TORQFLOW ASSEMBLY
OF TORQFLOW
ASSEMBLY Disassembly procedure 1. Preparation work Support the vehicle body with wood blocks, etc. so that the TORQFLOW assembly will be horizontal. A Support the transmission securely, too, so that it will not fall down when the TORQFLOW assembly is disconnected. 2. Wiring harness Remove wiring harness (1). Ir Remove the wiring clamp, too. 3. Tubes 1) Remove the clamp, 2 mounting bolts, and remove bracket (2). 2) Remove the 6 mounting bolts and drain tube (3). 3) Remove the 6 mounting bolts and drain tube (4). 4) Remove the 6 mounting bolts and drain tube (5). 5) Remove the 8 mounting bolts and drain tube (6). 6) Remove the 8 mounting bolts and lubrication tube (7). 4. Lubrication hose Remove lubrication hose (8). * Remove the hose clamp, too. 5. Removal of TORQFLOW assembly 1) Sling converter assembly (9) temporarily and remove the 25 mounting bolts. 2) Disconnect converter assembly (9) and transmission assembly (IO) from each other. Ir Pull out the torque converter horizontally until the input shaft of the transmission is disconnected. assembly: Approx. 1,450 kg Transmission assembly: r+ kg Approx. 3,750 kg * For the disassembly procedure of the converter assembly, see CONVERTER ASSEMBLY. * For the disassembly procedure of the transmission assembly, see TRANSMISSION ASSEMBLY.
r+lkg
Converter
Assembly procedure 1. Preparation work Support the vehicle body with wood blocks, etc. so that the transmission assembly will be horizontal. 2. Connection of TORQFLOW assembly 1) Fit the O-ring to the connecting parts of converter assembly (9) and transmission assembly (IO). & O-ring: Grease (G2-LI) 2) Sling converter assembly (9) and install it to transmission assembly (IO) with the 25 mounting bolts. assembly: Approx. 1,450 kg Transmission assembly: r+ kg Approx. 3,750 kg Lubrication hose Install lubrication hose (8). * Secure the lubrication hose with the hose clamp. Tubes 1) Fit the O-ring and install lubrication tube (7) with the 8 bolts. 2) Fit the O-ring and install drain tube (6) with the 8 bolts. 3) Fit the O-ring and install drain tube (5) with the 6 bolts. 4) Fit the O-ring and install drain tube (4) with the 6 bolts. 5) Fit the O-ring and install drain tube (3) with the 6 bolts. 6) Install bracket (2) with the 2 bolts and clamp. Wiring harness Install wiring harness (I). * Secure the wiring harness with the wiring clamp. 6 kg
3.
4.
5.
Converter
cwwo4950
WA1 200-3
30-070- 1 0
53l!R-$m
=I if
DISASSEMBLY AND ASSEMBLY
3 x\“-
SAss'y
f-
CONVERTER Ass’y
9Ass’y(l/6)
CONVERTER Ass’y (l/6)
K-K
Y (TO
CWWO4883)
(TO
(TO
CWWO4883)
CWWO4883)
i
f=fl
_+,q
GG(i:i)
E-E (I : I)
T/Clild-t PDRT PF T/C EXlT
TlGHTENlWC
TDROUE
913th944.1553.9Nm
(4. 5--5. 5 kern)
‘1 ‘1.
\\I?4 'ti (TO
N-N
CWWO4884)
-
.
t
“;/ AC- AC CWWO4881
WA1 200-3
30-071 0
Zl iJ<-9Ass’y CONVERTER Ass’y
H#*$m DISASSEMBLY
=I id-
AND ASSEMBLY
9Ass’y(3/6)
CONVERTER
Ass’y (3/6)
(FROM
cwwo48811 LT-2@b
A
TlG”iENlNG
h?lb9
h
TOROUE
58.6-73. 5Nm (6-7. Skeml
A-A (FROM
WA1 200-3
CWWO4881)
(FROM
cwwo4881)
cwwo4883
30-073 0
53~*mk DISASSEMBLY
1 id-
J j/tSAss’y CONVERTER Ass’y
AND ASSEMBLY
gAss’y(4/6)
CONVERTER Ass’y (4/6) LT-PM
(2%31.5koml
3uat1'I WC- 1 (42C-13-172603 Ilctxt.
SEE NOTE I
r
J-J (FROM
LT-Ptt
CWWO4881)
LT-2ltle
I
(FROM
c-c CWWO4881)
CWW04884
30-074 0
WA1 200-3
1 idSAss’y CONVERTER Ass’y
mB*sHz DISASSEMBLY AND ASSEMBLY
=I id
- 9Ass’y (5/6)
CONVERTER Ass’y (5/6)
--_
z-
(TO 214)
-I+!
,CWWO4866.
CWWO466;)
CWW04885
WA1 200-3
30-075 0
3 iJ\“- SAss’y CONVERTER Ass’y
53~*w45 DISASSEMBLY AND ASSEMBLY
ZI
id-
9Ass’y(6/6)
CONVERTER
Ass’y (6/6)
_
When assembling oil seal (07012-50110), coat with LG5 on fitting face of the housing (42G13-15250) lightly and after assembling, wipe off the rest completely. Shim is 2 division type. Right and left shims shall be same thickness and pieces. When adjusting preload for input transfer taper roller bearing, do as follows. (11 Obtain as preload of 0 - 1.08 Nm (0 - 0.11 kgm} from single shaft A, B, C, D, E. [When setting orderly do as follows] After setting shaft A and E, obtain the combined preload 0 - 2.16 Nm IO - 0.22 kgm1 from shaft B. Further when setting shaft C, obtain the combined preload 0 - 3.24 Nm (0 - 0.33 kgm1 from shaft C. Further when setting all of gears after setting D, obtain the combined preload 0 - 5.40 Nm {O - 0.55 kgm} from shaft D. (2) After preloads have been adjusted, check all gears that there are no plays.
I
Gear
Speed reduction ratio
A-B
68/74=0.919
A-C
68/74=0.919
A-D
68/74=0.9 19
A-E
58/74=0.784
42C-15-15150
VIEW
tt!fi&t9L6 FROM OUTPUT
SIDE
cwwo4934
Following right and left assemble position about PTO gear 42C-13-15140 and 42C-13-15150.
30-076 0
WA1 200-3
CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
GENERAL
DISASSEMBLY,
ASSEMBLY
OF CONVERTER
ASSEMBLY *
Disassembly procedure 1. Breather and breather hose I) Remove breather hose (I 1. 2) Remove the 2 mounting bolts, then remove breather (2) and the block as one unit. 3) Remove elbow (3). 2. Lubrication hoses and block I) Remove lubrication hoses (4) and (5). * Remove the hose clamps, too. 2) Remove the 4 mounting bolts, flange, and remove lubrication hose (6). * Remove the hose clamp, too. 3) Remove the 4 mounting bolts and block
3.
4.
5.
6.
(7). 4) Remove lubrication hose (8). Lubrication tubes and blocks I) Remove the 3 joints and lubrication tube (9). 2) Remove the 2 joints each from lubrication tubes (IO), (II), (121, and (131, then remove those tubes. 3) Remove the 2 mounting bolts, block (141, and bracket (15). 4) Remove the 3 mounting bolts and block (16). Main relief valve and torque converter relief valve assembly Remove the 7 mounting bolts and main relief valve and torque converter relief valve assembly (17). Torque converter regulator valve assembly I) Remove the 4 mounting bolts and block (18). 2) Remove sleeve (19). 3) Remove the 4 mounting bolts, cover (201, and block (21). 4) Remove the 4 mounting bolts and torque converter regulator valve assembly (22). 5) Remove valve block assembly (23). Modulated clutch ECMV assembly I) Remove the 3 mounting bolts and cover
Pull out the modulated clutch assembly with forcing screws (12 mm). Pull out the modulated clutch assembly horizontally so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other.
*
lel kg
Modulated
clutch assembly:
220 kg
f
9.
For the disassembly procedure of the modulated clutch assembly, see DISASSEMBLY, ASSEMBLY OF MODULATED CLUTCH ASSEMBLY. Torque converter assembly and PTO and transfer assembly 1) Remove the 19 mounting bolts, then remove torque converter assembly (28) from PTO and transfer assembly (29). assembly: 430 kg PTO and transfer assembly: &I kg 800 kg * For the disassembly procedure of the torque converter assembly, see DISASSEMBLY, ASSEMBLY OF TORQUE CONVERTER ASSEMBLY. * For the disassembly procedure of the torque converter assembly, see DISASSEMBLY, ASSEMBLY OF PTO AND TRANSFER ASSEMBLY. Remove coupling (30) from torque converter assembly (28). I+ kg
2)
Torque
converter
(24). Remove the 4 mounting bolts and modulated clutch ECMV assembly (25). Rotation sensor Loosen the locknut and remove rotation sensor (26). Modulated clutch assembly Remove the 10 mounting bolts and modulated clutch assembly (27). * Since the hexagon socket head bolt is not used for mounting, do not remove it. 2)
7.
8.
WA1 200-3
30-0760
1
DISASSEMBLY AND ASSEMBLY
CONVERTER ASSEMBLY
Assembly procedure 1. Torque converter assembly and PTO and transfer assembly I) Install coupling (30) to torque converter assembly (28). 2) Fit the O-ring to the connecting parts of torque converter assembly (28) and PTO and transfer assembly (29). & O-ring: Grease (G2-LI) 3) Install torque converter assembly (28) to PTO and transfer assembly (29) with the 19 bolts. * Since the outer race and inner race of the tapered roller bearing are coupled with each other, drop about 6 cc of engine oil (E030-CD or EOIOCD) onto the sliding surfaces of the rollers.
2.
63ks
Torque
!I+ks
PTO and transfer
Modulated
clutch assembly:
30-076-Z 0
5.
6.
7.
220 kg
Rotation sensor Install rotation sensor (26) and secure it with the locknut. & Threaded part of sensor: Gasket sealant (LG-51 Put the rotation sensor tip lightly against * the gear tooth tip in the modulated clutch and return by l/2 - 1 turn and secure with the locknut. m Locknut: 49.0 - 68.6 Nm (5 - 7 kgm1
Modulated clutch ECMV assembly I) Fit the O-ring and install modulated clutch ECMV assembly (25) with the 4 bolts.
9.
Breather and breather hose 1) Install elbow (3). 2) Install breather (2) with the 2 bolts. 3) Install breather hose (I). * Secure the hose with the hose clamp.
Mounting bolt: 27.4 - 34.3 Nm f2.8 - 3.5 kgm} 2) Install cover (24) with the 3 bolts. Torque converter regulator valve assembly I) Fit the O-ring and install valve block assembly (23) with the 4 bolts. w Mounting bolt: 44.1 - 53.9 Nm (4.5 - 5.5 kgm1 2) Fit the O-ring and install torque converter regulator valve assembly (22) with the 4 bolts. w Mounting bolt: 44.1 - 53.9 Nm 14.5 - 5.5 kgml 3) Fit the O-ring and install block (21) and cover (20) with the 4 bolts. 4) Fit the O-ring and install sleeve (19). & O-ring: Grease (G2-LI) 5) Fit the O-ring and install block (18) with 4 bolts. Main relief valve and torque converter relief valve assembly Fit the gasket and install main relief valve and torque converter relief valve assembly (17) with the 9 bolts. m Mounting bolt: 58.8 - 73.5 Nm j6.0 - 7.5 kgm} Lubrication tubes and blocks 1) Fit the O-ring and install block (16) with the 3 bolts. 2) Install bracket (15) and block (14) with the 2 bolts. 3) Fit the gasket and install lubrication tubes (131, (121, (II), and (IO) with the 2 joints each. w Joint: 44.1 - 53.9 Nm 14.5 - 5.5 kgm1 4) Fit the gasket and install lubrication tube (9) with the 3 joints. w Joint: 44.1 - 53.9 Nm 14.5 - 5.5 kgm1 Lubrication hoses and block Install lubrication hose (8). * Secure the hose with the hose clamp. Install block (7) with the 4 bolts. Fit the O-ring and install lubrication hose (6) with the 4 bolts and the flange. Install lubrication hoses (5) and (4). * Secure the hoses with the hose clamps. &I ks
assembly: 430 kg assembly: 800 kg
Modulated clutch assembly Fit the O-ring and install modulated clutch assembly (27) with the 10 bolts. 6 O-ring: Grease (G2-LB * Since the outer race and inner race of the roller bearing are coupled with each other, drop about 6 cc of engine oil (E030-CD or EOIO-CD) onto the sliding surfaces of the rollers and insert the modulated clutch assembly horizontally, taking care not to tilt it. r+lkg
3.
converter
4.
8.
WA1 200-3
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY,
ASSEMBLY
CONVERTER ASSEMBLY
OF MODULATED
CLUTCH ASSEMBLY Disassembly procedure 1. Cage I) Remove the 4 mounting
2.
3.
2) 3) 4) 5)
4.
5.
6.
7.
WA1 200-3
bolts and cage
(I). * Pull out the cage with forcing screws (12 mm). 2) Remove snap ring (2), then remove bushing (3) and ball (4) from cage (I). Case 1) Remove snap ring (5). 2) Remove the 2 mounting bolts and case (6). 3) Remove ball bearing (7) from case (6). * Use a press to remove the ball bearing. Cover and input drum assembly 1) Remove cover and input drum assembly (34). Remove
Assembly procedure 1. Shaft I) Press fit the inner race of roller bearing (33) to shaft (31). * Using a press, fit the bearing until the end of its inner race touches the shoulder of the shaft. 2) Install seal ring (32) to shaft (31). 6 Seal ring: Grease (G2-LI) 3) Install seal rings (30) and (29) to shaft (31). & Seal ring: Grease (G2-LI) * Install the seal rings as shown in the following figure.
I
snap ring (81, plate (9), and ball
(IO). Remove snap ring (II), cover (121, and ball (13). Remove input drum (17) from cover (14). Remove snap ring (15) and ball bearing
(16). * Use a press to pull out the ball bearing. Discs and plates 1) Remove snap ring (18) and plate (19). 2) Remove damper (20). 3) Remove 19 discs (21) and 18 plates (22) alternately. 4) Remove damper (23). Piston 1) Using tool C4, remove nut (24). 2) Remove plate (25). 3) Remove seal ring (26) from plate (25). 4) Remove piston (27). Ir Push out the piston from the shaft side with forcing screws (12 mm). Output drum Remove the 12 mounting bolts and drum
I
cwwo4953 Output drum Install drum (28) with the 12 bolts. 6 Threaded parts: Liquid adhesive (LT-2) m Mounting bolt: 98 - 123 Nm IlO. - 12.5 kgm1 Piston I) Install piston (27). 2) Install seal ring (26) to plate (25). 6 Seal ring: Grease (G2-LI) j, Install the seal ring as shown in the following figure.
(28). Ir Push out the drum from the shaft side with forcing screws (12 mm). Shaft 1) Remove seal rings (29) and (30) from shaft (31). 2) Remove 2 seal rings (32) from shaft (31). 3) Remove the inner race of roller bearing (33) from shaft (31). * Use a bearing puller to pull out the bearing.
30-076-3 0
DISASSEMBLY AND ASSEMBLY
CONVERTER ASSEMBLY
Install plate (25). Using tool C4, install nut (24). & Threaded parts of nut: Liquid adhesive (LT-2) * Install the nut with the chamfered periphery to plate (25). w Nut: . .313.8 - 392.3 Nm I32 - 40 kgm} Discs and plates I) Install damper (23). * install the damper with the cork side to the piston. 2) Install 19 discs (21) and 18 plates (22) alternately. f Soak the discs in clean engine oil (E030-CD or EOIO-CD) for at least 2 minutes before installing them. 3) Install damper (20). * Install the damper with the cork side to plate (19). 4) Install plate (19) and secure it with snap ring (18). Cover and input drum assembly 1) Using tool C2, install ball bearing (16) to cover (14) and secure it with snap ring (15). * Press fit the bearing until the end of its outer race touches the shoulder of the cover. * After press fitting the bearing, drop about 6 cc of engine oil (EOSO-CD or EOIO-CD) onto the sliding parts and rotate the bearing 10 turns to spread the oil.
2) 3)
3) 4)
4.
5.
4)
5) 6.
7.
Install input drum (17) to cover (14). Install ball (13) and cover (12) and secure them with snap ring (II). * Put the ball in the ball hole of the drum, then install the cover, matching its ball groove to the ball. Install ball (IO) and plate (9) and secure them with snap ring (8). * Put the ball in the ball hole of the cover, then install the plate, matching its ball groove to the ball. Install cover and input drum assembly
(34). Case I) Install ball bearing (7) to case (6). Using a press, fit the bearing until the end of its outer race touches the shoulder of the cover. After press fitting the bearing, drop about 6 cc of engine oil (E030-CD or EOIO-CD) onto the sliding parts and rotate the bearing 10 turns to spread the oil. 2) Fit the O-ring to the cover and install case (6) to shaft (31) and secure them with the 2 bolts. & O-ring: Grease (G2-LI) * Push the inner race of ball bearing (7) with a press until its end touches the shoulder of the shaft. * Check that the ball bearing is fitted perfectly, then tighten the 2 bolts. 3) Install snap ring (5). Cage I) Install ball (4) and bushing (3) to cage (I) and secure them with snap ring (2). * Put the ball in the ball hole of the bushing, then install the cage, matching its ball groove to the ball. 2) Fit the O-ring and install cage (I) with the 4 bolts. 6 O-ring: Grease (G2-LI)
cwwo4955
30-076-4 0
WA1 200-3
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY,
ASSEMBLY
CONVERTER ASSEMBLY
OF TORQUE
CONVERTER
ASSEMBLY Disassembly procedure 1. Preparation work Set the torque converter assembly vertically with the input shaft side up. * Adjust the height of the torque converter assembly so that the mounting bolts can be removed from the underside of the case. 2. Case Remove the 13 mounting bolts, then remove the torque converter from case (I). * Install a hanging bolt (12 mm) to the input shaft end and lift off the torque converter vertically with the all internal parts of the case assembled. * Place the removed torque converter with the input shaft side up on a work table. 3. input shaft 1) Remove the 20 mounting bolts and shaft (2). 2) Remove the inner race of tapered roller bearing (3) from shaft (2). * Use a bearing puller to pull out the inner race. 4. Case and turbine assembly I) Remove 36 mounting bolts and case and turbine assembly (4). 2) Remove snap ring (5) and wire (6). 3) Remove snap ring (7) and cover (8). 4) Remove turbine (9). * Pull out the turbine with forcing screws (IO mm). 5) Remove ball bearing (IO) from case (II). * When removing the ball bearing with a press, do not push its snap ring side. 5. Stator 1) Remove snap ring (12) and stator (13). 2) Remove spacer (14). 6. Pump assembly Remove pump assembly (15). Ir Remove the pump assembly vertically so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. Remove 16 mounting bolts, retainer (161, and guide (17) from pump (18). Remove the outer race of roller bearing (19) from guide (17). * Use a press to remove the outer race. Remove drain plug (20) from pump (18).
7.
Shaft I) Remove the 4 mounting bolts and plate (21) from shaft (22). 2) Remove seal ring (23) from shaft (22). 3) Remove the inner race of roller bearing (19) from shaft (22). * Use a bearing puller to pull out the inner race. 4) Remove sleeve (24) from shaft (22).
CWWO4956
WA1 200-3
30-076-5 0
CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
Assembly procedure 1. Shaft Install sleeve (24) to shaft (22). * Install the sleeve by expansion fit. Press fit the inner race of roller bearing (19) to shaft (22). f Push the inner race with a press until its end touches the shoulder of the shaft. Install plate (21) to shaft (22) with the 4 bolts. Install seal ring (23) to shaft (22). & Seal ring: Grease (GZ-LI) 2. Pump assembly 1) Install drain plug (20) to pump (18). w Drain plug: 9.8 - 12.7 Nm Il.0 - 1.3 kgm} 2) Press fit the outer race of roller bearing (19) to guide (17). Ir Apply bearing compound to 4 places of the periphery of the bearing. After installing the outer race, wipe off the projected compound so that it will not enter the bearing.
C_
i lO--20mm cwwo4957
*
3)
4)
Push the outer race with a press until its end touches the shoulder of the guide. Install guide (17) and retainer (16) to pump (18) with 16 bolts. 6 Threaded parts of mounting bolt: Liquid adhesive (LT-21 m Mounting bolt: 59 - 74 Nm IS.0 - 7.5 kgml Install pump assembly (15) to shat (22). Ir Since the outer race and inner race of the roller bearing are coupled with each other, lower the pump assembly vertically, taking care not to tilt it.
30-076-6 0
Stator 1) Install spacer (14). 2) Install stator (13) and secure it with snap ring (12). 4. Case and turbine assembly 1) Install ball bearing (IO) to case (11). * Push the ball bearing with a press until its snap ring touches the shoulder of the case. * After press fitting the bearing, drop about 6 cc of engine oil (E030-CD or EOIO-CD) onto the sliding parts and rotate the bearing 10 turns to spread the oil. Install turbine (9). * Support the inner race of the ball bearing and push the turbine with a press until the shoulder of the turbine touches the end of the inner race. Install cover (8) and secure it with snap ring (7). Install wire (6) and secure it with snap ring (5). Install case and turbine assembly (4) with the 36 bolts. * Match the internal oil groove on case to the drain plug of the pump. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 49 - 59 Nm 15 - 6 kgm1 5. Input shaft 1) Install the inner race of tapered roller bearing (3) to shaft (2). * Push the inner race with a press until its end touches the shoulder of the shaft. 2) Install shaft (2) with the 20 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 245 - 309 Nm (25.0 - 31.5 kgml 6. Case Install the torque converter to case (I) with the 13 bolts. * Install a hanging bolt (12 mm) to the input shaft end, then sling and install the torque converter vertically. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 245 - 309 Nm (25.0 - 31.5 kgml 3.
WA1 200-3
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY,
ASSEMBLY
CONVERTER ASSEMBLY
OF PTO AND TRANSFER
ASSEMBLY
20 \
/
CWWO4982
WA1 200-3
30-076-7 0
DISASSEMBLY
AND
Disassembly procedure Rotation sensor Loosen the locknut and remove rotation sensor (1). Cover Remove the 12 mounting bolts and cover (2). PTO gear 1 (Gear D) 1) Remove the 6 mounting bolts, cage (31, and shims (4). Ir Check the thickness and quantity of the shims. 2) Remove the outer race of tapered roller bearing (5) from cage (3). * Use a bearing puller to pull out the outer race. 3) Remove coupling (6). 4) Remove snap ring (7) from coupling (6). 5) Remove gear (8). 6) Remove snap ring (9) from gear (8). 7) Remove the inner races of tapered roller bearings (5) and (IO) from gear (8). * Use a bearing puller to pull out the inner races. PTO gear 2 (Gear C) I) Remove the 8 mounting bolts, cage (1 I), and shims (12). + Check the thickness and quantity of the shims. 2) Remove the outer race of tapered roller bearing (13) from cage (1 I). + Use a bearing puller to pull out the outer race. 3) Remove gear (14) 4) Remove the inner races of tapered roller bearings (13) and (15) from gear (14). * Use a bearing puller to pull out the inner races. 5. PTO gear 3 (Gear BI I) Remove the 8 mounting bolts, cage (161, and shims (17). Ir Check the thickness and quantity of the shims. 2) Remove the outer race of tapered roller bearing (18) from cage (16). Ir Use a bearing puller to pull out the outer race. 3) Remove gear (19) 4) Remove the inner races of tapered roller bearings (18) and (20) from gear (19). f Use a bearing puller to pull out the inner races.
30-076-8 0
CONVERTER
ASSEMBLY
Modulated clutch gear (Gear E) 1) Remove the 8 mounting bolts, cage (211, and shims (22). * Check the thickness and quantity of the shims. 2) Remove the outer races of tapered roller bearings (23) and (24) from cage (21). * Use a bearing puller and a press to pull out the outer races. 3) Remove gear (25). 4) Remove snap ring (26), then remove the outer race of roller bearing (27) from gear (25). * Use a bearing puller to pull out the outer race. 5) Remove the inner races of tapered roller bearings (23) and (28) from gear (25). * Use a bearing puller to pull out the inner races. Input gear (Gear Al I) Remove the mounting bolts and holder (29). 2) Remove coupling (30). 3) Remove the 17 mounting bolts and cage (31). Remove oil seal (32) from cage (31). Remove the outer race of tapered roller bearing (33) from cage (31). * Use a bearing puller to pull out the outer race. 6) Remove spacer (34). 7) Lift off gear (35). 8) Remove the inner races of tapered roller bearings (33) and (36) from gear (35). * Use a bearing puller to pull out the inner races. 9) Remove the 8 mounting bolts, cage (37), and shims (38). * Check the thickness and quantity of the shims. IO) Remove the outer race of tapered roller bearing (36) from cage (37). * Use a bearing puller to pull out the outer race. Case Remove the outer races of tapered roller bearings (IO), (15), and (20) from case (39). * Use a bearing puller to pull out the outer races. 4) 5)
Assembly procedure 1. Case Install the outer races of tapered roller bearings (201, (151, and (IO) to case (39). f Push each outer race with a press until its end touches the shoulder of the case. 2. Input gear (Gear A) I) Install the outer race of tapered roller bearing (36) to cage (37). * Push the outer race with a press until its end touches the shoulder of the cage. 2) Fit the O-ring and install shims (38) and cage (37) with the 8 bolts. + The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm 3) Install the inner races of tapered roller bearings (36) and (33) to gear (35). * Push each inner race with a press until its end touches the shoulder of the gear. 4) Install gear (35). 5) Install spacer (34). 6) Install the outer race of tapered roller bearing (33) to cage (31). * Push the outer race with a press until its end touches the shoulder of the cage. 7) Using tool Cl, press fit oil seal (32) to cage (31). * Thinly apply gasket sealant (LG-5) to the oil seal fitting part of the cage. After fitting the oil seal, wipe off the projected sealant. f Press fit the oil seal until the flange of tool Cl touches the cage. & Oil seal lip: Grease (G2-LI)
CWWO4958
3.
ASSEMBLY
Install cage (31) with the 17 bolts. A Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 245 - 309 Nm (25.0 - 31.5 kgm1 Using a push-pull scale, check that the rotational force at the gear tooth tip is within the standard range. j, Rotational force of gear: 0 - 1.08 N (0 - 0.11 kg} Ir If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm IO) Fit the O-ring and install coupling (30). 11) Install holder (29) with the mounting bolts. a Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 824 - 1,030 Nm I84 - 105 kgm1 Modulated clutch gear (Gear El 1) Install the inner races of tapered roller bearings (28) and (23) to gear (25). * Push each inner race with a press until its end touches the shoulder of the gear. 2) Install the outer race of roller bearing (27) to gear (25) and secure it with snap ring (261. Ir Push the outer race with a press until its end touches the shoulder of the gear. 3) Install gear (25). * Drop about 6 cc of engine oil tE030CD or EOIO-CD) onto the sliding parts of the bearing and rotate the bearing 10 turns to spread the oil. 4) Install the outer races of tapered roller bearings (24) and (23) to cage (21). j, Push each outer race with a press until its end touches the shoulder of the cage. 5) Install shims (22) and cage (21) with the 8 bolts. * Drop about 6 cc of engine oil (E030CD or EOIO-CD) onto the sliding parts of the bearing and rotate the bearing 10 turns to spread the oil.
WA1 200-3
CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
4.
The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm 6) Using a push-pull scale, check that the rotational force at the gear tooth tip is within the standard range. * Rotational force of gear: 0 - 1.08 N (0 - 0.11 kg} * If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm PTO gear 3 (Gear BI I) Install the inner races of tapered roller bearings (20) and (19) to gear (19). * Push each inner race with a press until its end touches the shoulder of the gear. 2) Install gear (19). * PTO gear 2 and PTO gear 3 are different parts and they must be installed in the correct directions respectively. There are 2 identification grooves on the end of gear (19). Install gear (19) with those identification grooves on the cage side (torque converter side). (The following figure is the gear seen from the torque converter side.)
4)
*
Ii
5)
WA1 200-3
3)
c312 /2) \ 5)
CWWO4960
5.
PTO gear 2 (Gear Cl 1)
14
Install the outer race of tapered roller bearing (18) to cage (16). * Push the outer race with a press until its end touches the shoulder of the cage.
6.
4)
2)
3)
Fit the O-ring and install shims (17) and cage (16) with the 8 bolts. * The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm Using tool C3 (2/2), check that the rotational force at the center of the gear is within the standard range. * Rotational force of gear: 0 - 2.16 Nm IO - 0.22 kgm} * If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
Install the inner races of tapered roller bearings (15) and (13) to gear (14). f Push each inner race with a press until its end touches the shoulder of the gear. Install gear (14). * PTO gear 2 and PTO gear 3 are different parts and they must be installed in the correct directions respectively. There is 1 identification groove on the end of gear (14). Install gear (14) with those identification grooves on the cage side (torque converter side). (The following figure is the gear seen from the torque converter side.)
Install the outer race of tapered roller bearing (13) to cage (II). * Push the outer race with a press until its end touches the shoulder of the cage. Fit the O-ring and install shims (12) and cage (I I) with the 8 bolts. * The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. Ir Standard thickness of shims: 2.0 mm Using tool C3 (2/2), check that the rotational force at the center of the gear is within the standard range. Rotational force of gear: 0 - 3.24 Nm (0 - 0.33 kgm) If the rotational force is out of the standard range, adjust it by changing the shim thickness. Adjustment range of shim thickness: 1.3 - 2.7 mm Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
PTO gear 1 (Gear D) I) Install the inner races of tapered roller bearings (IO) and (5) to gear (8). * Push each inner race with a press until its end touches the shoulder of the gear. 2) Install snap ring (9) to gear (8). 3) Install gear (8). 4) Install snap ring (7) to coupling (6). 5) Install coupling (6). 6) Press fit the outer race of tapered roller bearing (5) to cage (3). + Push the outer race with a press until its end touches the shoulder of the cage. 7) Fit the O-ring and install shims (4) and cage (3) with the 6 bolts. & O-ring: Grease (G2-LII Ir The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm 8) Using tool C3 (l/2), check that the rotational force at the center of the gear is within the standard range. * Rotational force of gear: 0 - 5.40 Nm 10 - 0.55 kgm) * If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
CWWO4961
:WWO4960
30-076-9 0
DISASSEMBLY
7.
8.
AND
ASSEMBLY
CONVERTER
ASSEMBLY
Cover Fit the gasket and install cover (2) with the 12 bolts. Rotation sensor Install rotation sensor (I) and secure it with the locknut. & Threaded parts of sensor: Gasket sealant (LG-5) Put the rotation sensor tip lightly against * the side of the input gear in the PTO and transfer assembly and return by l/2 - 3/ 4 turns and secure with the locknut. m Locknut: 49.0 - 68.6 Nm (5 - 7 kgml
30-076-10 0
WA1 200-3
%%*sm
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DISASSEMBLY AND ASSEMBLY
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CWWO4686
WA1 200-3
30-077 0
53l!B*%l~
b5iX:*~-iaiAss’y TRANSMISSION
DISASSEMBLY AND ASSEMBLY
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30-078 0
A-A
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CWWO4887
WA1 200-3
.
b5>iX*~_jsiAss’y TRANSMISSION
m#*smk DISASSEMBLY AND ASSEMBLY
Ass’y
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WA1 200-3
2861Ni293. Bkal LOAD
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30-079 0
DISASSEMBLY
GENERAL
AND ASSEMBLY
DISASSEMBLY,
ASSEMBLY
TRANSMISSION
OF TRANSMISSION
ASSEMBLY Disassembly procedure 1. Preparation work Raise the transfer section vertically and support it with wood blocks, etc. so that the transmission will be horizontal. 2. Lubrication tubes 1) Remove the 2 joints each from lubrication tubes (I), (21, (31, (4) and (51, then remove those tubes. * Remove the tube clamps, too. 2) Remove the 2 mounting bolts and block (6). 3) Remove the 2 mounting bolts and block 3.
4.
I .:_
5.
6.
I
I
ASSEMBLY
(7). Oil filter assembly 1) Remove the 1 mounting bolt and 3 sets of 1 nut and 1 stud bolt, then remove cover (8) and 4 spacers (9). 2) Remove 3 mounting bolts, oil filter assembly (IO), and cover (I 1). Forward-reverse control valve assembly I) Remove the 4 mounting bolts, reverse clutch ECMV assembly (121, and bypass fill and drain valve assembly (13). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. 2) Remove the 4 mounting bolts, forward clutch ECMV assembly (141, and bypass fill valve assembly (15). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. Gear speed control valve assembly I) Remove the 4 mounting bolts, 1st clutch ECMV assembly (16), and bypass fill valve assembly (17). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. 2) Remove the 4 mounting bolts and 2 sets of the 2nd clutch ECMV assembly and 3rd clutch ECMV assembly (18). Ir The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. Lubrication relief valve assembly Remove the 3 mounting bolts and lubrication relief valve assembly (19).
*
7.
8.
The mounting bolts are classified into 3 lengths. Make match marks on them to indicate their respective locations. Valve seats I) Remove the 4 mounting bolts and valve seat (20). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. 2) Remove valve seat (21). 3) Remove 14 mounting bolts and valve seat (22). Breathers I) Remove 2 breathers (23) and 2 elbows (24). 2) Remove the 4 mounting bolts and flange
(25). Transmission assembly and transfer and parking brake assembly I) Sling transmission assembly (26) temporarily. 2) Remove the 23 mounting bolts and disconnect the transmission assembly (26) and transfer and parking brake assembly (27) from each other. A When removing the transmission, take care extremely so that the transfer and parking brake assembly will not fall down. Shift the transmission toward the input shaft until its output shaft comes out of the transfer. Place the removed transmission assembly on blocks with the input shaft side up. For the disassembly procedure of the transmission assembly, see DISASSEMBLY, ASSEMBLY OF TRANSMISSION ASSEMBLY. For the disassembly procedure of the transfer and parking brake assembly, see DISASSEMBLY, ASSEMBLY OF TRANSFER AND PARKING BRAKE ASSEMBLY. 10. Strainer I) Remove the 2 mounting bolts and drain 9.
2) 3) 4)
plug (28). Remove the 4 mounting bolts and 4 covers (29). Remove the 4 springs (30) and 4 magnets (31). Remove 4 cases (32).
CWWO4962
WA1 ZOO-3
TRANSMISSION
DISASSEMBLY AND ASSEMBLY
Assembly procedure 1. Preparation work Support the transfer with blocks, etc. so that it will be vertical. 2. Strainer 1) Fit the O-ring and install 4 cases (32). & Periphery of O-ring: Grease (G2-LI) 2) Install 4 magnets (31) and 4 springs (30). 3) Fit the O-ring and secure 4 covers (29) with 4 bolts each. 4) Fit the O-ring and install drain plug (28) with the 2 bolts. & O-ring: Grease (G2-LI) 3. Transmission assembly and transfer and parking brake assembly 1) Fit the O-ring to the connecting parts of transmission assembly (26) and transfer and parking brake assembly (27). 6 O-ring: Grease (G2-LI) 2) Sling transmission assembly (26) and install it to transfer assembly (27) with the 23 bolts. A When installing the transmission, take care extremely so that the transfer and parking brake assembly will not fall down. * After installing the transmission, support it with blocks, etc. 4. Breathers 1) Install flange (25) with the 4 bolts. & Mating faces of flange and case: Gasket sealant (LG-51 2) Install 2 elbows (24) and 2 breathers (23). & Elbow and breather: Gasket sealant (LG-5) 5. Valve seat 1) Fit the O-ring and install valve seat (22) with 14 bolts. w Hexagon socket head bolts (6 pieces): 58.8 - 73.5 Nm IS.0 - 7.5 kgm} 2) Fit the O-ring and install valve seat (21). 3) Fit the O-ring and install valve seat (20) with the 4 bolts. * The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 58.8 - 73.5 Nm IS.0 - 7.5 kgm} 6. Lubrication relief valve assembly Fit the O-ring and install lubrication valve
WA1 200-3
7.
8.
assembly (19) with the 3 bolts. * The mounting bolts are classified into 3 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 58.8 - 73.5 Nm 16.0 - 7.5 kgml Gear speed control valve assembly f The ECMV assembly for gear speed control and that for forward-reverse control are different from each other. The cover of the ECMV assembly for gear speed control is secured with hexagon bolts. 1) Fit the O-rings and install the 2 sets of the 3rd clutch ECMV assembly and 2nd clutch ECMV (18) with the 4 bolts each. * The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 27.4 - 34.3 Nm 12.8 - 3.5 kgm) 2) Fit the O-ring and install bypass fill valve assembly (17) and 1st clutch ECMV assembly (16) with the 4 bolts. * The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 27.4 - 34.3 Nm (2.8 - 3.5 kgm} Forward-reverse control valve assembly The ECMV assembly for forward-reverse control and that for gear speed control are different from each other. The cover of the ECMV assembly for forward-reverse control is secured with hexagon socket head bolts. Fit the O-rings and install the bypass fill valve assembly (15) and forward clutch ECMV assembly (14) with the 4 bolts. + The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. m Mounting bolt: 27.4 - 34.3 Nm {2.8 - 3.5 kgm} Fit the O-ring and install bypass fill and drain valve assembly (13) and reverse clutch ECMV assembly (12) with the 4 bolts.
*
w
ASSEMBLY
The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. Mounting bolt: 27.4 - 34.3 Nm 12.8 - 3.5 kgm}
9.
Oil filter 1) Fit the O-ring and install cover (11) and oil filter assembly (IO) with the 3 bolts. m Mounting bolt: 58.8 - 73.5 Nm IS.0 - 7.5 kgml 2) Install the 3 stud bolts, then install the 4 spacers (9) and cover (8) with the 1 bolt and 3 nuts. 10. Lubrication tube I) Install block (7) with the 2 bolts. 2) Install block (6) with the 2 bolts. 3) Fit the gasket and install lubrication tubes (51, (41, (31, (21, and (I) with 2 joints each. w Joint: 44.1 - 53.9 Nm I4.5 - 5.5 kgm}
30-079-Z 0
TRANSMISSION
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY,
Il/2
ASSEMBLY
OF TRANSMISSION
ASSEMBLY
ASSEMBLY
40 27 Lk
-55 ”
\ 54
30-079-3 0
WA1 200-3
DISASSEMBLY AND ASSEMBLY
WA1 200-3
TRANSMISSION
ASSEMBLY
30-079-4 0
TRANSMISSION
DISASSEMBLY AND ASSEMBLY
Disassembly procedure 1. Preparation work Set the transmission assembly on blocks, etc. with the input shaft side up. 2. Case 1) Remove 7 sleeves (1). * Apply a bearing puller, etc. to the groove on the inside wall of the sleeve to pull out the sleeve. 2) Remove the 3 mounting bolts and case 3.
4.
(2). Housing Remove the 24 long bolts, 6 short bolts, and housing (3). Input shaft, reverse clutch carrier and reverse sun gear assembly 1) Sling the input shaft end and remove the input shaft, reverse clutch carrier and reverse sun gear assembly (4). * Sling the input shaft vertically so that the inner race and outer race of the taper roller bearing under the carrier will not be tilted when they are disconnected from each other. 2) Remove snap ring (5) and spacer (6). 3) Remove cage (7). Ir Use a puller to remove the cage. 4) Remove ball bearings (8) and (9) from cage (7). Jr Use bearing puller to pull out the bearings. 5) Remove the 8 mounting bolts and cage (IO). * Pull out the cage with forcing screws. 6) Remove 2 seal rings (11) from cage (IO). 7) Remove snap ring (12) and gar (13). 8) Remove snap ring (14). 9) Remove shaft (15). + Use a press to pull out the shaft. 10) Remove seal ring (16) from shaft (15). 11) Remove snap ring (17) and gear (18). 12) Remove ball bearing (19) from shaft (15). * Use a press to pull out the ball bearing. 13) Remove shaft (20) and ball (21) from carrier (22). * Remove the 4 sets. 14) Remove gear (23), 2 needle bearings (24) each, and 2 thrust washers (25) each. * Remove the 4 sets. 15) Remove the inner race of roller bearing (26). * Use a bearing inner race.
30-079-5 0
puller to remove
the
5.
6. 7.
8.
Reverse clutch plates and discs 1) Remove 6 springs (27). * The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 2) Remove 8 plates (28), 7 discs (29), and 48 springs (30) alternately. Reverse clutch ring gear Remove ring gear (31). Reverse clutch housing and piston 1) Remove housing (32). * Remove the housing and piston as 1 unit. 2) Remove piston (33) from housing (32). 3) Remove seal ring (34) from housing (32). 4) Remove seal ring (35) from piston (33). Connecting ring gear 1) Remove the 8 mounting bolts and plate (36). 2) Remove ring gear (37). 3) Remove snap ring (38) from ring gear
(37). Forward clutch plates and discs 1) Remove 6 pins (39) and 12 pins (40). Ir The length of the pins depends on the clutch. Put tags, etc. to the pins to indicate their respective locations. 2) Remove 6 springs (41). * The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 3) Remove 9 plates (42), 8 discs (43), and 72 springs (44). _ 10. Forward clutch ring gear Remove ring gear (45). 11. Forward clutch housing and piston 1) Remove housing (46). * Remove the housing and piston as 1 unit. 2) Remove piston (47) from housing (46). 3) Remove seal ring (48) from housing (46). 4) Remove seal ring (49) from piston (47). 12. 3rd clutch plates and discs 1) Remove 6 springs (50). f The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 2) Remove 5 plates (51), 4 discs (52), and 30 springs (53) alternately.
9.
13. Forward clutch and 3rd clutch carrier assembly 1) Remove the 4 mounting
bolts and collar
(54). 2) Remove 2 seal rings (55) from collar (54). 3) Lift off forward clutch and 3rd clutch carrier assembly (56). 4) Remove snap ring (57), ball bearing (58), and gear (59). * Use a press to pull out above parts. 5) Remove collar (60) from ball bearing (61). * Use a press to pull out the bearing. 6) Remove shaft (62) and ball (63) from carrier (64). * Remove the 4 sets. 7) Remove 2 gears (65) each, 4 needle roller bearings (66) each, and 4 thrust washers (67) each. * Remove the 4 sets. 8) Remove the outer race of roller bearing (26) from carrier (64). * Use a bearing puller to pull out the outer race. 14. 3rd clutch ring gear 1) Remove the 8 mounting bolts and plate (68). 2) Remove ring gear (69). 3) Remove snap ring (70) from ring gear (69). 15. 3rd clutch housing and piston 1) Remove housing (71). * Remove the housing and piston as 1 unit. 2) Remove piston (72) from housing (71). 3) Remove seal ring (73) from housing (71). 4) Remove seal ring (74) from piston (72). 16. 2nd clutch plates and discs 1) Remove 6 springs (75). * The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 2) Remove 6 pins (76) and 12 pins (77). Ir The length of the pins depends on the clutch. Put tags, etc. to the pins to indicate their respective locations. 3) Remove 4 plates (78), 3 discs (79), and 24 springs (80). 17. 2nd clutch ring gear Remove ring gear (81). 18. 2nd clutch housing I) Remove housing (82). * Remove the housing and piston as 1 unit.
ASSEMBLY
2) Remove piston (83) from housing (82). 3) Remove seal ring (84) from housing (82). 4) Remove seal ring (85) from piston (83). lg. 2nd clutch sun gear Remove gear (86). 20. 2nd clutch carrier and 1st clutch assembly 1) Remove 2nd clutch carrier and 1st clutch assembly (87). * Utilizing the bolt holes of the carrier, pull out the assembly with a puller. 2) Remove the 30 mounting bolts and cage (88). Remove snap ring (89) and spacer (90) from cage (88). * Remove the snap ring, compressing the spring with a press. 4) Remove 3 springs (91) from cage (88). 5) Remove piston (92) from cage (88). 6) Remove seal ring (93) from piston (92). 7) Remove snap ring (94) and ball bearing (95) from cage (88). * Use a bearing puller to pull out the ball bearing. 8) Remove snap ring (96) and collar (97) from cage (88). 9) Remove ball bearing (98) from cage (88). * Use a bearing puller to pull out the ball bearing. 10) Remove seal rings (99) and (100) from cage (88). 11) Remove hub (101). 12) Remove 2 seal rings (102) from hub (101). 13) Remove 9 discs (103), 8 plates (104), and 9 springs (105) alternately. 14) Remove snap ring (106) from carrier (107). 15) Remove shaft (108) and ball (109) from carrier (107). * Remove the 4 sets. 16) Remove gear (IIO), 2 needle bearings (111) each, and 2 thrust washers (I 12) each. * Remove the 4 sets. 21. Output shaft assembly and housing 1) Remove 6 mounting bolts and output shaft assembly (113) from housing (114). * Pull out the output shaft with forcing screws. 2) Remove snap ring (115) and cage (116) from shaft (I 17). * Use a press to pull out the cage. 3) Remove seal ring (I 18) from cage (I 16). 4) Remove snap ring (119) and ball bearing (120) from shaft (I 17). 3)
WA1 200-3
DISASSEMBLY AND ASSEMBLY
*
5)
Use a press to pull out the ball bearing. Remove seal ring (121) from shaft (117).
TRANSMISSION
7)
Install seal rings (100) and (99) to cage 038). & Seal ring: Grease (G2-LI) * Install seal ring (100) as shown low.
be-
3. Assembly procedure 1. Output shaft assembly and housing 1) Install seal ring (121) to shaft (117). 6 Seal ring: Grease (G2-LI) 2) Install ball bearing (120) to shaft (117) and secure it with snap ring (119). J, Push the bearing with a press until the end of its inner race touches the shoulder of the shaft. 3) Install seal ring (118) to cage (116). 6 Seal ring: Grease (G2-LI) 4) Install cage (116) to shaft (117) and secure it with snap ring (115). * Push the outer race of the bearing with a press until it touches the shoulder of the cage. 5) Install output shaft assembly (113) to housing (114) with the 6 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 98 - 123 Nm (10.0 - 12.5 kgml 2. 2nd clutch carrier and 1st clutch assembly I) Set 2 thrust washers (112) each and 2 needle bearings (I 1 I) each to gear (I IO), then install them to carrier (107). * When installing, take care not to bruise the thrust washers. * Install the 4 sets. 2) Set ball (109) to shaft (1081, then install them to carrier (107). * Match the ball to the cut of the carrier and push the shaft with a press until it is flush with the carrier. * Install the 4 sets. 3) Install snap ring (106) to carrier (107). 4) Install 9 discs (103), 8 plates (1041, and 9 springs (105) to carrier (107) alternately. 5) Install 2 seal rings (102) to hub (101). 6 Seal ring: Grease (G2-LI) 6) Install hub (101) to carrier (107).
WA1 200-3
4.
Install ball bearing (98) to cage (88). * Push the ball bearing with a press until the end of its outer race touches the shoulder of the cage. 9) Install collar (97) to cage (88) and secure it with snap ring (96). IO) Install ball bearing (95) to cage (88) and secure it with snap ring (94). * Push the ball bearing with a press until the end of its outer race touches the shoulder of the cage. 11) Install seal ring (93) to piston (92). & Seal ring: Grease (G2-LI) * Install the seal ring as shown below.
15) Install cage (88) to carrier (107) with the 30 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm (IO.0 - 12.5 kgml 16) Install 2nd clutch carrier and 1st clutch assembly (87) to the output shaft. Ir Push the assembly with a press until the end of the inner race of the ball bearing touches the shoulder of the shaft. 2nd clutch sun gear Install gear (86). 2nd clutch housing I) Install seal ring (85) to piston (83). & Seal ring: Grease (G2-LI) * Install the seal ring as shown below.
2)
7.
8)
8.
CWWO4967
2)
ASSEMBLY
Install seal ring (84) to housing (82). a Seal ring: Grease (G2-LI) f Install the seal ring as shown below. 9.
Install 12 pins (77) and 6 pins (76). * The length of the pins depends on the clutch. Before installing each pin, check its length. * Pin length: (77); 208 mm, (76); 223 mm 3) Install 6 springs (75). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 56.9 mm 3rd clutch housing and piston 1) Install seal ring (74) to piston (72). & Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 2) Install seal ring (73) to housing (71). & Seal ring: Grease (G2-LII f The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 3) Install piston (72) to housing (71). 4) Install housing (71). 3rd clutch ring gear 1) Install snap ring (70) to ring gear (69). 2) Install ring gear (69). 3) Install plate (68) with 8 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 98 - 123 Nm (IO.0 - 12.5 kgml Forward clutch and 3rd clutch carrier assembly
CWW04966
12) Install piston (92) to cage (88). 13) Install 3 springs (91) to cage (88). 14) Install spacer (90) and secure it with snap ring (89). * Install the snap ring, compressing the spring with a press. * Installed load of spring: 1,697 N {I73 kg1
CWW04968
5. 6.
3) Install piston (83) to housing (82). 4) Install housing (82). 2nd clutch ring gear Install ring gear (81). 2nd clutch plates and discs 1) Install 4 plates (781, 3 discs (791, and 24 springs (80) alternately.
Install the outer race of roller bearing (26) to carrier (64). j, Push the outer race with a press until its end touches the shoulder of the carrier. Set 2 thrust washers (67) each and 2 needle bearings (66) to gear (65), then install them to carrier (64). * When installing, take care not to bruise the thrust washers. * Install the 4 sets. Install ball (63) to shaft (62), then install them to carrier (64). * Match the ball to the cut of the carrier and push the shaft with a press until it is flush with the carrier. * Install the 4 sets. Install gear (59) to carrier (64).
30-079-6
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
10.
11.
12. 13.
Press fit collar (60) to ball bearing (58). * Push the collar with a press until its shoulder touches the end of the inner race. 6) Install bearing (58) to carrier (64) and secure it with snap ring (57). Ir Push the bearing with a press until the end of its outer race touches the shoulder of the carrier. 7) Install forward clutch and 3rd clutch carrier assembly (56). 8) Install 2 seal rings (55) to collar (54). & Seal ring: Grease (G2-LII 9) Install collars (54) with 4 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm I10.0 - 12.5 kgm} 3rd clutch plates and discs I) Install 5 plates (511,. 4 discs (521, and 30 springs (53) alternately. 2) Install 6 springs (50). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 68.8 mm Forward clutch housing and piston 1) Install seal ring (49) to piston (47). & Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 2) Install seal ring (48) to housing (46). & Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 3) Install piston (47) to housing (46). 4) Install housing (46). Forward clutch ring gear Install ring gear (45). Forward clutch plates and discs I) Install 9 plates (421, 8 discs (431, and 72 springs (44) alternately. 2) Install 6 springs (41). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 168 mm
3)
5)
30-079-7 0
14.
15.
16. 17.
18.
Install 12 pins (40) and 6 pins (39). j, The length of the pins depends on the clutch. Before installing each pin, check its length. * Pin length: (40); 315 mm, (39); 315 mm Connecting ring gear 1) Install snap ring (38) to ring gear (37). 2) Install ring gear (37). 3) Install plate (36) with 8 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm {IO.0 - 12.5 kgm} Reverse clutch housing and piston 1) Install seal ring (35) to piston (33). 6 Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 2) Install seal ring (34) to housing (32). 6 Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 3) Install piston (33) to housing (32). 4) Install housing (32). Reverse clutch ring gear Install ring gear (31). Reverse clutch plates and discs I) Install 8 plates (281, 7 discs (291, and 48 springs (30) alternately. 2) Install 6 springs (27). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 133 mm Input shaft, reverse clutch carrier and reverse sun gear assembly I) Install the inner race of roller bearing (26) to carrier (22). * Push the inner race with a press until its end touches the shoulder of the carrier. 2) Set 2 thrust washers (25) and 2 needle bearings (24) to gear (231, then install them to carrier (22). * When installing, take care not to bruise the thrust washers. Ir Install the 4 sets.
3)
Set ball (21) to shaft (201, then install them to carrier (22). * Match the ball to the cut of the carrier and push the shaft with a press until it is flush with the carrier. * Install the 4 sets. 4) Install ball bearing (19) to shaft (15). * Push the ball bearing with a press until the end of its inner race touches the shoulder of the shaft. 5) Install gear (18) and secure it with snap ring (17). 6) Install shaft (15) to carrier (22). + Push the outer race of the ball bearing with a press until its end touches the shoulder of the carrier. 7) Install snap ring (14). 8) Install gear (13) and secure it with snap ring (12). 9) Install 2 seal rings (I I) to cage (IO). & Seal ring: Grease (G2-LI) IO) Install cage (IO) to carrier (20) with the 8 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm {IO.0 - 12.5 kgm} 11) Install ball bearing (9) to cage (7). * Push the ball bearing with a press until the end of its inner race touches the shoulder of the cage. 12) Install cage (7) to cage (IO). * Push the cage with a press until the end of the inner race touches the shoulder of the cage. 13) Install ball bearing (8) to cage (7). * Push the inner race and outer race of the ball bearing simultaneously with a press until the end of the outer race touches the shoulder of the cage. 14) Install spacer (6) and secure it with snap ring (5). 15) Install seal ring (16) to shaft (15). & Seal ring: Grease (G2-LII 16) Sling the input shaft end and install the input shaft, reverse clutch carrier and reverse sun gear assembly (4). * Sling the input shaft vertically so that the inner race and outer race of the taper roller bearing under the carrier will not be tilted when they are coupled with each other.
ASSEMBLY
19. Housing Install housing (3) with 24 long bolts and 6 short bolts. 6 Threaded parts of short mounting bolt: Liquid adhesive (LT-2) w Long bolt: 353 - 392 Nm I36 - 40 kgm1 Short bolt: 98 - 123 Nm {IO.0 - 12.5 kgml 20. Case 1) Install case (2) with the 3 bolts. m Mounting bolt: 490 - 608 Nm (50 - 62 kgml 2) Fit the O-ring and install 7 sleeves (I).
WA1 200-3
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY,
ASSEMBLY
TRANSMISSION
OF TRANSFER
AND PARKING
ASSEMBLY
BRAKE ASSEMBLY
29
27
28 \ 32
WA1 200-3
30-079-8 0
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
Disassembly procedure Ir When removing only the parking brake assembly from the TORQFLOW assembly or vehicle body, see REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY. 1. Front coupling I) Remove the mounting bolts and holder (I). 2) Remove coupling (2). 2. Cage 1) Remove the 6 mounting bolts, cage (31, and shims (4). * Check the thickness and quantity of the shims. 2) Remove dust seal (5) from cage (4). 3) Remove oil seal (6) from cage (4). 3. Rear coupling I) Remove the bolts and holder (7). 2) Remove coupling (8). 4. Parking brake assembly I) Remove 2 mounting bolts and flange (9). 2) Remove sleeve (IO). * Screw a hanging bolt (12 mm) in the sleeve to pull out the sleeve. 3) Remove 2 plugs (11) and 2 sets of bolt and washer (12). * Any bolts and washers may be removed, since they will be used to secure the parking brake. Do not remove any of the 4 hexagon socket head bolts. 4) Install the removed 2 sets of bolt and washer (12) in the plug holes. * Screw in the 2 sets of bolt and washer alternately and slowly to pull the piston in the packing brake toward the housing.
5.
Remove the remaining 10 mounting bolts and parking brake assembly (13). * Do not remove the 4 hexagon socket head bolts.
30-079-9 0
(14). Remove output shaft and gear assembly (15). 3) Remove spacer (16) and gear (17) from shaft (IS). * Use a press to pull out the spacer and gear simultaneously. Idler gear I) Remove the 2 mounting bolts and plate (19). 2) Remove the 18 mounting bolts and cage 2)
6.
7.
5)
Pull out the assembly evenly with forcing screws. After it is pulled out to the shaft end, lift it off. For the disassembly procedure of the parking brake assembly, see DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY. Output shaft and gear assembly I) Remove the 8 mounting bolts and cover
(20). * Pull out the cage with forcing screws (12 mm). * Pull out the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. 3) Remove the outer race of roller bearing (21) from cage (20). * Use a bearing puller to pull out the outer race. 4) Remove gear (22). * Pull out the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. 5) Remove the 4 mounting bolts and joint (23) from gear (22). 6) Remove the inner races of roller bearings (21) and (24) from gear (22). * Use a bearing puller to pull out the inner races. Input gear Remove the 2 mounting bolts and plate (25). Remove the 6 mounting bolts and cage (26). * Pull out the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. Remove snap ring (27) and joint (28). Remove the 18 mounting bolts and cage (29).
8.
Remove the outer race of roller bearing (30) from cage (29). * Use a bearing puller to pull out the out races. Remove gear (31). * Pull out the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. Remove the inner races of roller bearings (30) and (32) from gear (31). * Use a bearing puller to pull out the inner races. Case 1) Remove the outer races of roller bearings (24) and (32) from case (33). * Use a bearing puller to pull out the outer races. 2) Remove tapered roller bearing (34) from case (33). Ir Use a bearing puller to pull out the bearing.
ASSEMBLY
Assembly procedure * When installing only the parking brake assembly to the TORQFLOW assembly or vehicle body, see REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY. 1. Case Install the outer races of roller bearings (24) and (32) to case (33). * Push each outer race with a press until its end touches the shoulder of the case. 2. Input gear 1) It-&all the inner races of roller bearing (32) and (30) to gear (31). * Push each inner race with a press until its end touches the shoulder of the case. 2) Install gear (31). * Insert the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other. 3) Install the outer race of roller bearing (30) to cage (29). * Push the outer race with a press until its end touches the shoulder of the cage. 4) Install cage (29) with the 18 bolts. * Insert the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other. 5) Install joint (28) and secure it with snap ring (27). 6) Fit the O-ring and install cage (26) with the 6 bolts. & O-ring: Grease (G2-LI) 7) Fit the O-ring and install plate (25) with the 2 bolts. 3. Idler gear Press fit the inner races of roller bearings (24) and (21) to gear (22). -Lr Push each inner race with a press until its end touches the shoulder of the gear. Install joint (23) to gear (22) with the 4 bolts. Install gear (22). * Insert the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other.
WA1 200-3
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
4)
Install the outer race of roller bearing (21) to cage (20). * Push the outer race with a press until its end touches the shoulder of the cage. 5) Fit the O-ring and install cage (20) with the 18 bolts. 6 O-ring: Grease (G2-LI) * Insert the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other. w Mounting bolt: 245.0 - 308.7 Nm I25.0 - 31.5 kgm} 6) Fit the O-ring and install plate (19) with the 2 bolts. 4. Output shaft and gear assembly I) Install tool D6 to case (31).
5.
Parking brake assembly 1) Fit the O-ring and set the parking brake assembly (13) in position, then tighten the 10 bolts temporarily. 2) Remove the 2 sets of bolt and washer (12) from parking brake assembly (131, then install parking brake assembly (13) with the 12 bolts in total. * Loosen the bolts and washers alternately and slowly so that the piston in the parking brake will not be tilted. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 205.9 - 269.7 Nm I21.0 - 27.5 kgml
6.
7.
ASSEMBLY
iii) Calculate shim thickness c. c = (a -b) - (0.05 to 0.10) * The bearing is pushed in by 0.05 to 0.10 mm with the cage. * Standard shim thickness (Reference): 0.8 to 2.0 mm * Types of shims: 0.15, 0.20 mm
Rear coupling I) Install coupling (8). 2) Install holder (7) with the bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 2,059 - 2,354 Nm (210 - 240 kgml Cage 1) Using tool D2, press fit oil seal (6) to cage (3). Sr Thinly apply gasket sealant (LG-5) to the oil seal fitting part of the cage. After fitting the oil seal, wipe off the projected sealant. f Push the oil seal until the flange of the tool touches the cage. & Oil seal lip: Grease (G2-Lll
l
cwwo4974
.D6
3)
Install selected shim (4) and cage (3) with the 6 bolts. * Since the shims are of 2-piece split type, be sure to set them to the same thickness on both sides. 4) Using tool D3, install dust seal (5) to cage
3) 4) 2)
Install gear (17) and spacer (16) to shaft
3)
(18). * After installing the gear, push it with a press until the end of the spacer touches the shoulder of the shaft. Install output shaft and gear assembly
4)
(15). Install cover (14) with the 8 bolts.
5) 6) 7)
Install 2 plugs (11) to parking brake assembly (13). Fit the O-ring and install sleeve (IO). & Sleeve: Grease (G2-LI) Fit the O-ring and install flange (9) with the 2 bolts. Remove tool D6. Using tool D5, install tapered roller bearing (34) to case (33). Ir Since the bearing is an assembly, handle it as one unit, when replacing. * Press fit the bearing one side by one and insert the ring without fail.
(3). * Push the dust seal until the flange of the tool touches the cage. & Dust seal lip: Grease (G2-LII
cwwo4973
2)
Select the shim thickness according to the following procedure. i) Install cage (3) to case (33) temporarily and measure distance a between the cage end and case end. * Do not install any shim at this time. ii) Remove cage (3) and measure cage thickness b.
a
8.
WA1 200-3
Front coupling I) Install coupling (2). 2) Install holder (1) with the bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 2,059 - 2,354 Nm 1210 - 240 kgm1
30-079- 10 0
DISASSEMBLY
REMOVAL,
AND
TRANSMISSION
ASSEMBLY
INSTALLATION
OF PARKING
BRAKE ASSEMBLY
(FROM VEHICLE
ASSEMBLY
BODY) Preparation of tools * Prepare the tools used for removal and stallation work. @ Shackle (2 pieces) * If the shackles are not manufactured the specified dimensions, they may terfere with some parts and may not usable. 45Lt ,Min. 45
30M Max.
30
j
to inbe
30MT
,
, ? -_
in-
Max.
30
Removal procedure 1. Remove the mounting bolts and holder (I). f When using a booster wrench to loosen the mounting bolts, hold it securely with a rope or a band from above so that it, bolts, and wrench adapter will not come Off.
2. 3. 4.
18M Min. 18
r‘
5.
6.
0
Guide bolt (3 pieces)
Remove Remove
coupling (2). the 2 mounting
bolts and flange
(3). Remove sleeve (4). f Screw a hanging bolt (12 mm) in the sleeve to pull out the sleeve. Remove 2 plugs (5) and 2 sets of bolt and washer (6). * Any bolts and washers may be removed, since they will be used to secure the parking brake. Do not remove any of the 4 hexagon socket head bolts. Install the removed 2 sets of bolt and washer (6) in the plug holes. Sr Screw in the 2 sets of bolt and washer alternately and slowly to pull the piston in the parking brake toward the housing.
I
MR : S43C-D MateriaI:S43C-D
CWWO4984
I 7.
I
CWWO4986
Remove the parking brake assembly (7) accordina to the following procedure. Remove the remaining 10 mounting bolts. * Do not remove the 4 hexagon socket head bolts. Using forcing screws, pull out parking brake assembly (7) to a position where 2 shackles @ can be installed. Install 2 shackles @ as shown in the figure. Sling parking brake assembly (7) from both sides of the transmission.
CWW04983
30-079-11 0
1
WA1 200-3
DISASSEMBLY
5)
TRANSMISSION
AND ASSEMBLY
Using output shaft (8) as a guide, slide off parking brake assembly (7) to the rear of the vehicle body.
m
Installation procedure 1. Install parking brake assembly (7) according to the following procedure and tighten the IO mounting bolts temporarily. 1) Install shackles @ as shown in the figure. 2) Sling parking brake assembly (7) from both sides of the transmission and slide it toward the transfer until it is placed on output shaft (8) perfectly.
ASSEMBLY
Mounting bolt: 205.9 - 269.7 Nm (21.0 - 27.5 kgm}
CWW04986
CWW04987 3. 4. 5. CWW04988
3) 4)
5)
Remove shackles @ and install 3 guide bolts @ as shown in the figure. Push parking brake assembly (7) toward the transfer to set it to the position for installation. Tighten the 10 bolts temporarily and remove guide bolts 0.
6. 7.
Install 2 plugs (5) to parking brake assembly (13). Fit the O-ring and install sleeve (4). & Sleeve: Grease (G2-LI) Fit the O-ring and install flange (3) with 2 bolts. Install coupling (2). Install holder (1) with the bolts. f When using a booster wrench to tighten the mounting bolts, hold it securely with a rope or a band from above so that it, bolts, and wrench adapter will not come Off. &
w
Threaded
parts of mounting bolt: Liquid adhesive (LT-2) Mounting bolt: 2,059 - 2,354 Nm I210 - 240 kgm)
CWW04989
2.
WA1 200-3
Remove 2 sets of bolt and washer (6) from parking brake assembly (7), then install parking brake assembly (13) with the 12 bolts in total. Sr Loosen the bolts and washers alternately and slowly so that the piston in the parking brake will not be tilted. & Threaded parts of mounting bolt: Liquid adhesive (LT-2)
30-079-12 0
DISASSEMBLY
DISASSEMBLY,
AND
TRANSMISSION
ASSEMBLY
ASSEMBLY
OF PARKING
ASSEMBLY
BRAKE ASSEMBLY
IO
6
1
I
Disassembly procedure 1. Plate Remove snap ring (1) and plate (2). 2. Plates and discs Remove 9 plates (3),8 discs (41, and 8 springs 3. 4. 5.
6.
7. 8.
9.
(5). Drum 1 Remove drum (6). Spacer Remove spacer (7). Drum 2 I) Remove 2 sets of bolt and washer (8). * These are the bolts moved when the parking brake assembly was removed. + Loosen the 2 sets alternately and slowly, checking that the piston is coming out toward the drum. 2) Remove the 4 bolts and drum (9). 3) Remove snap ring (IO) from drum (9). Piston I) Remove piston (II). 2) Remove seal rings (12) and (13) from piston (11). Springs Remove 14 springs (14) and 14 springs (15). Bearing Remove snap ring (16) and bearing (17). * Use a bearing puller to pull out the bearing. Housing 1) Remove dust seal (18) from housing (19). 2) Remove oil seal (20) from housing (19).
Assembly procedure 1. Housing 1) Using tool D2, install oil seal (20) to housing (19). + Thinly apply gasket sealant (LG-5) to the oil seal fitting part of the housing. After fitting the oil seal, wipe off the projected sealant. * Press fit the oil seal until the flange of the tool touches the housing. & Oil seal lip: Grease (G2-LI)
2)
Using tool D3, install dust seal (18) to housing (19). * Press fit the dust seal until the flange of the tool touches the housing. & Dust seal lip: Grease (G2-LI)
1
Ii
CWW04978
1
2. Bearing Install bearing (17) and secure it with snap ring (16). * Push the bearing with a press until its end touches the shoulder of the housing.
CWWO4976
30-079- 13 0
WA1 200-3
DISASSEMBLY AND ASSEMBLY
3. 4.
TRANSMISSION
Springs Install 14 springs (15) and 14 springs (14). Piston I) Install seal rings (13) and (12) to piston (II). * Install the seal rings as shown in the following figure. I 1 I
I
I
d
6.
7. 8.
ASSEMBLY
Spacer Install spacer (7). Jr Insert the spacer vertically, since it is used as the inner race of the roller bearing, too. Drum 2 Install drum (6). Plates and discs Remove 9 plates (3), 8 discs (41, and 8 springs (5) alternately. Plate Install plate (2) and secure it with snap ring (I).
I
-
cwwo4979
I
2)
5.
Place piston (I 1) on the spring. * Match the dowel pin of the housing to the pin hole of the piston. Drum 2 I) Install snap ring (IO) to drum (9). 2) Place drum (9) over piston (11) and secure it with the 4 bolts. * Tighten the bolts slowly so that the piston will not be tilted in the housing. 3) Tighten the 2 sets of bolt and washer (8) in the plug holes. * Use the bolts and washers for the parking brake assembly temporarily. Do not remove them until the parking brake assembly is installed to the transfer. * Tighten the 2 sets alternately and slowly, checking that the piston is moving toward the housing.
WA1 200-3
30-079-14 0
lW7Ass’y
5M*i#m DISASSEMBLY AND ASSEMBLY
I\” /I/
VALVE Ass?
j'Ass'y
VALVE Ass’y
_-_-_-_-_ _________--_-_-_-_ _________-__
-
L-J
30-080 0
AA
f?l
ll7-h
1i I
I
WA1 200-3
mB*$m
t-/l/~;,
DISASSEMBLY
bIL=Ii,
b?i7(:
T/C, T/M
bSiX2
AND ASSEMBLY
y-i~1>i5-fiAs.s’y T/C, T/M LINE Ass’y
~‘jaiffiAss’y(V5)
LINE Ass’y(V5)
d‘-_________!_______-_____-__-
D-D
___--- _-----_-____ --__ _------_______ >.:---
B-B(1
-__r__-__7____
.-~_-._-__r__-__-_-
:2)
F-F
-_--__-__-___ -__-__-__-__-__-__
_-__
._-__3
Y<
I’ ,/
,‘,,
3
5,’
_&_
0 0
CWW04889
WA1 200-3
30-081 0
bJI*=Ii,
!im*@3
b5i5Z:s~-i~i~-fiAss’y T/C, T/M LINE Ass’y
DISASSEMBLY AND ASSEMBLY
IdLO,
~~jsc~8~~~i~~iAss’y(2/5)
T/C, T/M LINE Ass’y(2/5)
/--1 --_,
‘\ \
\
n
(TO CW'w;892)
_Ip-__
A__-_
r\
L--r_ ___-;_-__-__h_ -________ __-__-__-__ I
. ,'
\
'\\ “\ '\\
I:0 CWWO48921 r
\( \
CWWO4890
30-082 0
WA1 200-3
5M#*%l3 DISASSEMBLY
bAai,
bJtXi,
AND ASSEMBLY
b3i;c-i
bYi;c<
~‘-iai5i>Ass’y T/C, T/M LINE Ass’y
~_jai5OAss’y(3/5)
T/C, T/M LINE Ass’y(3/5)
1 it-
___-______
-------.
(FROM
c-c (1 :2) CWWO48921
AIR BLEEOIHG PLUG
E-E
Y (FROM
WA1 200-3
CWWO4889)
CWW0489 1
30-083 0
t+Jb=I>,
33B+*?im DISASSEMBLY AND ASSEMBLY
bl1,=Ii,
bPii:
b?iX<-~_iz;5_I;Ass’y T/C, T/M LINE Ass’y
~_j~1=/3-IiAss'y(4/5)
T/C, T/M LINE Ass’y(4/5)
(FROM
CtWO4890)
PC1 2)
CWW04892
30-084 0
WA1 200-3
53@f*sm
bILzli,
DISASSEMBLY AND ASSEMBLY
T/C, T/M
6.
8.
WA1 200-3
LINE Ass’y
b~iX.*~-ia>i4>Ass’y T/C, T/M LINE Ass’v
(5/5) 1.
Bolt tightening torque per KES 04. 123. 1 impact wrench (Table 2).
2.
Install hoses free from twisting.
3.
KES 00. 258. 1 (Contaminant inspection method and contaminant limit in hydraulic circuit) and KES 00. 248. 1 (Contaminant removing method during manufacturing hydraulic parts and contaminant defecting method of finished parts and contaminant limit) shall be satisfied.
4.
Tightening 123. 3.
5.
Adjust number of shims so that of parallelism within 0.15 between center pin and matching surface of output yoke of transmission front end.
6.
Use oil E03@CD . .. Atmospheric temperature 0°C Min. EOIO-CD . ..Atmospheric temperature +lO”C Max.
7.
Oil capacity 360 Q At oil change 280 Q
8.
Oil inlet and air extract method at 1st oil inletting (At 1st time, oil level is not stabirized because the air was into oil circuit. So check oil level as follows) (I) Pour oil 300 Q into oil filler. (2) Run the engine. Then add oil 60 Q when oil level gauge starts to move downward. (3) Check oil level to be oil level of engine idle after idling engine 5 minutes. (4) Leave half a day as engine stop. Bleed air of torque converter oil cooler after loosening air bleeding plug of torque converter oil cooler. (5) Then run the engine and keep idle 5 minutes or more. So confirm oil level in regulated area.
torque of pipe thread per KES 04.
30-085 0
53l%*%l2 DISASSEMBLY
T”n4?-i
7’U’V -i t 7 bAss’y PROPELLER SHAFT Ass%
AND ASSEMBLY
-tt 7
PROPELLER
bAss’y
SHAFT
I L__~~______I_~__-__-__-_;
TlGWTEHlWG
8fiClb9
TDLPUE
343-427Nm
Ass’y
4
i I
’L_~I_-___-LI__I_-__-__-_~ ilG”TEYlYG
iiIth7
4
TORPUE
343-427Nm
(35-43.
5kaml
CWW04893
30-086 0
WA1 200-3
DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT
DISASSEMBLY, ASSEMBLY OF CENTER SUPPORT DISASSEMBLY 1.
Retainer Remove 3 mounting bolts (2) of retainer (1).
2.
Coupling 1) Turn over the center support assembly. 2) Remove bolt (3), then remove holder (4), coupling (5), and shim (6). fl Check the number and thickness of the shims.
3.
4.
Shaft 1) Set shaft and housing assembly (8) on press stand. 2) Remove shaft (9) with press. fl Receive the shaft so that it will not fall onto the floor.
3)
5.
Oil seal Remove oil seal (11) from retainers (1) and (7).
6.
Housing Remove outer race (12) from housing
Remove bearing (10) and retainer (1) from shaft.
Retainer Remove retainer (7).
WA1200-3
30-086-1 (9)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY 1.
Housing 1) Install outer race (12) to the housing. 2) Install the O-rings to both ends of the housing.
2.
Oil seal Using the push tool, install oil seal (11) to retainers (1) and (7). fl Press fit oil seal (11) until it comes in contact with the retainer. • Reference Dimension (a) = 2 ± 0.5 mm 2 Oil seal lip: Grease (G2-LI)
30-086-2 (9)
CENTER SUPPORT
3.
Shaft 1) Install retainer (1) to the shaft. 2) Using the push tool, install bearing (10) to the shaft.
3) 4)
5)
Install housing (13) to the shaft. fl Fill internal space (b) with grease (G2-LI). Tighten mounting bolt (2) of retainer (1). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} Using the push tool, install bearing (14).
4.
Retainer 1) Install retainer (7). fl Fill internal space (c) with grease (G2-LI). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
5.
Adjusting shim 1) Install coupling (5), holder (4), and bolt (3). fl Measure the thickness of the holder. fl Do not install the shim. 2) While rotating housing (13), tighten bolt (3) so that the starting torque of the housing will be 8 – 12 Nm {0.8 – 1.2 kgm}. 3) Measure clearance (d) between holder (4) and shaft (9) at 3 places in holder hole (e). 4) Calculate average (f) of clearance (d). 5) Select and install some of the set shims so that their total thickness will be as follows and the standard end play will be obtained. • Set shims: 0.05, 0.1, 0.3 mm • Total thickness of shims = (f) + 0.1 to (f) + 0.15 mm 6) While rotating housing (13), tighten bolt (3) to the following torque. 3 Bolt: 2,450 – 3,040 Nm {250 – 310 kgm}
7)
Using dial gauge [1], check that the end play is within the standard range. • End play: 0.05 – 0.15 mm
WA1200-3
53lB*Bl3
7Ui bP//XlLAss’y FRONT AXLE ASS’Y
DISASSEMBLY AND ASSEMBLY
7 q i I\ ;i7// XIbAss’y(l/Z) FRONT AXLE Ass’y (l/2)
(31 P6(425-22-13520. 425-22-13540) + (0. 610.
41’.‘7.
425-22-13530. ~/r\lbf(btL)
1)ta‘ikicti.
CWW04894
WA1 200-3
30-087 0
DISASSEMBLY AND ASSEMBLY
7ni
FRONT AXLE Ass’;
b73JWAss’y(2/2)
FRONT AXLE As&y (2/2)
NW04895
30-088 0
WA1 200-3
DISASSEMBLY
DISASSEMBLY,
AND
FRONT
ASSEMBLY
ASSEMBLY
AXLE
ASSEMBLY
OF FRONT AXLE ASSEMBLY
1
Disassembly procedure 1. Draining oil 1) Remove 3 level plugs (I ). 2) Remove 3 drain plugs (2) and drain the oil from the axle. -
:
Quantity
of drained
oil: 670 e
Axle assembly: 16,100 kg (Without oil) Sensor assembly 1) Remove the mounting bolts and clip (5). 2) Remove the 2 mounting bolts, sensor assembly (61, and shims (7). * Check the thickness and quantity of the shims. Shaft Remove the 2 mounting bolts and shaft (8), Tubes Remove tubes (91, (IO), and (11) and 6 connectors (12). Remove breather (13). &I kg
Assembly procedure 1. Breather Install breather (13). 2. Tubes 1) Install 6 connectors (12). 2) Install tubes (II), (IO), and (9). w Tube nut: 15.7 - 23.5 Nm (1.6 - 2.4 kgm} 3. Shaft Fit the O-ring and install shaft (8) with the 2 bolts. 4. Sensor assembly I) Assemble the sensor assembly according to the following procedure. i) Insert the sensor until its tip touches the flange of the axle. ii) Measure the clearance between the sensor fitting faces of the flange and housing. iii) Adjust the shims so that the clearance between the sensor tip and the housing in the axle will be as follows. * Clearance at sensor tip: 0.6 -C 0.1 mm * Types of shims: 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. 2) Fit selected shims (7) and the O-ring and install sensor assembly (6) with the 2 bolts. w Bolt: 98 - 123 Nm {IO - 12.5 kgml 3) Install clip (5) with the bolts. 5. Supplying oil, I) Fit the O-ring and install 3 drain plugs (2). w
2)
Drain plug: 127 - 176 Nm I13 - 18 kgm) Fit the O-ring and supply oil into the axle and install 3 level plugs (1). G
Oil: 670 L?(AX0751
w
Level plug: 127 - 176 Nm (13 - 18 kgml
CWW02772
WA1 200-3
30-088-l 0
53f%*%lilz DISASSEMBLY
‘/ P - 7 3 X JbAss’y REAR AXLE Ass’y
AND ASSEMBLY
‘H’-P%WAss’y(l/2) REAR AXLE Ass’y (l/2)
I. M94fV4l.
‘IL\V4l STD.
94f
OPT.
ttll 165/65-57155.5/80-57
'11.441
J7lfid4JL
1
52x57
1
44x57
/AKO75li.KES.90.751)I 670Q/
cwwo4902
WA1 200-3
30-089 0
‘IT-J3XJbAss’y REAR AXLE ASS’Y
53fE*%Z DISASSEMBLY AND ASSEMBLY
‘/ +‘--B3XJLAss’y(2/2)
_
REAR AXLE Ass’y (2/2)
WA1 200-3
fffR*wi
DISASSEMBLY,
REAR
ASSEMBLY
AXLE
ASSEMBLY
OF REAR AXLE ASSEMBLY Disassembly procedure 1. Draining oil I) Remove 3 level plugs (I). 2) Remove 3 drain plugs (2) and drain the oil from the axle. -
:
& kg
Quantity
of drained
oil: 670 .4
Axle assembly: 16,100 kg (Without
support Remove the 30 mounting
oil)
bolts and support
(5). Shaft Remove the 2 mounting bolts each and 2 shafts (6). Tubes Remove tubes (71, (81, and (9) and 6 connectors (IO). Breather Remove breather (I I).
Assembly procedure 1. Breather Install breather (11). 2. Tubes 1) Install 6 connectors (IO). 2) Install tubes (91, (81, and (7). m Tube nut: 15.7 - 23.5 Nm Il.6 - 2.4 kgml 3. Shaft Fit the 2 O-rings and install 2 shafts (6) with the 2 bolts each. 4. support Install support (5) with the 30 bolts. m Mounting bolt: 1,520 - 1,910 Nm I155 - 195 kgml 5. Supplying oil 1) Fit the O-ring and install 3 drain plugs (2). m 2)
Drain plug: 127 - 176 Nm I13 - 18 kgml Supply oil into the axle and install 3 level plugs (I).
G#
Oil: 670 .@.(AX0751
w
Level plug: 127 - 176 Nm I13 - 18 kgm}
cwwo2773
WA1 200-3
30-090-l 0
a~*%!43
? 7 3 f ‘I PAss’y DIFFERENTIAL CARRIER Ass’y
DISASSEMBLY AND ASSEMBLY
?7
+ -v ‘I PAss’y(F)
DIFFERENTIAL
(l/5)
CARRIER
Ass’y (F) (l/5)
CWWO4896
WA1 200-3
30-09 1 0
7‘7 + t ‘I 7Ass’y DIFFERENTIAL CARRIER Ass’y
53fiff-sm DISASSEMBLY ANti ASSEMBLY
?7+
+ ‘J JAss’y(F)
DIFFERENTIAL
(2/5)
CARRIER
Ass’y (F)
@/5)
CLEARANCE
COAT
GREASE
G2-Ll
i LT-2Lf APPLY
LT-2 ON THREAD
A-A
30-092 0
(FROM
cwwo4896)
CWWO4897
WA1 200-3
%‘3-v ‘IPAss’y DIFFERENTIAL CARRIER Ass’y
a$E*mi DISASSEMBLY
AND ASSEMBLY
? 7 + -r ‘I 7Ass’y DIFFERENTIAL
Z-2413
(R) (315)
CARRIER
Ass’y (R) (315)
/
4-24X3 I
c1w04904
WA1 200-3
30-093 0
77 + P 'I JAss’y DIFFERENTIAL CARRIER Ass’y
53-?s*$Im DISASSEMBLY AND ASSEMBLY
?7
+ -v ‘I PAss’y(R)
(4/5)
DIFFERENTIAL CARRIER Ass’y (R) (4/5) to.2
to.3
t1.0
CLEARANCE
A-A
30-094 0
(FROM
cwwo4904)
WA1 200-3
aBE*%l.a DISASSEMBLY
WA1 200-3
F-7 3 P ‘I PAss’y DIFFERENTIAL CARRIER Ass’y
AND ASSEMBLY
1.
Adjustment of differential side bearing. Tighten nut (568-22-11611) to obtain pre-load as follows. Pre-load: 15.7 - 31.4 kN 11,600 - 3,200 kg1
2.
Adjustment of bevel pinion Select shims (427-22-11460, 22-11480, 427-22-11490) to shown. Pre-load: 7.8 - 35.3 kN
bearing. 427-22-l 1470, 427obtain pre-load as I800 - 3,600 kg}
3.
Installation of bevel pinion and gear (I) Select shims (42C-22-11371, 42C-22-11381, 42C-22-11390) to obtain specified mounting distance on the end face of pinion (42G2211211). (2) Install gear ass’y and adjust bearing preload. See item 1. (3) Adjust backlash to 0.43 - 0.61 mm by using nut (568-22-I 1611).
4.
Oil seal (428-22-11780) and dust seal (428-22. .. . . 11790) installatron posmon and greasrng 1s as shown. Other to be per KES 83. 271. 2.
30-095 0
DISASSEMBLY AND ASSEMBLY
REMOVAL,
INSTALLATION,
DIFFERENTIAL CARRIER ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF DIFFERENTIAL
4
CARRIER ASSEMBLY
3 4 5
‘\ ‘\
“\ 13
-”
‘\
‘\.(J
-1
/
‘\
.\
Ii -_-.-_
j cwwo2774
so-095 1 0
WA1 200-3
DISASSEMBLY AND ASSEMBLY
Removal procedure 1. Differential carrier assemblv
1) Remove the 13 mounting bolts and cover assembly
(3).
2) Remove gear (4). 3) 4) 5)
Remove shaft assembly (5). Remove the mounting bolts and t-piece (7). Remove 23 mounting bolts and differential carrier assembly (6). kg &?I
Differential
carrier assembly: 1,570 kg
DIFFERENTIAL CARRIER ASSEMBLY
Disassembly procedure 2. Cover Remove the 2 mounting bolts and cover (8). Ir Front differential carrier only 3. Flange Remove snap ring (9) and flange (IO). * Front differential carrier only 4. Lock plate Remove the 4 mounting bolts and 2 lock plates (I I). 5. Cage assembly bolts and 1) Remove the 2 mounting bracket (12). 2) Remove the 22 mounting bolts and cage assembly (13). 3) Remove shims (14) from cage (15). * Check the thickness and quantity of the shims. 4) Remove the mounting bolts, holder (16), and shims (17). * Check the thickness and quantity of the shims. 5) Remove coupling (18). 6) Remove the 4 mounting bolts and cage (19). 7) Remove dust seal (20) from cage (19). 8) Remove oil seal (21) from cage (19). 9) Remove pinion (22) from cage (15). IO) Remove the inner race of roller bearing (23) from cage (15). 11) Remove the inner race of roller bearing (24) from pinion (22). * Use a press to pull out the inner race. 12) Remove the outer races of roller bearings (23) and (24) from cage (15). + Use a bearing puller to pull out the outer races. 6. Differential assembly I) Remove the 4 mounting bolts and 2 caps (25). 2) Remove 2 nuts (26). 3) Remove differential assembly (28) and 2 outer races of bearing (27) from carrier 4) 5) 6)
7)
WA1 200-3
(29). Remove
the 8 mounting
bolts and case
(30). Remove the inner race of bearing (27) and thrust washer (31) from case (30). Remove side gear (321, then remove spider shaft (33) and pinion gear assembly (34) as one unit. Remove 4 pinion gear assembly (34) from spider shaft (33).
8)
Disassemble the pinion gear assembly according to the following procedure. i) Secure pinion gear assembly (34) with a press and remove locknut (35) with wrench WI. ii) Using a press, remove sleeve (37) from pinion gear (36). iii) Remove inner race (38A) from pinion gear (36). iv) Remove spacer (38B) and inner race (38C) from sleeve (37).
v)
Using a press, remove outer race (38D) from pinion gear (36). vi) Using a press, remove collar (38E) and outer race (38F) from pinion gear
Assembly procedure 1. Differential assembly I) Install bevel gear (44) to case (41) with the 20 bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml 2) Install 2 bushings (43) to case (41). * Front differential carrier only 3) Install tube (42) to case (41). * Front differential carrier only 4) Install the inner race of bearing (27) and thrust washer (40) to case (41). & Contact faces of thrust washer (40) and side gear (39): Axle oil (AX075). 5) Install side gear (39) to case (41). 6) Assemble the pinion gear assembly according to the following procedure. i) Using a press, install collar (38E) and outer race (38F) to pinion gear (36). * Push the outer race until its end touches the pinion gear. ii) Using a press, install outer race (38D) to pinion gear (36). * Push the outer race until its end touches the pinion gear.
(36).
I 9) Remove side gear (39). IO) Remove the inner race of bearing
(27) and thrust washer (40) from case (41). 11) Remove tube (42) and 2 bushings (43). Ir Front differential carrier only 12) Remove the 20 bolts and bevel gear (44).
cwwo4991 iii) install inner race (38C) and spacer (38B) to sleeve (37). iv) Install sleeve (37) to pinion gear (36). VI Install inner race (38A) to pinion gear (36).
30-095-2 0
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL CARRIER ASSEMBLY
vi) Secure
just it into the following range with the adjustment nut. * Rotational force: 20.6 - 23.5 N (2.1 - 2.4 kg} f The rotational force may be measured by winding a string onto plane half part b. (79.4 - 95.1 N I8.1 - 9.7 kg))
pinion gear assembly (34) with a press and tighten nut (35) with wrench WI.
m
Nut: 882 - 1,080
Nm I90 - 110 kgn 35 /
7)
8)
9)
IO)
11)
12) 13)
14) 15)
,38A
Install the assembly of 4 pinion gear assemblies (34) and spider shaft (33) to case (41). Install side gear (32). * Move the side gear to check that the pinion gear rotates lightly. Install the inner race of bearing (27) and thrust washer (31) to case (30). & Contact faces of thrust washer (31) and side gear (32): Axle oil (AX075). Install case (30) to case (41) with the 8 bolts. m Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml Install the 2 outer races of bearing (27) to cases (41) and (30). Install differential assembly (28) to carrier (29). Tighten 2 nuts (26) onto carrier (29) temporarily. * Check that the carrier can be rotated lightly with the hand. Install 2 caps (25) to carrier (29) with the 4 bolts. Adjust the preload on the differential side bearing according to the following procedure. i) Bring the lock groove of the nut on the bevel gear side to the position where the lock plate is inserted. ii) Rotate the bevel gear until it rotates smoothly. iii) Measure the rotational force of the bevel gear at large end a, then ad-
30-095-3 0
2.
iv) After adjusting, check that the adjustment nut groove on the plain half side is at the position where the lock plate is inserted. Cage assembly 1) Install the outer races of roller bearings (24) and (23) to cage (15). * Push each outer race until its end touches the shoulder of the cage. 2) Install the inner race of roller bearing (24) to pinion (22). * Push the inner race until its end touches the pinion. 3) Install pinion (22) to cage (15). & Bearing: Axle oil (AX0751 * Press fit the bearing, rotating the cage. Stop press fitting when a load is applied. * Limit the press fitting force to the minimum load to insert the bearing. 4) Install the inner race of roller bearing (23) to pinion (22). 5) Adjust the thickness of the shim for the input bearing according to the following procedure. i) Measure thickness a of the holder. ii) Install coupling (18) to pinion (22), then install holder (16) temporarily with the bolts. Sr Do not install the shims at this time. iii) Fitting the bearing, loosen the bolt gradually until the starting torque
becomes 15.7 Nm Il.6 kgml. iv) Measure distance b between the holder and pinion end. v) Calculate shim thickness c. . c = (b - a) - (0 to 0.04) * Select shims so that their thickness will be 0 to -0.04 mm less than the clearance. * Types of shims: 0.05, 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. vi) Install the selected shims and tighten the bolt. vii) Rotate cage (15) to fit the bearing, then check that the starting torque is 15.7 - 52.0 Nm (I.6 - 5.3 kgm). * If the starting torque is out of the above range, adjust the shims again. b
a
9)
10)
11)
12) 13)
Install cage (19) to cage (15) with the 4 bolts. w Mounting bolt: 157 - 196 Nm (16 - 20 kgml Install coupling (18) to pinion (22), then fit the O-ring. 6 Yoke end, shaft spline: Lubricant (LM-G) Install the selected shims and holder (16) with the bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 2,450 - 3,040 Nm (250 - 310 kgml Fit the O-ring to cage (15). Adjust the shim thickness for the differential carrier according to the following procedure. * After the bearing, pinion gear, bevel gear, etc. is replaced, adjust the shims. i) Measure distance a between carrier (29) and pinion gear (22).
a
CWW02777
6) 7) 8)
Fit the O-ring to cage (19). Install oil seal (21) to cage (19). Install dust seal (20) to cage (19). * Fitting dimension c of dust seal: 4 mm from cage end & Fitting part of oil seal: Gasket sealant (LG-I) or (LG-5) & Seal lip: Grease (G2-LI)
CWWO7776
cwwo2778
ii)
Calculate standard value b. b=(427+c)-(121.69id) * Dimensions c and d are indicated at the end of the pinion shaft on the unit of l/100 mm. (Take care of plus and minus.)
l
cwwo2787
WA1 200-3
DISASSEMBLY
AND
ASSEMBLY
DIFFERENTIAL
iii) Calculate shim thickness e. . e=b-a * Types of shims: 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. 14) Install selected shims (14) to cage (15) and install it to cage (29) with the 22 bolts. w Mounting bolt: 1,520 - 1,910 Nm 1155 - 195 kgml 15) Install bracket (12) to cage (15) with the 2 bolts. m Mounting bolt: 1,520 - 1,910 Nm I155 - 195 kgml 16) Adjust the backlash of the bevel pinion according to the following procedure. 1: Adjust movement of the bevel gear with the adjustment nuts. When moving the bevel gear, turn the nuts on both sides in the same direction by the same angle so that the preload on the bearing will not change. i) Apply dial gauge W2 to the outer end of the bevel gear. ii) Adjust the backlash into the specified range with the adjustment nuts. Ir Backlash: 0.43 - 0.61 mm * Fix the pinion gear and measure at 3 - 4 places. iii) Thinly apply minium to the tooth surfaces of the bevel gear and check the tooth contact. * Rotate the bevel gear and check that the convex and concave faces are in the following ranges respectively.
I-_
3.
4.
5.
Lock plate Install 2 lock plates (11) with the 4 bolts. m Mounting bolt: 245 - 309 Nm (25 - 31.5 kgml Flange Install flange (IO) and snap ring (9). Ir Front differential carrier only Cover Install cover (8) with 2 bolts. * Front differential carrier only m Mounting bolt: 98 - 123 Nm {IO - 12.5 kgml
Installation procedure 6. Differential carrier assembly 1) Fit the O-ring to differential carrier sembly (6). 2) Install differential carrier assembly with the 23 bolts. r+lkg w 3)
Install w
4) 5) 6)
Install Install Install bolts. w
CARRIER
ASSEMBLY
as(6)
Differential
carrier assembly: 1,570 kg Mounting bolt: 1,520 - 1,910 Nm (155 - 195 kgm} t-piece (7) with the bolt. Mounting bolt: 1,520 - 1,910 Nm 1155 - 195 kgml shaft assembly (5). gear (4). cover assembly (3) with the 16 Mounting bolt: 245 - 309 Nm I25 - 31.5 kgm)
(146) mm
kg--63mml
I3
169~83mA
CII
cwwo2779
WA1 200-3
30-095-4 0
53s*%I2
7 ~-ffJlr& j’k+Ass’y FINAL & BRAKE Ass’y
DISASSEMBLY AND ASSEMBLY
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WA1 200-3
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FINAL & BRAKE Ass’y(214)
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WA1 200-3
30-097 0
53f#s*~Z DISASSEMBLY
7 P f f JL & i‘ I/ - +Ass’y FINAL
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AND ASSEMBLY
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WA1 200-3
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7p4flL&?‘L-+Ass’y FINAL & BRAKE ASS’Y
DISASSEMBLY AND ASSEMBLY
7 57+ $-Jr, & i‘ I/ - +Ass’y (414) FINAL & BRAKE Ass’y(4/4) 9 + 7 b (42C-22-12820)@hj$j
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: 0.306-0.564mm
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Floating seal installation (1) To install floating seals, put tube (42C-2213231) upright. (2) O-ring (562-33-I 1922, 428-33-l 1650) to be clean with EOIO-CD. (3) Coat with EOIO-CD on O-ring contact faces of retainer (42G33-113223, cylinder (42C-33112531, retainer (42C-33-11331) and hub (42C-22-12710). (4) Coat with EOlO-CD on O-ring contact surfaces of seal (42G33-11410), and install Oring (562-33-11922) into these seals without twisting. (5) Coat with EOIO-CD on O-ring contact surfaces of seal (42C-33-115103, and install Oring (428-33-11650) into these seals without twisting. (6) Install half of seal ass’y (O-ring and seal) into hub, retainer and cylinder by pressing O-ring with cylindrical tool as shown. (Fig. 1) (7) Mating faces “a” of seal (42C-33-11410, 42C-33-11510) to be clean and free of dust. Coat with EOIO-CD on surface “a” before assembling. (Fig. 2)
Adjustment of wheel bearing. Select shims (42C-22-12230, 42G22-12240, 42C22-12250) to obtain pre-load as shown. Pre-load: 11.8 - 70.6 kN 0,200 - 7,200 kg} When assembling carrier ass’y (42C-22-12201) and hub (42C-22-12710), thru screw hole Y to be met with drill hole Z under drain plug. Disc wear indicator installation
(1) When assembling 9 plates (562-33-21231)
(2) (3) (4)
(5)
from tube (42C-22-132311, the center of tooth lack to be met with the center of tooth lack of gear (42C-33-11231). When assembling one plate (562-33-21231) from piston (42G33-11121), tooth must exist on the tooth lack of gear (42C-33-11231). Brake without cap (42C-33-12140). Push shaft (42C-33-12110) and adjust guide (42C-33-12130) until mating the surface of shaft (42C-33-12110) and the surface of guide (42C-33-12130), and fix with nut. Install cap (42C-33-12140).
3E%f-S?: 11.8-70.6kN I1,200-7,200kgI 8.
3 t ‘J 7Ass’y(42C-22-12201) &/\7*(42C-22-12710) t-$ij.sl;f-~?~k$
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2.
Degrease mating surface of seal (562-33-11941) and cylinder (42C-33-112531, and apply Loctite #648 before assembling.
3.
Brake testing procedure (1) Bleed air from brake cylinder with bleeder (566-32-I 1430). (2) Brake oil to be pressurized to 175 MPa 1178 kg/cm*} and left for 5 minutes. Pressure drop to be Max. 2.94 MPa 13 kg/cm*).
4.
End play of No. 1 planetary bearing (adjustment not to be required) Before inserting planetary shaft (42C-22-12820) . End play: 0.306 - 0.564 mm After inserting planetan/ shaft (42G22-12820) . End play: 0.089 - 0.346 mm
5.
Endplay of No. 2 planetary bearing (adjustment not to be required) Before inserting planetan/ shaft (42C-22-12830) . End play: 0.175 - 0.445 mm After inserting planetary shaft (42C-22-12830) . End play: 0.103 - 0.392 mm
6.
Studs (01145-93045) to be sunk to incomplete thread. Tightening torque to 441 - 883 Nm I45 - 90 kgm1
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WA1 200-3
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30-099 0
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY,
ASSEMBLY
FINAL DRIVE AND BRAKE ASSEMBLY
OF FINAL DRIVE AND BRAKE ASSEMBLY
36
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L 30-099- 1 0
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80 CWWO2780
WA1 200-3
)
DISASSEMBLY
Disassembly &I kg
AND ASSEMBLY
procedure
Final drive and brake assembly: 5,450 kg
1. Cover assembly I) Install the 16 mounting bolts and cover assembly (3). 2) Remove the O-ring from cover (4). 3) Remove spacer (5). 4) Remove the 3 mounting bolts and shaft 2. 3.
(6). Sun gear Remove gear (7). Carrier assembly (Large) 1) Remove the 4 cap bolts and carrier assembly (8). 2) Remove the O-ring from carrier assembly (8). Remove 4 shafts (10) from carrier (9), then remove 4 balls. (11). -k Remove the 4 sets. 4) Remove 4 gears (12) from carrier (9). * Remove the 4 sets. 5) Remove the bearing (13) from gear (12). Jr Remove the 4 sets. 6) Remove snap ring (14) from gear (12). * Remove the 4 sets. Ring gear I) Remove the 16 mounting bolts and 8 plates (15). 2) Remove ring gear (16). Shaft assembly I) Remove shaft assembly (17). 2) Remove snap ring (19) and gear (20). 3) Remove spacer (21) from shaft (18). Carrier assembly (Small) I) Remove carrier assembly (22). 2) Remove spacer (24) from carrier (23). 3) Remove snap ring (25) and pin (26). * Remove the 3 sets. 4) Remove 3 balls (27). 5) Remove 3 gears (28) from carrier (23). 6) Remove 2 bearings (29) and spacer (30). * Remove the 3 sets. 7) Remove snap ring (31) from gear (28). * Remove the 3 sets. Hub and brake assembly 1) Sling hub and brake assembly (32) temporarily, then remove the 36 mounting bolts and the assembly. 2) Remove the O-ring and plate (33). 3)
4.
5.
6.
7.
WA1 200-Z
FINAL
8.
Hub ring-- gear assembly 1) Remove the 8 mounting bolts, retainer (34), and shims (35). * Check the thickness and quantity of the shims. 2) Remove hub ring gear assembly (36). 3) Remove the O-ring from tube (74). bolts and 2 4) Remove the 2 mounting plates (37). 5) Remove retainer (38) and O-ring. 6) Remove seal (39) and O-ring. 7) Remove ball (40). 8) Remove the inner race of roller bearing (41) from hub (42). bolts and 8 9) Remove the 16 mounting plates (43). 10) Remove ring gear (44) from hub (42). 9. Wheel hub assembly 1) Remove 61 stud bolts (45) from wheel hub assembly (46). 2) Remove the outer race of roller bearing (41) from hub (51). 3) Remove seal (47) and O-ring. 4) Remove retainer (48) and seal (49). 5) Remove the O-ring from seal (49). 6) Remove the O-ring from hub (51). 7) Remove the outer race of roller bearing (50) from hub (51). 10. Cylinder and piston assembly 1) Remove the 16 mounting bolts and cylinder (52). 2) Remove the O-ring from cylinder (52). 3) Remove oil seal (53) and seal (54). 4) Remove the O-ring from seal (54). 5) Remove plug (55) and O-ring. 6) Remove bleeder (56). 7) Remove plug (57) and O-ring. 8) Remove 3 plugs (58). 9) Remove 2 plugs (59) and 2 O-rings. 10) Remove 2 plugs (60) and 2 O-rings. 11) Push in guide (61) and remove 8 dowel pins (62) and 8 plates (63). 12) Remove 8 guides (61) and 8 springs (64). 13) Remove piston (65) from cylinder (52). 14) Remove seals (66) and (67) from piston
12. Tube 1) Remove (74). Remove ing (50). 3) Remove 4) Remove (75). 13. Gear 1) Remove 2) Remove 3) Remove 4) Remove 5) Remove 2)
plug (70) and O-ring from tube the inner race from roller bearretainer (72) and 3 washers (73). the 34 mounting bolts and gear
plugs (76) and (77) and O-rings. plugs (78) and (79) and O-rings. spring pin (80). cap (81) and guide (82). lever (83) and shaft (84).
DRIVE
AND
BRAKE
ASSEMBLY
Assembly procedur 1. Gear 1) Fit the O-ring and install guide (82) to gear (75). 2) Fit the O-ring to shaft (84). 3) Insert shaft (84) in gear (75). Pass guide (82) and lever (83) onto the shaft in order, then install spring pin (80). 4) Fit the O-ring and install plug (79). w Plug: 58.8 - 78.4 Nm 16 - 8 kgm) 5) Install plug (78). 6) Fit the O-ring and plug (77). 7) Fit the O-ring and install plug (76) to gear (75). w Plug: 44.1 - 53.9 Nm 14.5 - 5.5 kgm) 2. Tube 1) Fit the O-ring to tube (74). & Fitting part of O-ring: Grease (G2-LI) 2) Install gear (75) to tube (74) with the 34 bolts. m Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml 3) Fit 3 washers (73) and install retainer (72). Install the inner race of roller bearing (50) to tube (74). 5) Fit the O-ring and install plug (70). Wheel hub assembly 1) Press fit the outer races of roller bearings (41) and (50) to hub (51). * Press fit each outer race until its end touches the shoulder of the hub. 2) Fit the O-ring to hub (51). a O-ring: Grease (G2-LI) 3) Install retainer (48) to hub (51). 4) Fit the O-ring to seal (49). a Seal: Engine oil (EOIO-CD) * Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). * Before fitting the O-ring, check that it is not skewed. 4)
3.
(65). 11. Discs and plates 1) Remove 10 plates (68) and 9 discs (69) alternately. 2) Remove gear (71).
30-099-2 0
DISASSEMBLY
5)
AND
ASSEMBLY
FINAL
8)
Install seal (49) to retainer (48). & Retainer: Engine oil (EOIO-CD) * Check the O-ring contact face of the retainer is free from flaw, dust, etc. * Use a push jig to install the seal. * After installing the seal, check that the O-ring is not skewed. * After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm.
Install 61 stud bolts (45) to hub (51). * Tighten each stud bolt to the incomplete thread portion. * Check that each stud bolt has an identification mark. * Tightening dimension (Reference): 139 mm w Stud bolt: 441 - 883 Nm I45 - 90 kgm}
* *
5.
CWW02784
cwwo4993
6)
7)
Fit the O-ring to seal (47). & Seal: Engine oil (EOIO-CD) t Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). * Before fitting the O-ring, check that it is not skewed. Install seal (47) to hub (51). & Hub: Engine oil (EOIO-CD) Check the O-ring contact face of the hub is free from flaw, dust, etc. Use a push jig to install the seal. After installing the seal, check that the O-ring is not skewed. After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm (similarly to seal (49)).
30-099-3 0
4.
Hub ring gear assembly I) Press fit the inner race of roller bearing (41) to hub (42). 2) Install ring gear (44) to hub (42). 3) Install 8 plates (43) with the 16 bolts. & Mounting bolt: Liquid adhesive (LT-21 w Mounting bolt: 245 - 309 Nm 125 - 31.5 kgm} 4) Install ball (40). 5) Fit the O-ring to retainer (38). 6) Install retainer (38) to hub (42). 6 Retainer fitting part: Grease (G2-LI) 71 Install 2 plates (37) with 2 bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm {IO - 12.5 kgm} 8) Fit the O-ring to seal (39). 6 Seal: Engine oil (EOIO-CD) * Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). Sr Before fitting the O-ring, check that it is not skewed. 9) Fit the O-ring and seal (39) to retainer (38). 6 Retainer: Engine oil (EOIO-CD) * Check the O-ring contact face of the retainer is free from flaw, dust, etc. * Use a push jig to install the seal.
After installing the seal, check that the O-ring is not skewed. After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm (similarly to seal
(49)). IO) Fit the O-ring to tube (74). & O-ring: Grease (G2-LI) II) Install hub ring gear assembly (36). & Fitting face of bearing seal: Engine oil (EOIO-CD) Adjustment of preload on wheel bearing 1) Install wheel hub assembly (46) and hub ring gear assembly (36). & Bearing: Axle oil (AX075) 2) Install preload adjustment jig W3 with the 3 bolts. 3) Checking the oil pressure with oil pressure gauge 0, apply the following specified hydraulic pressure to preload adjustment jig W3 with a hydraulic pressure pump. * Specified hydraulic pressure: 40.8 MPa (400 kg/cm*) 4) Close needle valve @ and remove the coupler. suffi5) Rotate the hub wheel assembly ciently to fit the bearing. * Check that the hydraulic pressure is about 38.8 MPa (380 kg/cm*}. If it is below that level, raise it again according to step 3). 6) Measure dimension b between cylinder upper face and piston upper face with a depth micrometer. * Measure the dimension at 3 places and obtain the average. 7) Calculate shim thickness d. d = (a - b - c) + (0 to 0.1) * a: 86.99 mm, c: 40.09 mm * Types of shims: 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. l
8)
6.
7.
DRIVE
AND
BRAKE
ASSEMBLY
Remove wheel hub assembly hub rina aear assembly (36).
(46) and
Discs and plates Remove gear (71). Install 10 plates (68) and 9 discs (69) alternately. Install the 9 plates from the tube side, matching the centers of their cuts to the centers of the cuts of the indicator mounting part of the gear. Install the 1 plate from the piston side, matching its tooth to the cut of the indicator mounting part of the gear. Cylinder and piston assembly 1) Install seals (67) and (66) to piston (65). & Periphery of seal: Grease (G2-LB * Before installing the seals, check the piston grooves for flaw and foreign matter. 2) Install piston (65) to cylinder (52). & Piston surface: Grease (G2-LI) 3) Install 8 springs (64) and 8 guides (61). 4) Push in guide (61) and install 8 dowel pins (62) and 8 plates (63). 5) Fit the O-ring to cylinder (52).
WA1 200-3
DISASSEMBLY AND ASSEMBLY
6)
7)
8)
9) IO) 11)
12)
13)
FINAL DRIVE AND BRAKE ASSEMBLY
Install cylinder (52) to gear (75) with the 16 bolts. w Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml Fit the 2 O-rings and install 2 plugs (60) to cylinder (52). m Plug: 58.8 - 78.4 Nm (6 - 8 kgm) Fit the 2 O-rings and install 2 plugs (59) to cylinder (52). w Plug: 9.8 - 12.7 Nm Il.0 - 1.3 kgm1 Install 3 plugs (58). Fit the O-ring and install plug (57). Install breather (56) to cylinder (52). & Threaded parts of breather: Gasket sealant (LG-51 Fit the O-ring and install plug (55) to cylinder (52). m Plug: 34.3 - 44.1 Nm I3.5 - 4.5 kgml Check the brake seal according to the following procedure. i) Install an oil pressurizing connector to pressurizing port a. ii) Supply oil through pressurizing port a and bleed air through bleeder b. iii) Keep the piston operating hydraulic pressure at 175 MPa (178 kg/cm*] and close the hand valve. iv) Check that the pressure does not fall more 0.29 MPa (3 kg/cm*) in 5 minutes.
15) Fit the O-ring to seal (54). 6 Seal: Engine oil (EOIO-CD) * Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). f Before fitting the O-ring, check that it is not skewed. 16) Install seal (54) to cylinder (52). & Cylinder: Engine oil (EOIO-CD) * Check the O-ring contact face of the cylinder is free from flaw, dust, etc. * Use a push jig to install the seal. * After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm (similarly to seal (49)). 17) Install oil seal (53) to cylinder (52). & Oil seal fitting part: LOCTITE 648 & Oil seal lip: Grease (G2-LI) Wheel hub assembly and hub ring gear assem-
b
a
CWWO.2781
14) Adjust the disc wear indicator according to the following procedure. i) Apply pressure to the brake. ii) Rotate guide (82) with shaft (84) pushed in and adjust the shaft end flush with the guide end, then secure the shaft with the nut. ’ w Nut: 237.7 - 321 Nm I24 - 33 kgm}
WA1 200-3
iii) Install cap (81) to guide (82). m Cap: 117.6 - 161.7 Nm (12 - 16.5 kgm)
bly I) Install wheel hub assembly (46). 6 Bearing: Axle oil (AX0751 2) Install hub ring gear assembly (36). & Bearing: Axle oil (AX0751 3) Install the selected shims (35) and retainer (34) with the 8 bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 1,520 - 1,910 Nm I155 - 195 kgm} Hub and brake assembly Fit the O-ring and plate (33) to tube (74). Install hub and brake assembly (32) with the 36 bolts. w Mounting bolt: 2,450 - 3,040 Nm (250 - 310 kgm}
10. Carrier assembly (Small) I) Install snap ring (31) to gear (28). * Install the 3 sets. 2) Install spacer (30) and 2 bearings (29). * Install the 3 sets. 3) Install 3 gears (28) to carrier (23) with 3 balls (27) and 3 pins (26). 4) Install 3 snap rings (25). 5) Install spacer (24) and carrier assembly (22). 11. Shaft assembly I) Install spacer (21) to shaft (18). 2) Install gear (20) and snap ring (19) to shaft (18). 3) Install shaft assembly (17). 12. Ring gear 1) Install ring gear (16) to ring gear (44). 2) Install 8 plates (15) with the 16 bolts. & Mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 245 - 309 Nm 125 - 31.5 kgml 13. Carrier assembly (Large) I) Install snap ring (14) to gear (12). * Install the 4 sets. 2) Install bearing (13) to gear (12). * Install the 4 sets. 3) Install 4 gears (12) to carrier (9) with 4 balls (II) and 4 shafts (IO). 4) Fit the O-ring to carrier assembly (81, then install them with the 4 cap bolts. m Mounting bolt: 123 - 157 Nm I12.5 - 16 kgm} Ir When installing the carrier assembly to the hub, match through tap hole a of the hub to hole b under the drain plug of the carrier.
I
6
CWWO2785
14. Sun gear Install gear (7). 15. Cover assembly Install shaft (6) with the 6 Mounting bolt: Liquid m Mounting bolt: 245 - 309 Nm Install spacer (5). Fit the O-ring and install (3) with the 16 bolts. w Mounting bolt: 245 - 309 Nm
3 bolts. adhesive
(LT-2)
(25 - 31.5 kgml cover assembly
I25 - 31.5 kgm}
1
30-099-4 0
53l?B*%l~ DISASSEMBLY AND ASSEMBLY
J/S & 7-LaLL/ J/S & ARM-REST
D-D
J/S & P--4L/iC bAss’y J/S & ARM-REST Ass’y
bAss’y(V3) Ass’y(V3)
(1~2)
CWWO4906
WA1 200-3
53lE*sm
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WA1 200-3
30-101 0
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J/S & 7-h L X b Ass’y J/S & ARM-REST Ass’v
DISASSEMBLY AND ASSEMBLY
J/S & Y--bit
bAss’y(3/3)
J/S & ARM-REST Ass’y(3/3)
1.
Method of assembling joint (Cf. Q, A-A): I-l) Assemble lever (42C-40-12310) in the same direction (as shown) of slit of upper joint ass’y (42C-40-123201, and install lever to the top limit of serration. I-PITurn lever toward fore-and-aft of vehicle. Assemble, joint ass’y (42C-40-12480) so that grease nipple turn in the direction as shown.
2.
Adjustment of slide rail in the direction of foreand-aft (Cf. A-A, D-D): Before assembling cover etc. tighten + marked bolt (01435-00814/direction for up-and-down) and [XI marked bolt (01435-OlOPOldirection for right-and-left) temporarily so that bracket (42C40-12160) can slide smoothly, and then tighten them firmly.
3.
Adjustment of slide rail of joint cover (Cf. P): When assembling cover (42G40-12350, 42C-4012360) and slide rail (42C-40-123401, tighten bolt (01435-00620) for slide rail, bracket (42C-4012380) temporarily and adjust them so that two slide rails parallel each other. And then tighten them firmly.
4.
Adjustment of stopper bolt for J/S (Cf. Q, and below): When turning vehicle on low-idling, adjust length of bolt for adjustment of steering angle bX_marked/ 01010-80620) so that gap of frameend stopper can be almost 37 - 40 mm.
5.
Lever for fore-and aft adjustment of J/S and lever for up and down adjustment of arm-rest and assembling stopper plate (Cf. S, T, B-B D-D): 5-I) Before assembling cover etc. assemble lever (42C-40-122403 as shown without handle part. 5-2)After assembling cover etc. assemble handle part at an angle of 30” clockwise from vertical upper position. 5-3)And then adjust the position of plate (42C40-12250) so that plate touches stopper bolt at an angle of 60” on turning back counterclockwise from “LOCK” position.
6.
Unless otherwise specified, tightening torque of bolt-nut to conform to KES 04.123. l/
7.
Method of assembling U-joint. (Cf. 2): 7-1)Assemble lever (42C-40-12450) at right angle from direction of slit of pilot valve (42C-40-12550). 7-2)Turn lever toward fore-and-aft and assemble U-joint ass’y (42G40-12470) so that grease-nipple turn in the direction as shown.
8.
Method of auto correction of offset angle of lever and frame potentio (0 & *) (Calibration): 8-1)Straighten vehicle and J/S lever (42C-4012310). (Direction may be desided at a guess.) 8-2) Put steering lock lever on “LOCK” position (Lower side). When arm-rest situated at storage position (most backward), slide arm-rest at forward optional position. 8-3) Start engine and keep low-idling. 8-4)Slide J/S console in the storage position (most backward). Switch (42A-06-15140) go on. (Cf. A-A) 8-5) Put steering lock lever on “FREE” position (Upper). 8-6)Calibration ends normally if it sounds “PiPi-Pi” after 1 second. Note: During operation 1 to 6, do not move steering lever. If calibration ends abnormally, check assembling angle of potentio (0 & Ir). And, restart calibration.
WA1 200-3
i‘k3XZf~Ass’y BRAKE SYSTEM Ass’y
53s*%I& DISASSEMBLY AND ASSEMBLY
i’k-+>X%Ass’y(1/2) BRAKE SYSTEM
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16. To assure contact on each contact surface, repeat step 15 three times. Then, tighten bolts @ and @ with torque M36: 2,450 - 3,040 Nm {250 - 310 kgm} and M45: 4,510 - 5,490 Nm I460 - 560 kgm} again. 17. Remove all bolts @,. Measure clearance between retainer and frame at 3 positions on circumference using thickness gauge and calculate average clearance value. Use shims so that average clearance is 0.08 to 0.18 mm. In this case, total thickness of shims must not exceed any measured clearance. 18. Keeping rear frame not to slide. Remove bolts @ and @ and set shim adjusted in step 17. 19. Perform steps 15 and 16. 20. Remove bolts @ and @ one after the other, apply Locktite #262 and tighten them with specified torque. (Degrease fully the tapped thread.) 21. Perform steps 15, 16 and 20 for upper pin bolts (01010-62485). In this case use tightening torque for M20 in steps 15 and 16. 22. Remove jack from under rear frame lower hinge. . Apply sufficient grease inside of bearing when assembling. . Supply grease into upper hinge and lower hinge shafts and steering hinge until grease exude from dust seal after assembling.
16.
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WA1 200-3
Center hinge assembling procedure 1. Attach-seal to front and rear frames and retainer (42C-46-13210, 42C-46-13230) so that seal lip faces outside. (See section A-A) Lock front and rear frame seals with plate (42C-46-13340, 427-46-11330). 2. Press fit bearing cup (One side). Make sure that bearing cup contacts tightly to bottom. 3. Install a set of bearing cone and spacer. (Bearing is adjusted as a set. Never change combination) 4. Press fit bearing cup. 5. Install retainer with 6 retaining bolts placed equally at 60” for upper side and 10 bolts at 36O for lower side. Tighten bolts uniformly with the following torque. . Upper hinge bearing retainer: 137 Nm {14 kgm] + 10 % . Lower hinge bearing retainer: 441 Nm I45 kgm} f 10 % 6. Loosen bolts once. Then tighten them uniformly to torque specified in step 5. Measure clearance between retainer and front and rear frames at 4 positions equally places on circumference. And calculate average clearance value. Use shims so that average clearance is 0.08 to 0.18 mm. In this case, total thickness of shims must be not exceed any measured clearance. 7. Add shims adjusted in step 6 and install retainer with the following torque. . Upper hinge 824 - 1,030 Nm (84 - 105 kgm) for each of 6 bolts . Lower hinge 2,450 - 3,040 Nm {250 - 310 kgm) for each of 10 bolts 8. Press fit bushing (42C-46-13320, 42C-46-13330) to front frame. 9. Install bushing @ into rear frame lower hinge. 10. Install bushing (42C-46-13120) into rear frame upper hinge. 11. Install retainer (42C-46-13110) onto upper pin. Bolt @: Tightening torque: 824 - 1,030 Nm {84 - 105 kgm) 12. Install front frame between rear frame hinge and insert upper pin. Bolt 0: Tightening torque: 824 - 1,030 Nm I84 - 105 kgm} 13 Insert lower pin and bushing into lower hinge and install retainer. (See view Y) 14. Place jack under rear frame lower hinge. Keep front frame to contact firmly to bushing @ without clearance. 15. After tightening retainer bolts @ and @ of lower hinge with torque M36: 2,450 - 3,040 Nm (250 - 310 kgm) and M45: 4,510 - 5,490 Nm I460 - 560 kgm) respectively, tap lower
Adhesion procedure (rear axle support bushing assembling procedtire.) 1. Remove dirt and oil with cleaning liquid etc. 2. Clean bushing contact surface with cloth soaked with primer (428-99-80080). 3. After coating primer, apply instant adhesive (428-99-80070). within 5 minutes. (Primer will dry instantly.) * Apply adhesive of about 18 g to each bushing (42C-46-17140). (Slightly smaller than 0.01 g per contact area of 1 cm*) * Set time of adhesive is 30 to 60 seconds. Set time: Time from starting of adhesive to end of assembling bushing to axle support. 4. Press bushing quickly onto axle support. (Caution) Never mix adhesive and primer. 0
Rear axle support bushing disassembling procedure. 1. Insert blade end of knife and remove bushing and support throughout circumference. In this case, if it is difficult to peel them, handy torch to about 100°C. 2. After removing bushing, apply peeling liquid (427-46-11890) to remained adhesive and wipe with cloth after 2 or 3 minutes.
a
Unspecified tightening of bolts and nuts shall be in accordance with KES 04.123. 1 Impact wrench.
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30-113 0
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30-117 0
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30-123 0
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30- 124 0
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53f#*%Z DISASSEMBLY
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30- 126 0
WA1 200-3
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WA1 200-3
1.
Install U-packing, piston seal, rod dust seal, and O-ring, taking care not to damage them.
2.
Before assembling, clean each part. After assembling, cover piping ports and holes for pin to prevent entrance of dust.
3.
When inserting back-up rings for O-ring, warm them in water of approx. 50 to 60°C and install under due pressure.
4.
Tighten bolts to conform to KES 04. 123. 1.
5.
Ensure that threaded portion of piston (707-3630013) and nut (01010-61670) are completely clean of all oil (grease). Apply hardener (Primer T manufactured by LOCTITE JAPAN CORP.) to each 6 places of threaded portion. Then apply 0.5 cc - 0.7 cc bonding agent (LOCTITE No. 262 manufactured by LOCTITE JAPAN CORP. or equiv.) on to T 6 places of piston screws and tighten bolt at torque of 245 - 309 Nm 125 - 31.5 kgm1. Then leave them for about 30 minutes (for the time of hardening the bonding agent).
6.
In the first operation after assembling the cylinder (including reassembling), deaeration of the cylinder shall be completely performed, particularly for the first 3 to 5 strokes, (extension and retraction) shall not load the set pressure of relief valve at the stroke ends.
7.
In transit, keep the assembly in most retracted condition.
30-127 0
53$3*4m DISASSEMBLY AND ASSEMBLY
gi7“‘j DUMP
Sflli7“i ‘J i$Ass’y DUMP CYLINDER Ass’y
‘J XfAss’y(l/2) CYLINDER
Ass’y(V2)
cwwo4930
30-128 0
WA1 200-3
DISASSEMBLY
WA1 200-3
AND ASSEMBLY
DUMP CYLINDER As.9
1.
Install U-packing, piston seal, rod dust seal, and O-ring, taking care not to damage them.
2.
Before assembling, clean each part. After assembling, cover piping ports and holes for pin to prevent entrance of dust.
3.
When inserting back-up rings for O-ring, warm them in water of approx. 50 to 60°C and install under due pressure.
4.
Tighten bolts to conform to KES 04. 123. 1.
5.
Ensure that threaded portion of piston (707-3636030) and nut (01010-62085) are completely clean of all oil (grease). Apply hardener (Primer T manufactured by LOCTITE JAPAN CORP.) to each 6 places of threaded portion. Then apply 0.5 cc - 0.7 cc bonding agent (LOCTITE No. 262 manufactured by LOCTITE JAPAN CORP. or equiv.) on to T 6 places of piston screws and tighten bolt at torque of 490 - 608 Nm {50 - 62 kgm1. Then leave them for about 30 minutes (for the time of hardening the bonding agent).
6.
In the first operation after assembling the cylinder (including reassembling), deaeration of the cylinder shall be completely performed, particularly for the first 3 to 5 strokes, (extension and retraction) shall not load the set pressure of relief valve at the stroke ends.
7.
In transit, keep the assembly in most retracted condition.
30-129 0
DISASSEMBLY AND ASSEMBLY
OIL COOLER
PROCEDURE FOR DISASSEMBLY AND ASSEMBLY OF MESABI OIL COOLER ASSEMBLY •
Outline
1. General locations of oil cooler assembly
WA1200-3
30-131 6
DISASSEMBLY AND ASSEMBLY
30-132 6
OIL COOLER
W1200-3
DISASSEMBLY AND ASSEMBLY
OIL COOLER
2. Specifications, points The overall dimensions are extremely large: approximately length 2162 mm x width 2880 mm x depth 143 mm. The total number of tubes is 912. The tubes have a top-bottom two- stage structure and there are four tubes to each line. 1) When mounted on the machine, it is difficult to pinpoint the location of any leakage. It is only possible at the front face at places where there are no ribs. 2) There is a top-bottom two-stage structure. To remove the tubes at the bottom (bottom core), first remove the tubes at the top (top core), then remove the tubes at the bottom. (Even if the top retainer clip is removed, it is still difficult to move.) fl When assembling, assemble the tubes at the bottom first, then assemble the tubes at the top. For the above reasons, carry out repairs or replacement when mounted on the machine only at the front where it easy. For other locations, take the machine to the repair shop and set the machine horizontal.
3. Tool list for disassembly and assembly Component
Symbol
Part No.
Part name
Q’ty
A
793-803-1110
Support installer
1
B
793-803-1130
Tube installer
1
C
793-803-1120
Breaker tool
1
D
799-301-1600
Air leak checker
1
E
793-803-1150
Flange
1
F
793-803-1160
Flange
1
Disassembly and assembly of oil cooler assembly
Details of operation
Removal, installation of core
Checking for leakage of air from core
4. Supply parts list No.
Part No.
Part name
Q’ty
1
LM35780
Rubber seal
1,824
2
LM63377
Copper washer
2,736
3
LM33567
Tube retainer
4
LM33083-107
Air baffle
2
5
LM123-10-4200
ITS tube
912
6
LM48622
Tube support
912
Note:
Remarks
912
The pressure is high, so a blind plug cannot be used. For this reason, no blind plug is available as a supply part.
WA1200-3
30-133 6
DISASSEMBLY AND ASSEMBLY
OIL COOLER
DISASSEMBLY OF MESABI OIL COOLER ASSEMBLY Preparatory work 1) Wash the oil cooler assembly with a hot water washing machine. Turn it over and wash it from the opposite side also. fl Pressure: Max. 1200 PSI, 8.3 MPa {Max. 84.4 kg/cm2} fl Water temperature: Max. 180° F {Max. 82° C} fl Do not use steam.
2) After completing the washing, blow with air to completely remove any water.
3) Set the oil cooler assembly on a horizontal workstand. fl To make it possible to put objects on top of the oil cooler, spread cardboard or a wooden board on top of the oil cooler. fl If it is necessary for a worker to get on top when carrying out the work, put a strong wooden board on top of the oil cooler to prevent any excessive force from being applied to the tubes or fins.
Disassembly fl When removing all the tubes, first remove the two lines at the front face, then turn the oil cooler assembly over and remove the two lines from the rear face. 1. Remove the support bars. fl Before removing the support bars, make counter marks to show the position when assembling.
30-134 6
W1200-3
DISASSEMBLY AND ASSEMBLY
BOTTOM DUMP OIL CYLINDER COOLER
2. Removal of tubes fl When removing the tubes, start from the top core. 1) Use pliers to grip the tubes in the retainer clip.
2) To clean, blow with air and wipe off any dirt.
3) When removing the tubes, move the copper washer down towards the fins to prevent any resistance.
4) To make it easier to remove the tubes, coat the top seal, bottom seal, and area around the tube support with lubricating oil.
WA1200-3
30-135 6
DISASSEMBLY AND ASSEMBLY
OIL COOLER
5) If the tube and rubber seal have stuck together and the tube is difficult to remove, use breaker tool C to move the tube and make it easier to remove.
6) Using tube installer B, remove the tube from the bottom seal. fl Set the round portion of the tube installer parallel to the tube fins, put the lower jaw in contact with the plate of the center tank, and tighten the handle. ª1: Position to put round portion in contact at first (after pushing the fins with the round portion and removing slightly)
7) The tube cannot be removed in the one movement, so insert the round portion of the tube installer at the side of the copper seal and tighten the handle until the tube end is removed. ª2: Position to put round portion in contact for second time
fl After carrying out the procedure in Steps 6) and 7), check that the connection of the tube support has been completely removed.
30-136 6
W1200-3
DISASSEMBLY AND ASSEMBLY
OIL COOLER
8) If the tube is stiff and does not move, use tube installer B and support installer A together when removing. fl When the spigot joint portion comes out completely, stop pushing. If it moves too much, the tube support may contact fins and bend them, so be careful not to push too much.
9) Remove the tube. fl When removing the tubes from the top seal, be sure to remove in a parallel direction and be careful not to damage the tube end or cause kinks.
10) In the places where the square rib of the oil cooler is, it is not possible to use the tool properly as it is, so use breaker tool C to change the angle of the tube fins 90° before removing.
11) Grasp of the tip of the rubber seal with finenosed pincers and pull out.
3. After completing disassembly of the top two stages, turn over and repeat the procedure to disassemble the bottom two stages.
WA1200-3
30-137 6
DISASSEMBLY AND ASSEMBLY
OIL COOLER
ASSEMBLY OF MESABI OIL COOLER ASSEMBLY Preparatory work Wipe with a cloth or blow with air to clean the surface and inside of the holes of all parts.
Assembly 1. Installation of tubes 1) Install the rubber seal by hand. fl If it is cold and the rubber seal is stiff, warm it up in hot water before installing. fl An oil film will cause leakage of oil, so do not use lubricating oil on the seal. fl Tap with a flat hammer to bring portion a of the rubber seal into tight contact.
fl If the rubber seal is concave as shown in the figure on the right after it is inserted, it has been inserted too far and the inside diameter has become smaller. When the tube is inserted, force will be brought to bear on the seal and it will be damaged, so be extremely careful not to insert it too far when installing.
2) Coat the inside surface of the rubber seal and end of the tube thoroughly with oil.
30-138 6
W1200-3
DISASSEMBLY AND ASSEMBLY
OIL COOLER
3) Coat the tube support thoroughly with oil also. 4) Check that the copper washer has entered both ends of the tube. • Top end: 2 • Bottom end: 1 fl When inserting vertically on the machine, to prevent the copper washer at the bottom end from falling out, insert just before inserting the tube into the bottom seal.
5) Align the top end of the tube with the position of the hole in the rubber seal, then insert.
6) Check the position of the tube support.
7) Align the bottom end of the tube with the position of the hole in the rubber seal and insert it slightly by hand.
WA1200-3
30-139 6
DISASSEMBLY AND ASSEMBLY
OIL COOLER
8) Insert the tube support by hand until just before the meshing part enters. fl If the tool is used to insert when the tube and rubber seal hole are not aligned, the rubber seal will be in the same condition as when it is pushed and inserted too far. This will cause damage to the rubber seal, so do not push it in by force.
9) Using tube installer B and support installer A, insert the tube until the copper washer is seated completely against the end face of the rubber seal.
10) Using pliers, install the retainer clip between the copper washers.
fl Align the position of the tabs of the retainer clip to prevent the air from escaping. (To prevent reduction of the cooling effect) fl When disassembling partially, if the position of the air buffer is moved, return it to its original position when assembling.
30-140 6
W1200-3
DISASSEMBLY AND ASSEMBLY
OIL COOLER
11) If the position of the tube support is not correct, the support bar cannot be assembled, so use breaker tool C to align the position of the tube support.
12) If the tube is bent for some reason, use breaker tool C to straighten it.
13) At the corner portion, if there is a rib, it is extremely difficult to carry out the work, so be extremely careful when aligning the position of the holes and inserting. fl Always carry out the work with two workers and use bright lighting.
14) At the corner portion, assemble four lines of tubes together. fl After completing the assembly of the bottom tubes, assemble the top tubes.
WA1200-3
30-141 6
DISASSEMBLY AND ASSEMBLY
OIL COOLER
2. Installing support bar After installing at the front face, align the counter marks made during disassembly and install the support bars. 3. Using the lifting hook, turn the oil cooler over and repeat the same procedure to assemble the two lines on the opposite side.
Pressurizing test 1. Install flange E to the oil cooler outlet port. 2. Fit flange F to the oil cooler inlet port, then install air leak checker D. 3. Apply air pressure and maintain it. fl Air pressure: 0.88 – 1.03 MPa {9.0 – 10.5 kg/cm2} fl Coat with soapy water to check that there is no leakage of air at the jig portion. 4. Disconnect the basic pressure hose for the air. 5. Check that there is no drop in the air pressure for one hour. fl If the air pressure goes down, coat with soapy water and check for the sound of air leakage, or use a bath with clean water to pinpoint the location of the air leakage.
30-142 6
W1200-3
40
MAINTENANCE
Engine mount ............................................... 40- 2 Transmission mount.. ................................. 40- 4 Damper.. ....................................................... 40- 6 Torque converter, transmission, brake cooling and brake pump .......... 40- 7 Input transfer . PTO ..................................... 40- 8 Modulated clutch ......................................... 40-10 Torque converter.. ...................................... 40-I 1 Transmission ............................................... 40-12 Transfer ........................................................ 40-16 Main relief, torque converter relief valve ............................................ 40-18 Torque converter regulator valve ............... 40-20 By-pass fill valve .......................................... 40-21 By-pass fill valve and by-pass drain valve .............................. .40-22 ECMV ............................................................. 40-23 Lubricating oil relief valve.. ........................ .40-25 Drive shaft.. .................................................. 40-26 Center support.. .......................................... 40-27 Differential.. .................................................. 40-28 Final drive .................................................... 40-32
WA1 200-3
STANDARD
Axle mount .................................................. 40-34 Center hinge pin.. ....................................... 40-36 Steering pump.. .......................................... 40-38 Switch pump ................................................ 40-39 Steering demand valve .............................. .40-40 Diverter valve ............................................. 40-42 Steering cylinder mount.. .......................... 40-43 Emergency steering pump ........................ 40-44 Brake valve .................................................. 40-45 Slack adjuster ............................................. 40-47 Brake.. ........................................................... 40-48 Parking brake ............................................... 40-50 Work euipment pump No. 1 ...................... .40-52 Work euipment pump No. 2 ....................... 40-53 PPC valve ..................................................... 40-54 PPC relief valve ........................................... .40-56 Pump control relief valve .......................... 40-57 Main control valve ....................................... 40-58 Hydraulic cylinder ........................................ 40-60 Bucket positioner and remote positioner .................................. 40-63 Bucket linkage .............................................. 40-64
40-l
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT n
n
i56* 6koml SWWO4865
40-2
WA1 200-3
MAINTENANCE STANDARD
TRANSMISSION
TRANSMISSION MOUNT
MOUNT
4
z-__ B-0
A-A
40-4
SWWO4666
WA1 200-3
MAINTENANCE
STANDARD
TRANSMISSION
MOUNT
A3~_.____________
--r---r------ ,---,-=jqpqy
SWW04667
Unit: mm
No.
1
Check item
Clearance between trunnion torque converter case
Criteria
and
2
Clearance between O.D. of shaft and I.D. of rubber cushion
3
Clearance between O.D. of rubber cushion and I.D. of bracket hole
4
Thickness
WA1 200-3
of mount
shim
Remedy
Tolerance
Standard size
Standard clearance Shaft
Hole
320
-0.125 -0.214
+0.089 0
0.125 0.303
90
0 -0.035
+0.035 0
0 - 0.070
125
+0.123 +0.083
+0.089 0
-0.123 -0.006
Clearance limit
Replace
Standard shim thickness: 1.5 mm (parallelism of coupling mating joint of transmission output shaft and sensor of sensor pin: Max. 0.5 mm)
40-5
MAINTENANCE
STANDARD
DAMPER
DAMPER 1.4 * 2.4Nm I0.75*0.25kPml
4.4* 1.4Nm
~0.45*0.15ksnl
279*29Nm ~28.5*3.0kml
279*29Nm {28.5h 3.0kml
__j__-_ ,i_-_
,c-ii /
112*9.8Nm 111.5* l.Okrrml
il
1 ____ __i
111.5* l.Okoml SJWO4868
Unit: mm
No. -
1
Check item
Criteria
Clearance shaft
between
bearing
and
120
-
2
Clearance housing
between
3
Clearance and shaft
between
bearing
Wear
of surface
of surface
5
Wear seal
6
Backlash
0 -0.020
-0.038 -6.003
0
0 -0.030
-0.008 -0.037
-0.037 0.022
0.025
+0.018 +0.003
+0.077 +0.047
0.029 0.074
215 inner body
120
size
Repair
Tolerance
Replace
0.1
limit
in shaft and oil seal 150
-
+0.018 +0.003
and
Standard
4
Remedy
I
I
in sleeve and oil 180
of spline
I
0 -0.100 0 -0.100
I
-0.160
I
-0.160
0.091 - 0.261
WA1 200-3
MAINTENANCE
TORQUE CONVERTER, TRANSMISSION, BRAKE COOLING AND BRAKE PUMP
STANDARD
TORQUE CONVERTER, AND BRAKE PUMP 4 2
TRANSMISSION,
BRAKE COOLING
SWWO3285 Unit: mm No.
Check item
Criteria Model
Standard clearance
SARl4) 200 1
2
Side clearance
Clearance between inside diameter of plain bearing and outside diameter of gear shaft
0.14 - 0.19
I
0.22
SAR(3) 71
0.10 - 0.15
0.19
SAR(2) 28
0.10 - 0.15
0.19
SARl4) 200
0.06 - 0.14
0.20
SARI41 200
0.06 - 0.14
0.20
SARl3) 71
0.06 - 0.149
0.20
0.06 - 0.125
I
( Standard size 1
4
Tolerance
I
SAR(4) 200
I3
SARl3) 71
13
I
4.5 O
-
1
-
1
I
1 Repair limit I
14
Rotating torque of spline shaft
0.20
I
SARl4) 200
SAR(2) 28
-
I
Replace
I
Insertion depth of pin
0.22
I
0.14 - 0.19
Model
3
Clearance limit
SARl4) 200
SARl2) 28
-
Remedy
l.5 0 -0.5
I
-
I
I-l
29.4 - 48.1 Nm f3.0 - 4.9 kgm}
I
Revolution tram)
Model
Discharge Oil: EOlO-CD Temperature: 45 - 55°C
2,000
SAR(2) 28
WA1 200-3
1 I
1
20.6 {210)
1
49
t
43
1
40-7
MAINTENANCE
INPUT TRANSFER - PTO
STANDARD
INPUT TRANSFER
. PTO
All IHt
9JBOO110
40-8
WA1 200-3
MAINTENANCE
STANDARD
INPUT TRANSFER - PTO
Unit: mm
Standard size
0.15 - 0.32
WA1 200-3
40-9
MAINTENANCE
STANDARD
MODULATED
CLUTCH
110.3*12.3Nm II
MODULATED CLUTCH
353*39.2Nm
,*c,,,
1,l)cI 1 rlEl,__l
7
1
93800111
Unit: mm
No
seal ring contact
Total assembly
thickness
of 19 discs
WA1 200-3
MAINTENANCE
STANDARD
TORQUE CONVERTER
TORQUE CONVERTER
277* 31. 9Nm (26.25 i3.25ko.I
53.5*4.9Nm (5.5*0.5knml
\
I
i
‘277* 31. 9Nm (26.25 * 3.25 kom)
‘66.2* 7.35Nm (6.75* 0.75kom 1
9JBOO112
Unit: mm
No.
Check item
Criteria
I Standard 1
inside diameter of seal ring contact surface of retainer
2
Inside diameter of seal ring contact surface of sleeve
3
Wear of seal ring of retainer
Width
Thickness
size
Remedy
I Tolerance
Repair
limit
0180
+0.040 0
180.5
085
+0.035 0
85.1
5.95
0 -0.1
5.45
6.3
*o.
1
Plate with hard chromium or replace.
5.67 Replace
4
Thickness
of plate
5
Thickness
of retainer
-
WA1 200-3
9
20.1
8.5
32
eo.1
31.5
40-l 1
MAINTENANCE
STANDARD
TRANSMISSION
TRANSMISSION
--_-------_
0
i
110.3*12.3Nm ~ll.25*1.25knmI
110.3*~2.3Nm
110.3~12.3Nm
(11.25*1.25kaml
(11.25*1.25kPml 9JBOO113
40-12
WA1 200-3
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm
No.
Check item
Criteria
Standard
1
No. 1 clutch spring
(6 PCS.)
Installation length
133
Installation load
94
379.5 N 138.7 kg}
125.02
322.6 N (32.9 kg}
168
106
536.4 N 154.7 kg)
157.92
456.0 N l46.5 kg}
55
No. 3 clutch spring (6 PCS.)
68.8
4
No. 4 clutch spring
56.9
357.9 N 136.5 kg}
9.5
(3 PCS.)
8.5
Standard Total assembly thickness of 8 discs and 7 plates for No. 1 clutch
I
83.8
1,697 N 1173.0 kg}
size
I
1.443 N 1147.1 kg}
8.93 Repair
Tolerance
I
358.9 N l36.6 kg}
53.49 I
I
304.0 N t31.0 kg}
64.67
42.7 N t43.0 kg}
43 !
No. 5 clutch spring
limit
Free length
3
5
Repair Installation load
No. 2 clutch spring
(6 PCS.)
size
Free length
2
(6 PCS.)
Remedy
kO.39
79.5
Total assembly thickness of 9 discs and 8 plates for No. 2 clutch
95.0
+0.41
90.2
Total assembly thickness of 5 discs and 4 plates for No. 3 clutch
50.2
kO.30
47.5
Total assembly thickness of 4 discs and 3 plates for No. 4 clutch I
39.0
10
Total assembly thickness of 9 discs and 8 plates for No. 5 clutch
77.6
11
Thickness
of No. 1 - 4 clutch disc
5.4
kO.1
4.87
12
Thickness
of No. 5 clutch disc
4.8
ao. 1
4.27
13
Thickness
of No. 1 - 4 clutch plate
14
Thickness
of No. 5 clutch plate
9
I
I
I
~0.26
20.41
I
I
36.9
limit
Replace
72.8
-
Wear 15
of seal ring of
transmission
Width
16
Wear 17
of seal ring of
transmission shaft
5.8
I
+o. 1
I
5.22
4.3
+O.l
3.87
3
-0.01 -0.03
2.7
3.5
20.1
3.35
4
-0.01 -0.03
3.6
4.6
eo.12
4.45
6
-0.01 -0.03
5.5
6.8
+0.15
6.65
input shaft Thickness
Wear
I
Width
output
of seal ring of
Thickness
Width
No. 5 clutch Thickness
WA1 200-3
40-l 3
MAINTENANCE
TRANSMISSION
STANDARD
Unit: mm Check item
No. 18 19
20
Criteria
Backlash between No. 1, 2, 3 gear and planetary pinion
I I
sun
0.16 - 0.40
Backlash between No. 1 planetary pinion and inside teeth of ring gear
I
Backlash between No. 2, 3 planetary pinion and inside teeth of ring gear
I
4
0.18 - 0.43 0.19 - 0.47
21
Backlash between No. and planetary pinion
22
Backlash between No. 4 planetary pinion and inside teeth of ring gear
0.18 - 0.44
23
Side clearance of planetary pinion
0.35 - 0.80 (Both sides)
40-14
sun gear
Remedy
I I Replace
0.17 - 0.39
WA1 200-3
MAINTENANCE
STANDARD
TRANSFER
TRANSFER
277 *31.%m -{Z&25* 3.25kml
17*147.lNm 1u5f15 km1
2207*147.lNm {225*15 kern1
,_*,.
(24.;
9JBOO114
40-l 6
WA1 200-3
MAINTENANCE
TRANSFER
STANDARD
Unit: mm
No.
Standard 1
size
Outside diameter of oil seal contact surface of front coupling
2
Outside diameter of oil seal contact surface of rear coupling
3
Backlash between idler gear
4
Backlash between put gear
input
gear
I
0140
+0.052 +0.027
139.8
and
0.20 - 0.44
idler gear and out-
0.20 - 0.44
Standard size between
I
6
Interference between input bearing and transfer case
7
Interference bearing
8
Interference between idler bear bearing and transfer case
9
Interference and bearing
10
between
between
1nte;znce
+0.078 +0.060
0 -0.025
0.060 0.103
0.060 0.103
0120
+0.045 +0.023
Jo20
0.023 0.065
0.023 0.065
0215
0 -0.030
-0.014 -0.060
-0.016 0.060
-0.016 0.060
0140
+0.052 +0.027
0 -0.025
0.027 0.077
0.027 0.077
0210
0 -0.030
-0.014 -0.060
-0.016 0.060
-0.016 0.060
Replace
gear
output
shaft
output
spacer
and
Interference between rear output bearing and parking brake cover
WA1 200-3
i:ta$dr;e
idler gear and
Interference between front bearing and transfer case Interference bearing
fii
I
input gear and
0140
between
limit
139.8
I
Interference bearing
Repair
+0.052 +0.027
-
5
I
Tolerance
0140 -
-
Remedy
Criteria
Check item
40-17
MAINTENANCE
MAIN
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
STANDARD
RELIEF, TORQUE CONVERTER
RELIEF VALVE
‘3
4
‘0
66.2*7.35Nm (6.75*0.75koml \
A-A
9JB00115
40-l 8
WA1 200-3
MAINTENANCE
STANDARD
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
Unit: mm
No
Check item
1
Clearance between main relief valve spool and valve body
2
Clearance between spool and piston
3
Clearance between torque converter relief valve spool and valve body
4
Clearance between torque converter relief valve spool and piston
Criteria
Remedy
-
-
-
main relief valve
Valve spring of main relief valve (Outside)
Valve spring of main relief valve (Inside) 7
Piston spring
of main relief valve
a
Valve spring lief valve
of torque
converter
re-
9
Piston spring lief valve
of torque
converter
re-
WA1 200-3
40-19
TORQUE CONVERTER REGULATOR VALVE
STANDARD
MAINTENANCE
TORQUE CONVERTER
REGULATOR
VALVE
49*4.9Nm 5 * 0.5 kern)
A-A
Unit: mm
No
Remedy
Criteria
Check item
-
I
I Tolerance
1
2
Clearance between torque converter regulator valve spool and valve body
Clearance between torque converter regulator valve spool and piston
Standard size
Valve spring of torque converter lator valve (Outside)
regu-
Standard clearance
Clearance limit
Shaft
Hole
040
-0.035 -0.045
+0.016 0
0.035 0.061
0.081
022
-0.020 -0.030
+0.021 0
0.020 0.051
0.071
Standard
3
Free length
Repair
size
Installation length
Installation load
Free length 155.6
4 -
Valve spring of torque converter
-
limit
Replace
Installation load 156.9 N 116.0 kg}
regu-
~ Piston
spring
of torque
converter
5
40-20
WA1 200-3
MAINTENANCE
BY-PASS FILL VALVE
STANDARD
BY-PASS FILL VALVE (For forward
clutch
and 1st speed clutch)
39. 2 * 9.6 Nm (4 f lkoml
4. 9 f INm {O. 5 f 0. lkom) 9JB00117
No.
Clearance between by-pass fill valve spool and valve body
Standard size
040
&I
-0.035 -0.045
3
of by-pass
fill valve
Return spring of by-pass fill valve (Inside)
WA1 200-3
0.035 0.056
+O.Oll 0 size
Free length
Installation length
33.4
17.3
38.2
17.3
Repair
I Installation load
Remedy
Clearance limit
~;Z
Standard Return spring (Outside)
T
Criteria
Check item
Unit: mm
0.076
limit
Free length
Installation load
63.7 N (6.5 kg}
32.4
60.8 N f6.2 ka}
33.3 N (3.4 kg}
37.1
31.4 N 13.2 kg}
Replace
40-21
MAINTENANCE
BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE
STANDARD
BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE (For reverse
clutch)
H
I’
?t 1 ;
tL,8,b
4.9 f 1 Nm (0.5*0.1 koml
4.9 * f 1 Nm (0. 5 0. I knm1
9JBOOl18
Unit: mm
No.
Criteria
Check item
Remedy
-
1
Clearance between by-pass spool and valve body
2
Clearance between by-pass valve spool and valve body
-
fill valve
drain
Replace 3
Return spring (Outside)
4
Return spring of by-pass fill valve (Inside)
5
Return
40-22
of by-pass
spring of by-pass
fill valve
drain valve
‘#Al 200-3
MAINTENANCE
ECMV
STANDARD
ECMV (For modulated
clutch)
30. 9 *3. 43 Nm 13. 15 *O. 35kam)
9JBOOl 19
Unit: mm
No
Criteria
Check item
Remedy
Standard 1
Clearance between flow sensor valve spool and valve body
2
3 Replace
4
Spring
for fill switch
5 6
WA1 200-3
40-23
ECMV
STANDARD
MAINTENANCE
(For transmission)
30. 9 *3. 43 Nm (3. 15 *O. 35komI
9JBOO120
Unit: mm
No.
Remedy
Criteria
Check item
-
1
Clearance between flow sensor valve spool and valve body 019
-0.035 -0.045
+0.013 0
0.035 0.058
0.064
014
-0.035 -0.045
+O.Oll 0
0.035 0.056
0.062
05.7
-0.035 -0.045
+0.012 0
0.035 0.057
0.063
2
Clearance between oressure valve spool and valve body
contra
3
Clearance between pressure valve SDOOI and oiston
contra
Standard
4
Spring
Free length
for fill switch
5
Return spring of flow sensor valve
6
Return valve
40-24
spring
of
pressure
control
size
Installation length
Replace Repair
I Installation load
Free length
limit Installation load
15
13
41.7 N (4.25 kg}
14.7
37.6 N c3.83 kg}
33.5
29.5
4.9 N (0.5 kg}
32.8
4.4 N CO.45 kg}
16.2
11.7
10.6 N Il.08 kg}
15.9
9.5 N IO.97 kg}
WA1 200-3
MAINTENANCE
STANDARD
LUBRICATING
LUBRICATING OIL RELIEF VALVE
OIL RELIEF VALVE
66.2*7.35Nm 1 6.75i 0.75 kam]
A-A SJBOO121
Unit: mm
No.
1
Check item
Criteria
Clearance between lubricating oil relief valve spool and valve body
Tolerance
Standard size Shaft
Standard clearance
022
Clearance limit
Hole I
-
Remedy
-0.035 -0.045
I
I
0.035 0.058
+0.013 0
0.078 Replace
Standard
2
Valve valve
WA1 200-3
spring
of lubricating
oil relief
size
I
Repair
limit
,I: 40-25
MAINTENANCE
DRIVE SHAFT
STANDARD
DRIVE SHAFT
385.4*41.2Nm (39.3*4.2koml
'277*31.4Nm t28.3*3.2bd
176.5*19.6Nm (18.0*2.0ksm) 176.5*19.6Nm ~l8.0*2.0hl
I
367.8*24.5Nm
367.8*24.5Nm {37.5*2.5kPmI 367.8*24.5Nm (37.5*2.5ksml
1 I I fl
367.8*24.5Nm ~37.5~2.5knml
385.4*41.2Nm (39.3+4.2kml
213.8*6.9Nm (21.8*0.7ksml SJWO4869
40-26
WA1 200-3
MAINTENANCE
STANDARD
CENTER SUPPORT
CENTER SUPPORT
Unit: mm
No.
1
Clearance bearing
between
case and
2 3 4
5
Wear
of oil seal surface
6
WA1 200-3
40-27
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL
(I/Z)
A-A
40-28
WA1 200-3
MAINTENANCE
DIFFERENTIAL
STANDARD
Unit: mm
No
Clearance of bearing outer race in differential gear assembly
shaft bearing
6 7 _ 8
11 12 13 14
Backlash of differential gear
15
Preload of pinion bearing
16
Preload of side bearing
17
Rear face runout of bevel gear
18
Standard thickness of shims for differential cage
0.31- 0.40 7.8 - 35.3 N {800 - 3,600 kg} Adjust 15.7 - 31.4 N {l,SOO - 3,200 kg1 0.13
-
WA1 200-3
1.3
MAINTENANCE
DIFFERENTIAL
STANDARD
DIFFERENTIAL
(2/2)
176.5* 19.6Nm (18.0+2.0koml
277*31.4Nm (28.3* 3.2bmJ
1715*195Nm (175*20kPml
927* 103Nm (94.5* 10.5koml
2746 i294Nm ~260-t30ko.1
1715 *195Nm il75i20kml
927* 103Nm 194.5* IO.5kPml SJWO4872
Unit:
No.
Check
item
Criteria
Standard 1
Thickness
size
Tolerance
mm
Remedy
Repair
limit
of side gear washer 9.0
8.5
10.8
10.3
Replace 2
Thickness sleeve
3
Wear
40-30
of pinion
gear washer
of oil seal surface
160
0 -0.100
159.84
WA1 200-3
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE
277131.4Nm ~28.3~3.2ksmI
277*31.4Nm (28.3*3.2ksml
277*31.4Nm ,(28.3*3.2bml
1715*195Nm -~175*2Okaml
\
\
i5
i
IO
II
2
3
13
12
152*24.5Nm ~15.5~2.5kivnl
4 SJWO4873
40-32
WA1 200-3
MAINTENANCE
FINAL DRIVE
STANDARD
Unit: mm
No.
I
Check item
Tolerance ,
Clearance between and bearing
planetary
Shaft
Hole
+0.018 0
0 -0.020
0 -0.025
-0.035 -0.075
-0.075 -0.010
99.982
+0.041 +0.026
+0.025 0
-0.041 -0.001
190.5
+0.025 0
-0.005 -0.051
-0.076 -0.005
479.425
+0.127 +0.076
+0.051 0
-0.127 -0.025
679.45
+0.076 0
-0.050 -0.130
-0.206 -0.050
409.575
-0.020 -0.060
+0.051 0
-0.020 0.111
546.1
+0.051 0
-0.044 -0.114
-0.165 -0.044
90 2
I
Clearance between and bearing
planetary
gear
3
Clearance between I and bearing
planetary
shaft
planetary
5
ring gear hub
6
Clearance between I and bearing
I
Clearance bearing
I
I
Clearance between 4 I and bearing
gear
I
I
between
wheel
7
Clearance between and bearing
axle
wheel
*
Clearance bearing
hub and
Standard clearance
Standard size
shaft
I
housing
Remedy
Criteria
I
155
-0.038-
Clearanc limit
0
_
Replace between
hub and
Standard 9
Thickness of retainer hub mount
size
40
Standard IO
11 12
I 13 ,4
Backlash between sun gear
planet gear and
Backlash between ring gear
planet gear and
Backlash between sun gear
planet
gear and
Backlash between ring gear
planet
gear and
Repair
limit
39.6
to.1
clearance
Clearance
limit
0.25 - 0.66
Thickness of standard wheel hub
WA1 200-3
Tolerance
at ring gear
0.28 - 0.83
0.27 - 0.72
I shim for
I
0.30 - 0.91
I I 2.4
40-33
MAINTENANCE
AXLE MOUNT
STANDARD
AXLE MOUNT
5000*490Nm ~510*50ksm~
5000*490Nm (510*50id
5000*490Nm ~510*50koml
2746*294Nm (280~30koml
19.6Nm 176.5-t ~l8.0*2.0hl
2746*294Nm (280~3Okp.l B-B SJW04874
40-34
WA1 200-3
MAINTENANCE
STANDARD
AXLE MOUNT
Unit: mm
-
1
No -
Check item
~ Remedy
Criteria
Tolerance
1
Clearance of shaft and hole (Front support side) (Before press-fit bushing)
Standard clearance
Standard size Shaft
Hole
540
+4.000 0
+0.175 0
-4.000 +0.175
530
-0.076 -0.185
+0.522 -0.345
0.270 0.707
540
+4.000 0
+0.175 0
-4.000 +0.175
530
-0.076 -0.185
+0.522 -0.345
-0.270 0.707
Clearance limit
2
Clearance of shaft and hole (Front support side)
(After press-fit bushing) 3
Clearance of shaft and hole (Rear support side) (Before press-fit bushing) Clearance of shaft and hole (Rear SUDDO~~side) (After p&s-fit bushing)
Standard Thickness
of thrust washer
size
I
8
Thickness
of thrust
plate
7
Thickness
of rear bushing
5
a
Thickness
of front bushing
5
WA1 200-3
Repair
limit
-0.21 -0.35
-
-
I
Replace 1.6
kO.2
53
6
Tolerance
1.6
-to.1
I I
20.1
I
I
-
40-35
MAINTENANCE
STANDARD
CENTER HINGE PIN
CENTER HINGE PIN
927*103Nm {94.5*10.5kml
(When adiustinQ with shim) 927*103Nm 194.5*10.5kml (Final value)
53.9 15.52
441*44Nm 145*4.5bml (When adjusting 'with shim) 2746 *294Nm 18 {260* 30koml (Fina I value)
17 A-A
5’
Ii B - B
\
5000*4QONm (510*50kaml
'2746*294Nm
(280*3Okml
sxwo4935
40-36
WA1 200-3
MAINTENANCE
CENTER HINGE PIN
STANDARD
Unit: mm
No.
Check item
1
Clearance between and bushing
lower
hinge pin
2
Clearance between and (small) spacer
lower
hinge pin
3
and bearingbetween Clearance
lower hinge pin
4
and (large) spacer between Clearance
lower
I -
_ 5
Criteria
I
hinge pin
spacer (large) and bushing Clearance between lower hinge
6
Clearance between front frame upper hinge bearing
7
and rear frame Clearance between
8
Clearance between and bearing
9
Clearance between front frame lower hinge bearing
I
I
228.6
-0.079 -0.050
+0.078 0
0.050 0.157-
228.6
-0.050 -0.079
+0.072 0
0.050 0.151
I
228.6
-0.079 -0.050
0 +0.025
0.1040.050
I
228.6
-0.079 -0.050
0 +0.072
0.151 0.050 -
I
305.0
-0.137 -0.056
0 +o.oss
269.875
+0.025 0
-0.074 -0.126
-0.151 -0.074
187.325
-0.079 -0.050
0 +0.072
0.1510.050
187.325
-0.050 -0.079
+0.025 0
0.050 0.129
355.6
+0.025 0
-0.093 -0.150
-0.175 -0.093
248
-0.079 -0.050
0 +0.072
0.1510.050
210
+0.26 +0.16
+0.072 0
-0.260 -0.088
310
+0.260 +0.160
+0.081 0
-0.260 -0.079
250
+0.242 +0.196
+0.072 0
-0.242 -0.124
I
325
+0.325 +0.268
+0.089 0
-0.325 -0.179
I
and
Remedy
1.0
I 1.0
0.2360.056
I I
upper hinge
pin
I
upper hinge pin
-
I
Replace
10
bushing Clearance
between
rear frame
and
and
11
Clearance at press-fitted of upper hinge pin
part of seal
12
Clearance at press-fitted of lower hinge pin
part of seal
13
Clearance between bushing and frame
lower hinge (upper)
14
Clearance between bushing and frame
lower hinge (lower)
15
Height
-
I
I I
Standard of lower hinge spacer
16
Height of lower
17
Thickness retainer
18
Shim thickness retainer
for lower
19
Shim thickness retainer
for lower
Shim thickness retainer
for upper
WA1 200-3
hinge spacer
Repair
Tolerance
size
I
limit
(small)
(large)
for lower hinge and
I hinge and
*o. 1
220
to. 1
45
I
kO.8
I
I
3.0
I
I
2.52
I
hinge and
hinge and
177.2
Adjust
2.62
40-37
MAINTENANCE
STEERING PUMP
STANDARD
STEERING PUMP (HPF160 + 160)
66*6.9Nm {6.73~0.7kml
68.j*9.81Nm i7.0*l.Obd
9JYOO286
40-38
WA1 200-3
MAINTENANCE
STANDARD
SWITCH PUMP
SWITCH PUMP (HPV160
+ HPF160)
34.3*4.9Nm ~3.5*0.5l@ml
24.5*4.9Nm ~2.5*0.5koml
66*6.9Nm {6.73*0.7bml
\
l-----l 9JYOO287
WA1 200-3
40-39
MAINTENANCE
STEERING DEMAND VALVE
STANDARD
STEERING DEMAND
VALVE
7
C
A
2
--I
I
A-A svwo3soo
40-40
WA1 200-3
MAINTENANCE
STEERING DEMAND VALVE
STANDARD
Unit: mm Remedy
Standard
WA1 200-3
size
Repair
limit
MAINTENANCE
DIVERTER VALVE
STANDARD
DIVERTER VALVE
A-A
SEW01614
Unit: mm
No.
Remedy
Criteria
Check item
I
1
Clearance
between
I
body and spool 40
I
I
I
-0.023 -0.005
+0.015 +0.007
I
I
0.020 0.030 Repair limit
Standard size
Replace 2
Spool spring
Free length
Installation length
Installation load
Free length
Installation load
122.6
a4
216.7 N 122.1 kg}
120.7
205.9 N I21.0 kg}
79.2
54.5
5.6 N IO.57 kg}
77.9
5.3 N fO.54 kg}
79.2
57.5
4.9 N {0.50 ka)
77.9
4.6 N IO.47 kg)
3
Check valve spring
4
Check valve spring
-
40-42
WA1 200-3
MAINTENANCE
STANDARD
STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
A-A
SJWO4876
Unit: mm
No.
Check item
Criteria
I 1
Tolerance
Remedy
I
I
Clearance between mounting pin and bushing connection of steering cylinder rod and frame -0.043 -0.106
160
2
Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame
3
Connection front frame
+0.025 0
0.131 0.043
1.0
Replace of steering
cylinder
and 120 -0.25 O
135 +; I
4
Connection of steering snd rear frame
5
width
cylinder
rod
size
Tolerance
Repair
limit
of spacer 7.0
WA1 200-3
0 - 3.25
135+:,
120:.25
Standard
I
to.5
40-43
EMERGENCY STEERING PUMP
STANDARD
MAINTENANCE
EMERGENCY STEERING PUMP Model SAM131100 + 100
A-A
‘2
SWWO3661
Unit:
No.
1
Check
between gear
Standard
model
Pump Clearance side plate
1
Remedy
Criteria
item
mm
limit
Clearance
clearance
gear case and I
Clarance between inside diameter of plain bearing and outside diameter of gear shaft
I
0.075
0.020 - 0.043
SAM(3)lOO
Standard
Replace
0.19
0.10 - 0.15
SAM(3)lOO
Tolerance
size
Replace
4
1 Rotating
torque
Discharge Oil: EOlO-CD Temperature:
-
I
of spline
shaft
13.7 - 23.5 Nm Il.4
I Pump
45 to 55°C
I
model
SAM(3)lOO
+ 100
Rerrtf:on ‘.I-..., 2000
- 2.4 kgm}
Pressure
1 ?0.6
MPa kg/cm? 210
,
Standard discharge IO,,“;“\ lLilllllli 352
,
ltmlt Fcepalr '. discharge Wmin) 312
WA1 200-3
MAINTENANCE
STANDARD
BRAKE VALVE
(RIGHT)
SWWO4877
Unit: mm
No. -
1
Check item
Criteria
Clearance between pedal hole and bracket hole
2
Clearance
3
Outside
between
roller and pin
!
I
!
10
-0.025 -0.075
+O.l 0
0.175 0.025
10
-0.025 -0.075
+O.l 0
0.175 0.025
Standard diameter
I
Remedy
size
Tolerance
Repair
0.25
0.25
limit
of roller 0 -0.5
30
29.2 I
Standard
4
Control
spring
Control
6
Return spring
7
Spring
8
Return
spring
Installation height
Installation load
Free length
34
33.5
4.6 N IO.47 kg)
33
46.3
46.0
11.8 N Il.2 kg}
45.3
86.2
58
60.8 N 16.2 ka1
78
16.5
17.7 N (1.8 kg}
16.2
19.5
16.7 N (1.7 kg}
28
17
-
-
WA1 200-3
spring
Repair
I
Free length
5
size
31.5
I
limit
Replace
Installation load
40-45
MAINTENANCE
BRAKE VALVE
STANDARD
(LEFT)
7.3Nm 0.75kom
/
152*24.5Nm ~15.5*'2.5koml
Unit: mm
No. -
/ 1
Remedy
Criteria
Check item
St;$xd
/
shafofer”““Ho,e
1 $eyici~
(
Clsa;;ce
Clearance between pedal mount hole and bracket hole 10
-0.025 -0.075
+O.l 0
0.175 0.025
0.25
10
-0.025 -0.075
+O.l 0
0.175 0.025
0.25
2
Clearance
3
Outside
between
roller and pin
Standard diameter
size
Tolerance
Repair limit
0 -0.5
29.2
of roller 30
Replace
4
Control
spring
5
Control
spring
6
Return
7
I
46.3
34.3
45.9 N (4.7 kg}
45.3
spring
86.2
58
N 60.8 (6.2 kg}
78
Return spring
31.5
19.5
16.7 N (1.7 kg1
28
WA1 200-3
MAINTENANCE
SLACK ADJUSTER
STANDARD
SLACK ADJUSTER
55.9* 6.9Nm (5.7*0.7kml
1 I2*9.8Nm (1 1.5* l.Okml SXW04878
Unit: mm
No.
Criteria
Check item
Tolerance Standard size 1
Clearance
between
body and piston 55
Shaft
Hole
-0.030 -0.076
+0.074 0
Standard
2
3
Slack adjuster
spring
Check valve spring
Remedy
Standard clearance
Clearance limit
0.030 0.150
0.250
Repair limit
size
Free length
Installation length
246
88
44.8
38
Installation load
Free length
Installation load
117.7 N I12 kg} 123.6 N 112.6 kg}
-
-
WA1 200-3
40-47
MAINTENANCE
BRAKE
STANDARD
BRAKE
i’
I
I
\
\
\
\ I_------%_/
927i-98
G
Nm
194.5*IO km1
40-48
7
SXWO4879
WA1 200-3
MAINTENANCE
STANDARD
BRAKE
Unit: mm
No.
Criteria
Check item Standard
1
Free length
Return spring
Standard Thickness
size Installation load
Free length
104.8
1,600 N 1163 kg)
123.0
size
Tolerance
Wear
limit Installation load 1,520 N f154.9 kg}
Repair
limit
of plate
of disc
of contact
surface
6.7
I
of oil seal
Wear of surface piston seal
in contact with
Wear of surface piston seal
in contact
2.85
kO.1
3.1
Thickness
Repair
Installation length
124.9
2
Remedy
839.5
I I
eo.3
I
6.2 Replace
0 -0.230
I
+0.140 0
I
+0.140 0
with 864
I Deformation plate
of friction
surface
Standard
of
I
Repair
limit
Max. 0.5
8
Deformation disc
of friction
surface
of Max. 0.7 L
WA1 200-3
40-49
MAINTENANCE
STANDARD
PARKING BRAKE
PARKING BRAKE
2207 f 147.INm (225 *I5 ken I
1 I
2207 * 147.1Nm (225 ~15 kernI
237. 8 f 31.9 Nm (24.25 f 3.25 kern)
9JBOO122
40-50
WA1 200-3
MAINTENANCE
PARKING BRAKE
STANDARD
Unit: mm
No
Criteria
Check item Standard
1
2
3
No. 1 Clutch spring
No. 2 Clutch spring
(14 PCS.)
I
(14 PCS.)
Repair
size
Free lenoth
Installation lenath
113
111
Standard
Total assembly thickness of 8 brake discs and 9 separator plates
Remedy limit
Installation load
Free lenath
Installation load
77.4
2,444 N I249.2 kg}
101.7
2,200 N 1224.3 kg}
77.4
1,313 N 1133.9 kg}
99.9
1,182 N 1120.5 kg}
size
Repair
Tolerance
61.6
-co.41
56.8
4.0
kO.05
3.9
0.20
0.6
2.77
limit
Replace
Thickness 4
Separator
plate Distortion
5
Brake disc
Thickness
3.2
+0.08
Lining groove depth (One side)
0.45
+0.7 0
I
20.16
I
Lining thickness (One side) 6
Load on wave spring (Height: 3.2 mm)
WA1 200-3
I
0.7 626.6 N 163.9 kg}
I
~176.5 N {*I8 kg)
0.235
405 N 141.3 kg}
40-51
MAINTENANCE
WORK EQUIPMENT PUMP No. 1
STANDARD
WORK EQUIPMENT
PUMP No. 1
HPV160 + 160
66* 6.9Nm (6.73*0.7kp.l 24.5i4.9Nm ~2.5*0.5kPml
30.5*3.5Nm ~3.11*0.36bml 34.3*4.9Nm ~3.5*0.5lwnI
9JYOO288
40-52
WA1 200-3
MAINTENANCE
STANDARD
WORK EQUIPMENT HPV95
WORK EQUIPMENT
PUMP No. 2
PUMP No. 2
+ 95
34.3i4.9Nm
(3.5*0.5kp.l
24.554.9Nm
30.9*3.43Nm {3.15*0.35bml
66.2*7.35Nm 16.75*0.75kml
\
66.7*9.81Nm (7.0*l.O!all 9JYooza9
WA1 200-3
40-53
MAINTENANCE
STANDARD
PPC VALVE
PPC VALVE
SVWO3605
40-54
WA1 200-3
MAINTENANCE
PPC VALVE
STANDARD
Unit: mm
No.
I
Check item
Criteria
I Standard
1
2
3
4
Centering spring (Bucket dump, boom
Centering spring (Bucket tilt, boom
Metering
spring
Return spring
WA1 200-3
lower)
raise)
Free length
I
size
Installation length
I
Installation load
Repair Free length
39.9
34.5
5.4 N iO.55 kg}
-
56.7
34.5
21.1 N i2.15 kg}
-
29.4
33.3 N c3.4 kg)
-
17.5
14.7 N (1.5 kg}
-
33.5
26.2
limit
Remedy
I
Installation load Replace if damaged or deformed
1
40-55
MAINTENANCE
PPC RELIEF VALVE
STANDARD
PPC RELIEF VALVE
152 *24.5Nm ~l5.5*2.5k.m1
39.2* l.ONm (4* lkml
108 f 14.7Nm 1
i 11.0*1.5koml
2
34.3ik.SNm 13.5*0.5kml
SJWO4897
Unit: No.
Remedy
Criteria
Check item
Repair limit
Standard size
1
2
Main valve spring
Poppet spring
Free length
Installation load
32.5
17.6 N Il.79 kg}
-
13.7 N (1.4 kg}
25.5
46.9 N c4.78 kg)
-
37.4 N 6.8 kg1
Installation length
Installation load
44.5 31.0
Free length
mm
Replace
WA1 200-3
MAINTENANCE
STANDARD
PUMP CONTROL RELIEF VALVE
PUMP CONTROL RELIEF VALVE
I 52 f 24.5Nm {15.5*2.5bml
1
108 f 14.7Nm (1 l.O* 1.5koml
2
39.2* l.ONm (4* Ibml
34.3+4.9Nm 13.5*0.5!Qml
SJW04897
Unit: mm
No -
Check item
Criteria Standard Free length
1
I
Remedy
size
Installation length
Repair
I
Installation load
I
Free length
limit
I
Installation load
I Replace
Poppet spring
WA1 200-3
44.5
32.5
17.6 N f1.79 kg}
-
13.7 N il.4 kg}
31.0
26.7
36.9 N 13.77 kg}
-
29.5 N i3.0 kg}
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
MAIN CONTROL VALVE
152.0*24.5Nm
A-A
\
c-c
3
68.7*9.8Nm (7.0*I.Okaml
B-B
D-D
304+9.8lNm 131.0*I.Obml
E-E
9JYOO290
40-58
WA1 200-3
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
Unit: mm
No.
Check item
1
Spool return spring
2
Spool return spring
3
Spool return spring
4
Main valve spring
5
Check valve spring
6
Float selector
7
Unloader
6
Relief valve
Criteria
Remedy
-
-
-
Replace
-
valve spring
valve spring
-
WA1 200-3
poppet
spring
40-59
MAINTENANCE
HYDRAULIC CYLINDER
STANDARD
HYDRAULIC
CYLINDER
BOOM CYLINDER
2450*250Nm (250*25kml SJWO4898
Unit: mm
No.
1
Clearance between rod and bushing
240
-0.050 -0.122
+0.247 +0.034
0.084 0.369
0.669
-0.050 -0.122
+0.519 +0.421
0.471 0.641
1.0
-0.050 -0.122
+0.519 +0.421
0.471 0.641
Clearance mounting
between piston rod pin and bushing
240
3
Clearance mounting
between cylinder pin and bushing
240
Cylinder
bore
bottom
I
Standard
360
40-60
Remedy
boom cylinder
2
4
I
Criteria
Check item
size
Replace
Tolerance +0.2 0
I
1
Repair
1.0
I
limit
I
WA1 200-3
MAINTENANCE
BUCKET
HYDRAULIC CYLINDER
STANDARD
CYLINDER
2450*250Nm 1250*25kml
277* 32Nm (28.25*3.25kPml SJW04899
No.
T
Criteria
Check item
I
1
Clearance between rod and bushing
Unit: mm Remedy
Clearance limit
bucket cylinder
0.622 -
Replace 2
Clearance mounting
between piston rod oin and bushing
1.0
3
Clearance mounting
between cylinder pin and bushing
1.0
4
Cylinder
-
bottom
Standard bore 300
WA1 200-3
size
Tolerance +0.2 n
Repair
limit
1 40-61
MAINTENANCE
STEERING
HYDRAULIC CYLINDER
STANDARD
CYLINDER
176.5* 19.6Nm
1150*120Nm ~117.5~12.5kem1
~18*2kml
i
I
SJWO4900
Unit: mm
Clearance between steering cylinder rod and bushing
Standard 4
Cylinder
bore 225
40-62
size
Tolerance
Repair
limit
+0.20 0
WA1 200-3
MAINTENANCE
STANDARD
BUCKET POSITIONER AND REMOTE POSITIONER
BUCKET POSITIONER AND REMOTE POSITIONER
2 17.2*2.5Nm (1.75*0.25kPml
A-A
-1
SJWO4901
Unit: mm No.
Criteria
Check item
1
Clearance of bucket positioner Clearance switch
of remote
2
3
Clearance positioner
between bucket protector and switch
WA1 200-3
switch
positoner
Remedy
3-5
3-5
Adjust
0.5 - 1
40-63
MAINTENANCE
STANDARD
BUCKET LINKAGE
BUCKET LINKAGE
20 II 20 18
\
I! SJWO4902
40-64
WA1 200-3
MAINTENANCE
STANDARD
BUCKET LINKAGE
e
d
d’ b
c
I7
B-0
A-A
n
c-c
n
d d d
e b
14 D-D
b
E-E
F-F
d
d b 13’ G-G
a
b la I2
H-H
C
b J-J
SJWO4903
WA1 200-3
40-65
MAINTENANCE
STANDARD
BUCKET LINKAGE
Unit:
No.
1
,
Check
Criteria
item
Clearance between bushing each end of bucket link
Remedy
and pin at
180
-0.043 -0.106
+0.401 +0.309
0.352 0.507
1.0
2
andbucket pin at Clearance boom and connecting between parts of bushing
240
-0.050 -0.122
+0.519 +0.421
0.471 0.641
1.0
3
andframe pin at Clearance between boom and connecting parts of bushing
280
-0.056 -0.137
+0.605 +0.493
0.549 0.742
1.0
4
Clearancebetweenbushingand pin at connecting parts of bucketcylinder rod and bellcrank
180
-0.043 -0.106
+0.401 +0.309
0.352 0.507
1.0
5
Clearancebstwas~ bushing and pin at connecting parts of bucket cylinder bottom and frame
180
-0.043 -0.106
+0.401 +0.309
0.352 0.507
1.0
6
Clearance between bushing and pin at connecting parts of bellcrank and boom
240
-0.052 -0.122
+0.519 +0.421
0.471 0.641
1.0
240
-0.050 -0.122
+0.519 +0.421
0.471 0.641
1.0
240
-0.050 -0.122
+0.519 +0.421
0.471 0.641
1.0
7
I
Clearancebetweenbushingand pin at connecting parts of boom cylinder bottom and frame
I
Clearance between bushing and pin at connecting parts of boom cylinder rod and boom
Length
Width of bushing a
of pin
Connecting parts of bucket cylinder and bellcrank
IO
393 20.3
209.5
t 0.1
+ 0.1
Width
of collar b
Width
91.3 f 0.1
/
of color
91.3 f 0.1
parts of boom
and frame
655 2 0.3
304.5
Connecting
parts of boom
and bucket
594 -c 0.3
349.4 t 0.1
121.8 + 0.1
121.8 f 0.1
I2
Connecting bucket
parts of bucket
461 f 0.3
259.5 f 0.1
91.3 + 0.1
109.3 f 0.1
I3
Connecting bucket link
parts of bellcrank
443 f 0.3
259.5
91.3 * 0.1
91.3 f 0.1
I4
Connecting and frame
parts of boom
Connecting boom
parts
I6
Connecting and frame
parts of bucket cylinder
,7
Connecting cylinder
parts of boom
I8
Wear of bucket tooth
II
I5
I
I
link and
and
cylinder
of bellcrank
and I
and boom
f 0.1
274.4 + 0.1
121.8 + 0.1
183.3 + 0.1
594 * 0.3
349.4 * 0.1
121.8 + 0.1
121.8 * 0.1
411 * 0.3
209.5 + 0.1
109.3 + 0.1
91.3 + 0.1
479 f 0.3
274.4 + 0.1
101.8 * 0.1
101.8 + 0.1
size
Repair
20
21
I I
Wear of wear plate
Wear of edge protector
Wear of side edge protector
I I
70
189
83
If clearance ofd+e becomes 2.5 mm, replace bushing and collar.
limit
340
504 Ig
174.7+0.1-
580.5 * 0.3
Standard
Replace (Replace when pin has scuff mark, too)
C
Connecting
I
mm
I I
12
Replace
40
30
WA1 200-3
90
OTHERS
Transmission hydraulic circuit diagram ................................................... Brake circuit diagram .................................................................................. Work euipment hydraulic circuit diagram (l/2) ....................................... Work euipment hydraulic circuit diagram (2/2) ....................................... Electrical circuit diagram (I/i’) ................................................................... Electrical circuit diagram (2/i’) ................................................................... Electrical circuit diagram (3/i’) ................................................................... Electrical circuit diagram (4i7) ................................................................... Electrical circuit diagram (5/7) ................................................................... Electrical circuit diagram (6/7) ................................................................... Electrical circuit diagram (7/7) ...................................................................
WA1 200-3
90- 2 90- 4 90- 7 90- 9 90-I 1 90-13 90-15 90-17 90-19 90-21 90-23
90-l
OTHERS
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
90-2 6
WA1200-3
OTHERS
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case 2. Strainer 3. Transmission and torque converter charging pumps 4. Torque converter charging pump 5. Oil filter 6. Main relief valve 7. Torque converter relief valve 8. Torque converter 9. Torque converter regulator valve 10. Oil cooler 11. Transmission lubricating circuit 12. Transfer lubricating circuit 13. PTO and input transfer lubricating circuits 14. Modulated clutch lubricating circuit 15. Lubricating oil relief valve 16. Brake circuit (see brake circuit diagram) 17. Parking brake pilot lamp switch 18. Parking brake (Builtin transmission) 19. Clutch No. 1 (Reverse) ECMV 20. Clutch No. 1 (Reverse) by-pass fill valve and by-pass drain valve 21. Clutch No. 1 (Reverse) 22. Clutch No. 2 (Forward) ECMV 23. Clutch No. 2 (Forward) by-pass fill valve 24. Clutch No. 2 (Forward) 25. Clutch No. 3 (3rd speed) ECMV 26. Clutch No. 3 (3rd speed) 27. Clutch No. 4 (2nd speed) ECMV 28. Clutch No. 4 (2nd speed) 29. Clutch No. 5 (1st speed) ECMV 30. Clutch No. 5 (1st speed) by-pass fill valve 31. Clutch No. 5 (1st speed) 32. Pilot oil filter 33. Modulated clutch ECMV 34. Modulated clutch 35. Transmission control valve oil temperature sensor a. From parking brake emergency actuation valve port A b. To parking brake solenoid valve port P c. From parking brake solenoid valve port T
WA1200-3
90-3 6
OTHERS
BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
90-4 6
WA1200-3
OTHERS
BRAKE CIRCUIT DIAGRAM
1. Torque converter, transmission, brake cooling and brake pump 1A. Torque converter pump 1B. Transmission pump 1C. Brake cooling pump 1D. Brake pump 2. Strainer 3. Accumulator charge valve 3A. Safety relief valve 3B. Relief valve 3C. Strainer 4. Check valve 5. Low pressure sensor 6. Rear brake accumulator 7. Front brake accumulator 8. Emergency brake switch 9. Brake valve (left) 10. Transmission cut-off switch 11. Brake valve (right) 12. Stop lamp switch 13. Rear slack adjuster 14. Front slack adjuster 15. Parking brake solenoid valve 16. Parking brake switch 17. Parking brake (Built in transmission) 18. Parking brake pilot lamp switch 19. Brake oil tank 20. Parking brake emergency actuation valve 21. Transmission (see transmission hydraulic circuit diagram) A. From transmission main circuit
WA1200-3
90-5 6
ELECTRIC CIRCUIT DIAGRAM (1/7)
WA1200-3
90-11 (7)
ELECTRIC CIRCUIT DIAGRAM (2/7)
90-13 (7)
ELECTRIC CIRCUIT DIAGRAM (3/7)
WA1200-3
90-15 (7)
ELECTRIC CIRCUIT DIAGRAM (4/7)
WA1200-3
90-17 (7)
ELECTRIC CIRCUIT DIAGRAM (5/7)
WA1200-3
90-19 (7)
ELECTRIC CIRCUIT DIAGRAM (6/7)
WA1200-3
90-21 (7)
ELECTRIC CIRCUIT DIAGRAM (7/7)
WA1200-3
90-23 (7)
DataKom Publishing Corporation 440 North Fairway D&e _ Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186
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